SM BW124D 0852636 Manual Reparacion BW124 PDF

BW 124D, BW124PD,
BW124 PDB
Single drum rollers
Instructions for repair

Catalog number 0852636 - 06/96
SYMBOLS USED IN THIS MANUAL
The following symbols have been used in THIS Manual to help communicate the intent of
instructions. When one of the symbols appears, it conveys the meaning defined below:
DANGER: Serious personal injury, death and/or WARNING: Serious personal injury and/or
extensive property damage can extensive property damage can
result if the DANGER instructions are result if the WARNING instructions
not followed. are not followed.
CAUTION: Minor personal injury can result or NOTE: Gives additional, and/or clarification
a part, an assembly, or the engine details, which are to be used in
can be damaged if the CAUTION conjunction with previously
instructions are not followed. presented information.
CALIFORNIA
Proposition 65 Warning
WARNING: Diesel engine exhaust and
some of its constituents are known to the
state of California to cause cancer, birth
defects, and other reproductive
harm.
CALIFORNIA
Proposition 65 Warning
WARNING: Battery posts, terminals and
related accessories contain lead and
lead compounds, chemicals known to the
state of California to cause cancer, birth
defects, and other reproductive
harm. Wash hands after handling.
SERVICE AND REPAIR PRECAUTIONS
ALWAYS inspect all slings, chains, or cables when lifting components, be sure that they are properly
tied, fastened and balanced before lifting. Be sure that the lifting device is capable of retaining the
weight to be lifted.
NEVER attempt to lift heavy parts by hand when a lifting device should be used.
ALWAYS wear safety glasses when performing any maintenance or repair work on the machine.
NEVER attempt to remove or repair any component, on the machine, while the engine is running.
NEVER leave the machine and/or heavy parts in an unstable position during repair.
ALWAYS support the machine with sound blocking.
ALWAYS keep the machine and work area clear of lubricants and dirt.
ALWAYS use the correct tools for the repair procedures being done on the machine,
ALWAYS keep tools in a good and clean condition.
ALWAYS use approved parts, that are designed for the machine being repaired. This helps
to ensure maximum service life of the machine.
ALWAYS be sure that all necessary nuts, bolts, snap rings, and other fastening devices, are
removed before using force to remove components.
ALWAYS attach a sign in the machine operator’s area, stating “DO NOT OPERATE” when the
machine is being repaired.
ALWAYS observe ALL WARNING AND CAUTION statements given in the Operating Manual and
Service Manual and found on the machine decals.
MANUAL - TABLE OF CONTENTS
PAGE
SECTION 1 - INTRODUCTION .................................................................................................................. 1-1.
SECTION 2 - SPECIFICATIONS ............................................................................................................... 2-1.
SECTION 3 - OPERATION ........................................................................................................................ 3-1.
SECTION 4 - MAINTENANCE ................................................................................................................... 4-1.
SECTION 5 - FRAME, HITCH AND FALLING OBJECT/

ROLL OVER PROTECTION STRUCTURE ............................................................................................ 5-1.
SECTION 6 - ENGINE ................................................................................................................................ 6-1.
SECTION 7 - ELECTRICAL SYSTEM ....................................................................................................... 7-1.
SECTION 8 - TRANSMISSION SYSTEM .................................................................................................. 8-1.
SECTION 9 - BRAKE SYSTEM ................................................................................................................. 9-1.
SECTION 10 - STEERING SYSTEM ....................................................................................................... 10-1.
SECTION 11 - VIBRATION SYSTEM ...................................................................................................... 11-1.
SECTION 12 - CONTROL SYSTEMS ..................................................................................................... 12-1.
SECTION 13 - OPTIONAL EQUIPMENT ................................................................................................ 13-1.
SECTION 14 - SPECIAL TOOLS ............................................................................................................ 14-1.
6/96 i
Section 1
INTRODUCTION
TABLE OF CONTENTS
PAGE
GENERAL INFORMATION ............................................................................................................................ 1-2
SPECIFICATIONS .......................................................................................................................................... 1-2
OPERATING INSTRUCTIONS ....................................................................................................................... 1-2
MAINTENANCE PROCEDURES ................................................................................................................... 1-4
REPAIR PROCEDURES ................................................................................................................................ 1-4
NAME PLATE / SERIAL NUMBER PLATE ................................................................................................... 1-4
SERIAL NUMBER .......................................................................................................................................... 1-4
11/95 1-1
Section 1
INTRODUCTION
GENERAL INFORMATION. OPERATING INSTRUCTIONS.
This manual contains SPECIFICATION, OPERA- Read, understand and follow ALL operating instruc-
TION and MAINTENANCE procedures for the tions given in Section 3 - OPERATION, of this
BOMAG Model BW124D, BW124PD and manual.
BW124PDB Single Drum Rollers [See figures
1-1,1-2 and 1-3].
WARNING: Only authorized personnel, who are
fully trained in the machine opera-
SPECIFICATIONS. tion procedures, can operate the
BOMAG Model BW124D, BW124PD
See Section 2 - SPECIFICATIONS, of this manual, and BW124PDB Single Drum Rollers.
for specifications on major systems used on the Follow ALL operating instructions
BOMAG Model BW124D, BW124PD and given in this manual and written on
BW124PDB Single Drum Rollers. the “Warning” decals, found on the
machine.
FIGURE 1-1. BOMAG MODEL BW124D SINGLE SMOOTH DRUM ROLLER.
1-2 11/95
Section 1
INTRODUCTION
FIGURE 1-2. BOMAG MODEL BW124PD SINGLE PAD DRUM ROLLER.
FIGURE 1-3. BOMAG MODEL BW124PDB SINGLE PAD DRUM ROLLER - WITH BLADE.
11/95 1-3
Section 1
INTRODUCTION
MAINTENANCE PROCEDURES.
The maintenance schedules and procedures are

found in Section 4 - MAINTENANCE, of this manual.
CAUTION: Follow ALL the maintenance sched-

ules and instructions, given in this
manual.
REPAIR PROCEDURES.
Major machine component repair procedures are

found in the “System Repair Procedure” sections of
Instructions For Repair Manual pn. 0852636.
CAUTION: For correct machine component repair

procedures, use Instructions For
Repair Manual pn. 0852636 or other
referenced written materials. FIGURE 1-4. NAME PLATE/SERIAL NUMBER
PLATE LOCATION.
NAME PLATE/SERIAL NUMBER PLATE [See Fig-

ure 1-4].
The combination name plate/serial number plate is

found on the left hand outer side of the control con-
sole. The plate must stay fastened to the machine at
all times.
If the plate is lost, or damaged, it must be replaced

immediately. Contact your nearest Distributor to ob-
tain a replacement nameplate and install it immedi-
ately.
SERIAL NUMBER [See Figures 1-4, 1-5 and Table

1-1].
The serial number indicates the design series, manu-

facturing location, serial number and year of ship-
ment [see table 1-1]. The serial number is found on
the name plate/serial number plate [see figure 1-4].
FIGURE 1-5. SERIAL NUMBER LOCATION -
The serial number is also stamped into the top flat ON FRONT FRAME.
area of the right front frame [see figure
1-5].
1-4 11/95
Section 1
INTRODUCTION
A219 C 1535 R
BW124D KEWANEE SERIAL NUMBER YEAR SHIPPED

BW124PD
BW124PDB
TABLE 1-1. MACHINE SERIAL NUMBER DESIGNATIONS.
11/95 1-5
Section 1
INTRODUCTION
NOTES
1-6 11/95
Section 2
SPECIFICATIONS
TABLE OF CONTENTS
PAGE
GENERAL INFORMATION ..................................................................................................................... 2-2.
TABLE 2-1. FRAME AND HITCH SPECIFICATIONS ............................................................................ 2-2.
TABLE 2-2. ENGINE SPECIFICATIONS ................................................................................................ 2-2.
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 AND LEVELING BLADE SYSTEMS SPECIFICATIONS ................................ 2-8.
TABLE 2-7. DRUM, VIBRATION, AND SCRAPER SPECIFICATIONS ............................................... 2-10.
TABLE 2-8. TIRE SPECIFICATIONS ................................................................................................... 2-12.
TABLE 2-9. CONTROL AND INDICATOR SPECIFICATIONS ............................................................ 2-13.
TABLE 2-10. OPTIONAL EQUIPMENT SPECIFICATIONS................................................................. 2-14.
TABLE 2-11. DIMENSION SPECIFICATIONS ..................................................................................... 2-15.
TABLE 2-12. MACHINE WEIGHT SPECIFICATIONS ......................................................................... 2-17.
TABLE 2-13. PERFORMANCE SPECIFICATIONS ............................................................................. 2-18.
TABLE 2-14. MACHINE SYSTEM CAPACITY SPECIFICATIONS...................................................... 2-18.
TABLE 2-15. COMPONENT WEIGHTS................................................................................................ 2-19.
TABLE 2-16. TORQUE SPECIFICATIONS FOR STANDARD

METRIC FASTENERS ................................................................................................... 2-21.
TABLE 2-17. TORQUE SPECIFICATIONS FOR STANDARD

INCH FASTENERS ........................................................................................................ 2-22.
TABLE 2-18. LUBRICATION OILS, HYDRAULIC OILS AND

COOLANT SPECIFICATIONS ........................................................................................ 2-23.
TABLE 2-19. ADHESIVE THREAD LOCKING SPECIFICATIONS...................................................... 2-23.
11/95 2-1
Section 2
SPECIFICATIONS
GENERAL INFORMATION.
This section gives specification tables for each major machine system of the
BOMAG Model BW124D, BW124PD and BW124PDB Single Drum Rollers.
Machine dimensions, weights, and performance specifications are

also given in this section.
TABLE 2-1. FRAME AND HITCH SPECIFICATIONS.
ITEM DESIGN DATA
FRAME and HITCH
Material And Plate steel unitized, all-

Construction welded 2 section
HITCH
Oscillation +/- 6.5˚- up or down, from center,

13˚ total
Articulation +/- 30˚- right or left turn, from center,

60˚ total
TABLE 2-2. ENGINE SPECIFICATIONS.
ITEM DESIGN DATA
ENGINE
Model and F3L1011, Deutz

Manufacturer
Type 4 Stroke diesel
Number of Three [3]

Cylinders
2-2 11/95
Section 2
SPECIFICATIONS
TABLE 2-2. ENGINE SPECIFICATIONS [continued].
ITEM DESIGN DATA
ENGINE [continued]
Bore 3.58 in. [91 mm]
Stroke 4.13 in. [105 mm]
Displacement 125.1 in3 [2 049 cm3]
Rated Brake 38 HP [28.3 kW] @ 2,500 RPM

Horsepower - per SAE J 1349
Compression Ratio 18.5:1
Firing Order 1-2-3
Low Idle Speed 1,100 RPM
High Idle Speed 2,500 RPM [governed]
Engine Oil 6.3 qts. [6.0 liters]

Capacity, W/Filter
Engine Oil Type Texaco Ursa Super Plus SAE 15W40,

or equivalent, premium motor oil
meeting CD/SF standards
ENGINE COOLING
Cooling Method Air cooled, blower forced
Cooling Blower Belt Tension With thumb pressure on belt midway between the blower and
crankshaft pulleys, belt deflection of 0.40-0.60 in. [10-15 mm]
11/95 2-3
Section 2
SPECIFICATIONS
TABLE 2-2. ENGINE SPECIFICATIONS [continued].
ITEM DESIGN DATA
ENGINE FUEL
Type Used Use ONLY distillate fuels [A.S.

T.M. No.1 or No.2 fuel oil or
No.1D or No.2D diesel fuel are
EXAMPLES [Also see Deutz FL 1011 Operating Manual]
The fuel MUST have a MINIMUM

cetane number of 35. Heavier oil
is generally preferable because
of its higher energy content
Fuel Capacity 10 Gallons [38 liters]
Rate of Fuel 1.8 Gallons per hour

Consumption [at [6.8 liters per hour]*
maximum engine
H.P. at 100% load *Operating conditions, that vary,
conditions] can cause different fuel consumption
amounts than those given
FUEL FILTER
Fuel Filter Pressure line, replaceable

“spin-on” element
FUEL PUMP
Type CAV, distributor type
2-4 11/95
Section 2
SPECIFICATIONS
TABLE 2-3. ELECTRICAL SPECIFICATIONS.
ITEM DESIGN DATA
BATTERY
Number per One [1]

Machine
Ampere Hour Rating 580 CCA hours
Voltage 12 Volts
ALTERNATOR
Voltage, Type and 12 Volt, negative ground,

Manufacturer Bosch
Output Amperage 60 Amps
11/95 2-5
Section 2
SPECIFICATIONS
TABLE 2-4. TRANSMISSION SYSTEM SPECIFICATIONS.
ITEM DESIGN DATA
TRANSMISSION SYSTEM
System Type Hydrostatic
System Oil 8.0 Gallons [30.3 liters]

Capacity.
NOTE: Also supplies steering, vibration and leveling blade
[BOMAG Model BW124PDB] systems.
.
Oil Type MOBIL 423, TEXACO TDH,

or equivalent, having JDM - JDA
specifications
Transmission System One [1] pressure line replaceable "spin on" element
Charge Oil Filter - Type
CAUTION: Use ONLY approved

filter, see Machine Parts Catalog.
Oil Cooler Type Aluminum, full flow
TRANSMISSION
HYDRAULIC PUMPS
Quantity And Type Two [2], variable displacement, axial piston [one [1] supplies
wheel drive oil flow , one [1] supplies drum drive oil flow]
Charge Relief
Valve Pressure - At
Hydraulic Oil Filter
Neutral 290 psi. [20 bar] MINIMUM - gauge

375 psi. [26 bar] MAXIMUM - gauge
2-6 11/95
Section 2
SPECIFICATIONS
TABLE 2-4. TRANSMISSION SYSTEM SPECIFICATIONS [continued].
ITEM DESIGN DATA
HYDRAULIC TRAVEL [WHEEL]

MOTORS
Type Radial piston, fixed displacement, with integral SAHR brake
Number Per Two [2]

Machine
HYDRAULIC DRUM DRIVE

MOTOR
Type Radial piston, fixed displacement
Number Per Machine One [1]
TRANSMISSION SYSTEM
PRESSURES
NOTE: Pressures given are with hydraulic oil at

operating temperature of 100-150˚F. [38-66˚ C]
with the engine throttle speed at HIGH idle.
ALL given pressures apply to both wheel and
drum drive motor[s] systems.
Neutral Charge 290 psi. [20 bar] MINIMUM - gauge

375 psi. [26 bar] MAXIMUM - gauge
System Relief
Forward 5,000 psi. [345 bar] - gauge
Reverse 5,000 psi. [345 bar] - gauge
Pump Case 43.5 psi. [30 bar] Cold/intermittent ONLY - gauge
11/95 2-7
Section 2
SPECIFICATIONS
TABLE 2-5. BRAKE SYSTEM SPECIFICATIONS.
ITEM DESIGN DATA
BRAKE SYSTEM
Service Brake Type Hydrodynamic, through hydrostatic

Transmission system
Secondary/Parking Spring applied/Hydraulically released [SAHR],

Brake Type multi-disc, integral within each travel [wheel] motor
System Pressures
Secondary/ 290-375 psi. [20-26 bar] - gauge

Parking Brake
Release System
TABLE 2-6. STEERING AND LEVELING BLADE SYSTEMS SPECIFICATIONS.
ITEM DESIGN DATA
STEERING SYSTEM
System Oscillating, articulated, center joint
Method Hydraulic
STEERING CONTROL UNIT
Type Rotary actuated, load sensing

and non-load reacting, with integral relief valve
STEERING RELIEF
VALVE
Relief Pressure 1,850 psi [128 bar] @ 5.2 GPM [20 LPM] - gauge,
and Rate @ 2500 RPM
BLADE SYSTEM RELIEF VALVE -

[Model BW 124PDB]
Relief Pressure 2,500 psi [172.5 bar] - gauge, @ 2500 RPM

and Speed
2-8 11/95
Section 2
SPECIFICATIONS
TABLE 2-6. STEERING AND LEVELING BLADE SYSTEMS SPECIFICATIONS [continued].
ITEM DESIGN DATA
HYDRAULUIC PUMP
Type Gear pump, rear section of two [2] section pump [Also
supplies transmission pump[s] charge oil and blade
system oil flow [Model BW124PDB]]
STEERING CYLINDER
Type Double acting
Number per One [1]

Machine
LEVELING BLADE CYLINDER -

[MODEL BW 124PDB]
Type Double acting
Number per One [1]

Machine
STEERING
PERFORMANCE
Steering Time -
Stop to Stop
Right to Left 3.0 Seconds
Left to Right 3.5 Seconds
Total Number of
Wheel Turns
Left To Right 5 Revolutions
Right To Left 4 Revolutions
Inside Turning 120.1 in. [3 050 mm]

Radius
Total Steering [articulation] 60˚ - 30˚ each side of center
11/95 2-9
Section 2
SPECIFICATIONS
TABLE 2-7. DRUM, VIBRATION AND SCRAPER SPECIFICATIONS.
ITEM DESIGN DATA
BW124D BW124PD BW124PDB
DRUM
Width 47.0 in. 47.0 in. 47.0 in.

[1200 mm] [1200 mm] [1200 mm]
Diameter 30.0 in. 31.0 in. 31.0 in.

[750 mm] [790 mm] [790 mm]
Wrapper Thickness 0.48 in. 0.40 in. 0.40 in.

[12 mm] [10 mm] [10 mm]
Tamping Feet
Number ----- 70 70
Contact Area ----- 12.6 in2 12.6 in2

[per foot] [81 cm2] [81 cm2]
Foot Height 2.3 in. 2.3 in.

[58.4 mm] [58.4 mm]
Pounds Per 65.5 PLI 428 PSI 428 PSI

Lineal Inch [29.8 kg/mm] [295 bar] [295 bar
[PLI] OR on EACH foot on EACH foot
Pounds Per having ground having ground
Square Inch contact contact
[PSI] of
Contact Area -
With Drum
Vibrator “OFF”
Drum Weight
Drum With 3,097 lbs. 3,131 lbs. 3,131 lbs.

Vibrator Assy, [1 405 kg] [1 420 kg] [1 420 kg]
Motor, Drum Drive
Motor and Isolators
2-10 11/95
Section 2
SPECIFICATIONS
TABLE 2-7. DRUM, VIBRATION AND SCRAPER SPECIFICATIONS [continued].
ITEM DESIGN DATA
VIBRATION SYSTEM
Type Eccentric, single weight, hydraulic motor driven
HYDRAULIC VIBRATOR PUMP
Type Gear pump, front section of two [2] section pump
Pump Output Rate 5.2 GPM [20 lpm] @

and Speed 2500 RPM
HYDRAULIC VIBRATOR MOTOR
Type Gear, fixed displacement
Motor Input Rate 5.2 GPM [20 lpm] @

4000 psi. [276 bar]
CONTROL VALVE
Type Single spool - open center, electrically controlled
Relief Valve Pressure Setting 4000 psi. [276 bar] - gauge
VIBRATION ISOLATION
Type Rubber buffer
Quantity
Left [Vibrator Motor] 4
Right [Drum Drive Motor] 8
11/95 2-11
Section 2
SPECIFICATIONS
TABLE 2-7. DRUM, VIBRATION AND SCRAPER SPECIFICATIONS [continued].
ITEM DESIGN DATA
BW124D BW124PD/BW124PDB
VIBRATION PERFORMANCE
Centrifugal Force 10,060 lbs. 10,060 lbs.

[4 573 kg] [4 573 kg]
@ 2,480 VPM @ 2,480 VPM
Frequency 2,480 VPM 2,480 VPM

[41.3 Hz] [41.3 Hz]
Amplitude 0.064 in. 0.064 in.

[nominal] Zero [1.6 mm] [1.6 mm]
To Peak
SCRAPERS
Type Scraper Full width, Full width,

bolt on type bolt on type
Number Scrapers Two [2] Twelve [12]

Per Machine non-reversible, non-reversible,
and Material bolt on, synthetic element bolt on, steel
Scraper To Drum Against drum 0.25 in. [6.4 mm]

Clearance
TABLE 2-8. TIRE SPECIFICATIONS.
ITEM DESIGN DATA
BW124D BW124PD/BW124PDB
DRIVE WHEEL TIRES
Size 7.50 x 16 7.50 x 16
Tread Design Open faced diamond Bar
Inflation 26 psi. 28 psi.

Pressure [1.8 bar] [2.0 bar]
2-12 11/95
Section 2
SPECIFICATIONS
TABLE 2-9. CONTROL AND INDICATOR SPECIFICATIONS.
ITEM DESIGN DATA
FUNCTION TYPE
CONTROL
Direction of Travel control lever,

Machine Travel mechanical linkage to
transmission pumps
Engine Speed Throttle lever and lock,

mechanical linkage to fuel
injector pump
Steering Control Steering wheel, hydraulic

steering control unit and
system
Brake-Service Travel control lever,

mechanical linkage to transmission
pumps, hydrostatic through
transmission system
Brake-Secondary/ Hand lever, seat riser mounted

Parking
Engine Start, Run Electrical key switch, control

and Stop panel installed
Vibration System Push button switch, travel

“ON-OFF” control lever contained
Horn Button switch, control panel

installed
Optional Rotary switch, control

Operation panel installed
Lighting System
Leveling Blade Control Pedal control acts to control

[Model BW124PDB] position of leveling blade. The
leveling blade control pedal
has four [4] positions:
“I” - LIFTING leveling blade

“0” - STOP position
“II” - LOWERING leveling blade
“III” - FLOAT leveling blade - with lock
11/95 2-13
Section 2
SPECIFICATIONS
TABLE 2-9. CONTROL AND INDICATOR SPECIFICATIONS [continued].
ITEM DESIGN DATA
FUNCTION TYPE
INDICATOR/GAUGE
Engine Hours Hourmeter, electrical, control

panel installed
Engine Lubrication Oil Oil pressure Indicator light, electrical,

Pressure control panel installed
Engine Inlet Air Restriction Air restriction Indicator light, electrical,

control panel installed
Fuel Level Low fuel level indicator light, electrical,

High Engine Lubricating Oil High engine lubricating oil temperature indicator light,
Temperature electrical, control panel installed
Charging System Voltage Low charging voltage indicator light, electrical,

Secondary/Parking “ON” indicator light and buzzer, electrical,

Brake System Condition control panel installed
Indicator [“ON-OFF”]
TABLE 2-10. OPTIONAL EQUIPMENT.
ITEM DESIGN DATA
LIGHTING SYSTEM
Type and quantity 12 volt, halogen, adjustable,

and Control two [2] per machine - one [1] front and one [1] rear
mounted, rotary switch controlled
2-14 11/95
Section 2
SPECIFICATIONS
TABLE 2-11. DIMENSION SPECIFICATIONS [See Figures 2-1, 2-2 and 2-3].
.
ITEM DESIGN DATA
DIMENSIONS
A. Overall Height - 91.0 in. 91.5 in. 91.5 in.

To Top of [2 311 mm] [2 324 mm] [2 324 mm]
FOPS/ROPS
B. Height - To Top Of 59.0 in. 59.0 in. 59.0 in.

Steering Wheel [1 490 mm] [1 490 mm] [1 490 mm]
C. Overall Width 55.0 in. 55.0 in. 56.0 in.

[1 390 mm] [1 390 mm] [1 422 mm]
D. Overall Length 117.0 in. 117.0 in. 130.4 in.

[2 970 mm] [2 970 mm] [3 312 mm]
E. Wheel Base 65.0 in. 65.0 in. 65.0 in.

[1 660 mm] [1 660 mm] [1 660 mm]
F. Ground Clearance 10.0 in. 10.0 in. 8.6 in.

[260 mm] [260 mm] [219 mm]
G. Drum Diameter 30.0 in. 31.0 in. 31.0 in.

[750 mm] [790 mm] [790 mm]
H. Drum Width 47.0 in. 47.0 in. 47.0 in.

[1 200 mm] [1 200 mm] [1 200 mm]
I. Frame Overhang - 4.0 in. 4.0 in. 4.5 in.

Each Side [95 mm] [95 mm] [114.3 mm]
J. Drum Wrapper Thickness 0.48 in. 0.40 in. 0.40 in.

[12 mm] [10 mm] [10 mm]
K. Leveling Blade Width --------- --------- 55.0 in.

[ModelBW124PDB ONLY] [1 390 mm]
L. Leveling Blade --------- --------- 2.5 in.

[Model BW124PDB ONLY] [63.5 mm]
Max. Depth Below Ground
Level - W/ Foot Penetration
M. Leveling Blade --------- --------- 15.9 in.

[Model BW124PDB ONLY] [405 mm]
Bottom Blade to Ground -
With Blade “RAISED” -
W/O Foot Penetration
11/95 2-15
Section 2
SPECIFICATIONS
A I I
J F
E H
C
D
FIGURE 2-1. BOMAG MODEL BW124D - MACHINE DIMENSIONS.
A I I
J F
E H
C
D
FIGURE 2-2. BOMAG MODEL BW124PD - MACHINE DIMENSIONS.
2-16 11/95
Section 2
SPECIFICATIONS
I
A
B
G
L F
E C
K
D
FIGURE 2-3. BOMAG MODEL BW124PDB - MACHINE DIMENSIONS.
TABLE 2-12. MACHINE WEIGHT SPECIFICATIONS.
ITEM DESIGN DATA
WEIGHTS
Operating Weight 5,957 lbs. 5,990 lbs. 5,990 lbs.

[2 702 kg] [2 717 kg] [2 717 kg]
Shipping Weight 5,717 lbs. 5,750 lbs. 5,750 lbs.

[2 593 kg] [2 608 kg] [2 608 kg]
Drum End [Front] Weight 2,727 lbs. 2,760 lbs. 2,760 lbs.
[1 238 kg] [1 253 kg] [1 253 kg]
Tire End [Rear] Weight 2,990 lbs. 2,990 lbs. 2,990 lbs.
[1 356 kg] [1 356 kg] [1 356 kg]
Drum Static Linear Load 63.1 lbs./in. ------------- -------------

[11.3 kg/cm]
11/95 2-17
Section 2
SPECIFICATIONS
TABLE 2-13. PERFORMANCE SPECIFICATIONS.
ITEM DESIGN DATA
TRAVEL SPEEDS
Forward or Reverse 0-5.6 MPH 0-5.6 MPH 0-5.6 MPH

[0-9.0 km/h] [0-9.0 km/h] [0-9.0 km/h]
EFFECTIVE COVERAGE 47.0 in. 47.0 in. 47.0 in.

[Per Pass] [1 200 mm] [1 200 mm] [1 200 mm]
TABLE 2-14. MACHINE SYSTEM CAPACITY SPECIFICATIONS.
ITEM DESIGN DATA
SYSTEM CAPACITIES
Fuel 10 Gallons [38 liters]
Engine 6.3 Quarts [6.0 liters]

Lubrication Oil
W/ Filter
Hydraulic Oil 8.0 Gallons [30.3 liters]

Reservoir
Drive Tires - 26 psi [1.8 bar] - DIAMOND tread, COLD and

Inflation Pressure 28 psi [2.0 bar] - BAR tread, COLD
2-18 11/95
Section 2
SPECIFICATIONS
TABLE 2-15. COMPONENT WEIGHTS.
NOTE: The following list of component weights is

APPROXIMATE and is given as a guide ONLY for
selecting sling and lifting equipment used
in machine servicing.
ITEM DESIGN DATA
FRONT FRAME
Bare 1,700 lbs. 1,700 lbs. 1,375 lbs.

[773 kg] [773 kg] [624 kg]
With Drum, Drum Drive Motor, 2,727 lbs. 2,760 lbs. 2,760 lbs.
All Vibration System Compon- [1 238 kg] [1 253 kg] [1 253 kg]
ents [And Blade - BW124PDB]
REAR FRAME
Bare 740 lbs. 740 lbs. 740 lbs.

[336 kg] [336 kg] [336 kg]
With Engine and Drive 2,990 lbs. 2,990 lbs. 2,990 lbs.
Components [1 356 kg] [1 356 kg] [1 356 kg]
OTHER COMPONENTS
Engine
Dry 450 lbs. [205 kg]
With Pumps 700 lbs. [318 kg]

Installed
Battery 40 lbs. [18 kg]
Transmission 55 lbs. [25 kg], each

Hydraulic Pumps
Drum Drive 75 lbs. [34 kg]

Hydraulic Motor
11/95 2-19
Section 2
SPECIFICATIONS
TABLE 2-15. COMPONENT WEIGHTS [continued].
ITEM DESIGN DATA
OTHER COMPONENTS
[continued]
Hydraulic Pump - 25 lbs. [11 kg]

Charge/Steering/Vibration
Steering 30 lbs. [14 kg]

Control Unit
Steering 25 lbs. [11 kg]

Cylinder
Machine Drive 70 lbs. [32 kg], Each

Tire/Wheel
Assembly
Drum Vibrator 10 lbs. [5 kg]

Hydraulic Motor
Drum Vibrator 125 lbs. [57 kg]

Assembly
Falling Object/ 400 lbs. [181 kg]

Roll Over
Protection
Structure
[FOPS/ROPS]
Leveling Blade Assembly 325 lbs. [148 kg]

[BOMAG Model BW124PDB]
Leveling Blade 5 lbs. [2.3 kg]

Control Valve
2-20 11/95
Section 2
SPECIFICATIONS
TABLE 2-16 TORQUE SPECIFICATIONS FOR METRIC FASTENERS.
BOLT DIMENSIONS TIGHTENING TORQUE - FT. LBS. / Nm.
8.8 10.9 12.9
M4 2 ft. lbs. / 3 Nm 3 ft. lbs. / 5 Nm 4 ft. lbs. / 5 Nm
M5 4 ft. lbs. / 6 Nm 7 ft. lbs. / 10 Nm 7 ft. lbs. /10 Nm
NOTE: Strength class for capscrews with untreated, non-lubricated surface.

The quality designation of the capscrews is marked on the screw head:
8.8 = 8G
10.9 = 10K
12.9 = 12K
The values result in a 90% utilization of the capscrews yielding point at a coef-
ficient of friction of u total = 0.14.
Use a torque wrench to tighten capscrews to the CORRECT torque. The above given
torques do NOT apply when using lubricants.
11/95 2-21
Section 2
SPECIFICATIONS
TABLE 2-17. TORQUE SPECIFICATIONS FOR STANDARD INCH FASTENERS.
GRADE 5 GRADE 8 PLACEBOLT SOCKET HEAD 12 POINT

CAPSCREW CAPSCREW
FIGURE 2-4. STANDARD HARDWARE
2-22 11/95
Section 2
SPECIFICATIONS
TABLE 2-18. LUBRICATION OILS, HYDRAULIC OILS AND COOLANT SPECIFICATIONS.
TABLE 2-19. ADHESIVE THREAD LOCKING SPECIFICATIONS.
264159
11/95 2-23
Section 2
SPECIFICATIONS
NOTES
2-24 11/95
Section 3
OPERATION
TABLE OF CONTENTS
PAGE
GENERAL INFORMATION ..................................................................................................................... 3-2
OPERATING CONTROLS AND INDICATORS ....................................................................................... 3-2
CHECKS WITH THE ENGINE STOPPED .............................................................................................. 3-11
STARTING THE ENGINE ....................................................................................................................... 3-11
CHECKS WITH THE ENGINE RUNNING ............................................................................................. 3-13
OPERATING PRECAUTIONS ............................................................................................................... 3-14
OPERATING THE MACHINE ................................................................................................................ 3-16
DYNAMIC BRAKING OF THE MACHINE ............................................................................................. 3-17
STOPPING THE ENGINE ...................................................................................................................... 3-18
MACHINE TOWING ............................................................................................................................... 3-18
TRANSPORTING THE MACHINE ........................................................................................................ 3-20
11/95 3-1
Section 3
OPERATION
GENERAL INFORMATION. OPERATING CONTROLS AND INDICATORS.
This section gives the operating instructions for the The BOMAG Model BW124D, BW124PD and
BOMAG Model BW124D, BW124PD and BW124PDB Roller operating controls and indicators
BW124PDB Single Drum Rollers. are shown on Figure 3-1. and are listed in Table 3-1.
Read, understand and follow ALL instructions given

on the machine "Operating Instruction and Warning" WARNING: Do NOT start, or operate, a Model
decals and written in this manual, BEFORE starting, BW124D, BW124PD or BW124PDB
or operating the machine [see figure 3-2]. Roller BEFORE reading, understand-
ing and following ALL information
given in this section and shown on
DANGER: Failure to observe the "Operating And the machine "Operating Instruction
Warning Instructions", given in this and Warning Decals", found on the
manual and found on the decals machine. The operator MUST read
affixed to the machine can cause about and understand thefunction of
serious INJURY, or DEATH. ALL controls and indicators BEFORE
Only authorized personnel, who are starting the engine.
fully trained in the machine operating
procedures, can operate Model
BW124D, BW124PD and BW124PDB
Single Drum Rollers.
Keep the machine in GOOD mechanical condition at

ALL times.
WARNING: Do NOT operate a machine needing

repair. Put an information tag on the
steering wheel which says "DO NOT
OPERATE". Remove the ignition key
from the ignition switch. Repair ALL
damage at once. Operation of a
machine with damage can result
serious injury and/or major machine
damage.
3-2 11/95
Section 3
OPERATION
TABLE 3-1. MACHINE OPERATING CONTROLS AND INDICATORS.
ITEM NO. DESCRIPTION TYPE FUNCTION

[SEE FIG’ 3-2]
1 IGNITION Key Controls engine

SYSTEM Operated starting”, “running”
CONTROL Interlock and “stopping”.
Switch -
Three [3] NO. 0 POSITION: “OFF”
Position condition.
Removes ALL electrical
current from circuits.
NO. I POSITION: “ON”

condition.
Applies electrical current
to ALL circuits. This
position also
is a “lock out” position
and prevents
accidental engagement
of the starter motor when
the engine is in a “run
ning” condition. The
ignition key MUST
be rotated back past this
position, to the NO. 0
[OFF] position, before
the starter motor can be
energized again
[start position].
NO. II POSITION:
“START” position.
Applies electrical current
the starter motor to crank
the engine. Switch spring
returns key to the NO.1
“ON/RUN” position
when the key is released.
11/95 3-3
Section 3
OPERATION

[SEE FIG’ 3-2]
2 TRAVEL Travel Controls forward/reverse

CONTROL Lever movement of the machine.
Travel control lever in

“CENTER” position -
transmission in “NEUT-
RAL”.

“FORWARD” position -
transmission in “FOR-
WARD”.

“REARWARD” position -
transmission in “RE-
VERSE”.
3 ENGINE Throttle Controls engine throttle

THROTTLE Lever- speed.
SPEED Two [2]
Position Move the throttle lever
“BACKWARD” to “HIGH”
engine idle speed position.
Move the throttle lever

“FORWARD” to “LOW”
idle engine speed position
position.
4 STEERING Manually Provides machine turning

SYSTEM Operated control.
Wheel
Turn the steering wheel in
the direction the machine is
desired to steer.
5 SECONDARY/ Manually Manually controls

PARKING Controlled secondary/parking
BRAKE SYSTEM Valve - Two brake system application
[2] Position and release.
Handle placed in “OFF”

position RELEASES the
brake system.
Handle placed in “ON”

position APPLIES the
brake system.
3-4 11/95
Section 3
OPERATION

[SEE FIG’ 3-2]
6 DRUM VIBRATOR Electrical “On/Off” control of

“ON/OFF” Push Button vibration system.
Switch -
Two [2] “PRESS” button IN
Position WARD and release -
Travel system STARTS.
Control
Lever “PRESS” button IN
Mounted WARD, again, and
release - system STOPS.
7 ENGINE Electrical Indicates total hours

OPERATION hourmeter engine has been in
HOURS operation.
Operates when ignition
key switch is switched
“on” and the engine
engine is “running”.
8 LOW ENGINE OIL Indicator Electrical Indicator light

PRESSURE Light monitors engine
lubrication oil pressure.
Electrical Indicator light is

lighted when ignition
switch [ITEM 1] is
switched "on", or if low
engine lubrication oil
pressure exists.
Light must NOT remain

lighted after engine has
started and is “running”.
CAUTION: STOP the

engine
IMMEDI -
ATELY if
the light
remains
lighted, or
lights, when
the engine
is "running".
11/95 3-5
Section 3
OPERATION

[SEE FIG’ 3-2]
9 ELECTRICAL Indicator Electrical Indicator light

CHARGING Light monitors electrical
SYSTEM charging system.
Electrical Indicator light is

lighted when ignition
switch [ITEM 1] is
switched "on" or if
battery is NOT being
charged.

CAUTION: STOP the

engine
IMMEDI -
ATELY if
the light
remains
lighted, or
lights, when
the engine
is "running".
10 SECONDARY/ Indicator Electrical Indicator light

PARKING BRAKE Light/buzzer and warning buzzer
SYSTEM monitors application
condition of secondary/
parking brake system.
With secondary/parking
brake system lever in
"on" position, electrical
Indicator light is lighted
and warning buzzer
sounds when ignition
switch [ITEM 1] is
switched "on" or if
charge pressure is lost.

started and is “running”
with brake system lever
in "off" position.
3-6 11/95
Section 3
OPERATION

[SEE FIG’ 3-2]
11 HORN Electrical Push Operates acoustic

button horn.
Switch Operates when

ignition key switch is
“on” position and when
the engine is “running”.
Push horn button to

sound horn.
12 FUSE BOX Covered Electrical fuse box

Fuse Box contains fuses for
standard and optional
electrical systems.
Electrical power is
supplied to the fuse box
when ignition switch
[ITEM 1] is switched
“on”.
13 HIGH ENGINE Indicator Electrical Indicator light

OIL light Light monitors engine
TEMPERATURE lubrication oil tempera-
ture
Electrical Indicator light

is lighted when ignition
switch [ITEM 1] is
switched “on” or if high
engine lubrication oil
temperature exists.

CAUTION: STOP the

engine
IMMEDI-
ATELY if
the light
remains
lighted, or
lights,
when the
engine is
“running”.
11/95 3-7
Section 3
OPERATION

[SEE FIG’ 3-2]
14 ENGINE Indicator Electrical Indicator light

INLET AIR Light monitors engine inlet air
PATH path.

switch [ITEM 1] is
switched "on" or if engine
inlet air path is restricted.

CAUTION: STOP the

engine
IMMEDI -
ATELY if
the light
remains
lighted, or
lights,
when the
engine is
"running".
15 LOW FUEL Indicator Indicator light monitors

LEVEL Light fuel level contained
within fuel tank.

switch [ITEM 1] is
switched "on" when a
"low" fuel condition
exists.
3-8 11/95
Section 3
OPERATION

[SEE FIG’ 3-2]
16 VANDAL Movable, Helps stop unauthorized

GUARD Lockable machine use and/or damage
Guard to instrument panel area.
Install over controls and

indicators on instrument
panel to help stop possible
damage and/or unauthorized
use. Secure in position with a
padlock. Remove
lock and move guard back
from panel for authorized
start and operation of
machine.
17 LIGHT Rotary Turns light system “On”

SYSTEM Switch and “Off”.
[Optional]
Turn switch knob to 1st
position to turn parking light
system “on”.
Turn switch knob to 2nd

position to turn operation
lighting system “on”.
18 LEVELING Foot Pedal Control of leveling blade

BLADE Four [4] system.
SYSTEM Positions
[BOMAG During machine operation,
Model BW124PDB control leveling blade by
Only] foot pedal movement.
1 - LIFT blade position.

0 - STOP/HOLD blade
position.
2 - LOWER blade position.
3 - FLOAT and LOCK
blade position.
11/95 3-9
Section 3
OPERATION
FIGURE 3-1. MODEL BW124D, BW124PD AND BW124PDB "OPERATING INSTRUCTION" DECAL.
3-10 11/95
Section 3
OPERATION
CHECKS WITH THE ENGINE STOPPED. b. If installed, unlock and then move the vandal
guard [ITEM 19] from the instrument panel and to the
With the engine “STOPPED”, inspect the machine stowed position. Keep the secondary/parking brake
BEFORE use, and AFTER every eight [8] hours of system “ON” [APPLIED] by leaving the secondary/
operation, or daily, as directed in Section 4 - parking brake system handle [ITEM 5] in the “ON”
MAINTENANCE - in this manual. position.
Park the machine on level and firm terrain. Check, or

inspect, the following items: WARNING: The machine must NOT move, at ANY
time, when the secondary/parking
Fuel level. brake system handle is in the “ON”
Engine lubrication oil level. [APPLIED] position.
Condition of engine cooling fan/alternator Do NOT operate the machine, if the
drive belt. machine will move when the second-
Hydraulic system oil level. ary/parking brake system is “ON”
Fluid leaks from engine, fuel system or [APPLIED], until the fault is corrected.
hydraulic system.
Drum scraper system.
Inflation air pressure of the drive tires. c. Put the transmission system in “NEUTRAL” by
Operation of the horn. positioning the travel control lever [ITEM 2] in the
Condition of the seat belt set. “NEUTRAL” [CENTER] position. Keep the travel con-
Falling object and roll over protection struc- trol mounted drum vibrator “ON/OFF” switch [ITEM 6]
ture [FOPS/ROPS] to machine mounting “OFF”.
capscrews torque and overall structure
condition.
NOTE: The transmission system MUST be in
"NEUTRAL" before the engine can be
started.
STARTING THE ENGINE [See Figure 3-2 and
Table 3-1].
d. If so equipped, keep the leveling blade lowered
WARNING: Do NOT start, or operate, a BOMAG to the ground by leaving the system control foot
ModelBW124D, BW124PD or pedal [ITEM 18] in the blade “LOWER” [#2] position.
BW124PDB Roller BEFORE reading,
understanding and following ALL e. Keep the engine throttle speed lever [ITEM 3] in
information given in this section and the “LOW” idle speed position.
shown on the machine “Operating
Instruction and Warning decals”,
found on the machine. CAUTION: Do NOT put the engine throttle speed
The operator MUST read about, and lever in the “HIGH” idle speed posi-
understand, the function of ALL tion, at this time. Engine damage can
controls and indicators BEFORE occur.
starting the engine.
Serious INJURY, or DEATH, can
result if these procedures are NOT
followed.
a. IMMEDIATELY, after being seated place the

seat belt across the lap and securely insert the metal
end into the buckle. Tighten the belt, against the
body, by pulling on the loose end of the belt.
11/95 3-11
Section 3
OPERATION
FIGURE 3-2. MACHINE CONTROLS AND INDICATORS -

MODEL BW124D, BW124PD AND BW124PDB SINGLE DRUM ROLLERS.
3-12 11/95
Section 3
OPERATION
f .Turn the ignition key [ITEM 1] to the number [II] WARNING: Keep ALL personnel clear of the
[START] position. Crank and start the engine. Re- machine and travel path when check-
lease the ignition key when the engine as the engine ing the secondary/parking brake
starts. system operation.
The machine must NOT move, at ANY
CAUTION: Make a note of the amount of continu- brake system is “ON” [APPLIED].
ous cranking time. Do NOT crank the Do NOT operate the machine, if the
engine MORE than twenty [20] sec- machine will move when the
onds continuously. secondary/parking brake system
If the engine is NOT started within the lever is in the “ON” [APPLIED]
above time, put the ignition key in the position, until the fault is corrected.
number [0] [OFF] position. Wait one [1]
minute. This will allow the starter
motor time to cool. Repeat step “f” Operation of the steering system.
until the engine is started. After the
engine has started, Do NOT increase a. Turn the steering wheel to the left, or right, turn
the engine speed, above “LOW” idle, position a SMALL amount. Note that the machine
for a period of two - three [2-3] min- turned smoothly in the same direction in which the
utes to allow the engine and hydraulic steering wheel was turned and that the steering sys-
systems to warm. tem operated correctly.
DANGER: Keep ALL personnel clear of the hitch

CHECKS WITH THE ENGINE RUNNING. area. The clearance between the front
and rear frames, at the hitch, closes
With the engine “running”, check or inspect the ma- when the machine is turned in either
chine BEFORE operation, using the following infor- direction. Serious INJURY, or DEATH,
mation. Also do these checks and/or inspections after can occur if caught between the
every eight [8] hours of machine operation, frames.
or daily, as directed in Section 4 - MAINTENANCE -
in this manual.
WARNING: Do NOT operate the machine if the
Check or inspect the following items: steering system did NOT operate
correctly. Repair the system immedi
Operation of the secondary/parking brake ately, before ANY machine operation.
system.
a. Keep the secondary/parking brake system lever Operation of the transmission system, in BOTH
in the “ON” [APPLIED] position. SLOWLY move the directions of travel, and operation of the back up
travel control lever one fourth [1/4] of the full forward alarm system in the REVERSE direction of
or reverse travel distance. Note that the brake sys- travel.
tem keeps the machine from ANY movement. Repeat
the procedure for the opposite direction of travel. a. Move the secondary/parking brake system lever
Move the travel control lever to the “NEUTRAL” to the “OFF” [RELEASED] position. Move the travel
[CENTER] position. control lever toward the forward direction of travel
position, a SMALL amount. Note that the transmis-
sion system functioned and the machine moved for-
ward. Move the travel control lever to the forward
neutral position.
11/95 3-13
Section 3
OPERATION
b. Move the travel control lever toward the reverse CAUTION: Do NOT operate the machine if the
direction of travel position, a SMALL amount. Note hourmeter, or indicator lights, do NOT
that the transmission system functioned, that the operate correctly. Repair the system
back up ALARM sounded and the machine moved fault immediately, before ANY
rearward. Move the travel control hand lever to machine operation.
“NEUTRAL”. Put the secondary/parking brake sys-
tem lever to the “ON” [APPLIED] position.
OPERATING PRECAUTIONS [See Figures 3-1 and

DANGER: Check the operation of the transmis- 3-3].
sion system ONLY when the machine
is in an area clear of personnel and To help prevent injury to personnel and damage to
other machines. the machine ALWAYS observe ALL of the following
Keep ALL personnel CLEAR of the “Operating Precautions”.
machine and the travel path when
checking the transmission system Read, understand and follow ALL information shown
operation. on the “Operating Instruction and Warning Decals”,
found on the machine and the instructions written in
this manual.
WARNING: Do NOT operate the machine if the
transmission system did NOT operate
correctly. Repair the system immedi- DANGER: Failure to observe the following “Oper-
ately, before ANY machine operation. ating Precautions”, and/or the ma-
Do NOT operate the machine if there chine “Operation And Warning Instruc
is a malfunction in the back up tions”, given in this section and found
ALARM SYSTEM. Repair the system on the “Operating Instruction and
IMMEDIATELY. Keep the alarm, Warning Decals” affixed to the ma-
clean and free of mud, dirt and other chine, can cause serious INJURY,
debris at ALL times. After cleaning or or DEATH.
removal of these items, ALWAYS test Only authorized personnel, who are
the alarm system, for CORRECT fully trained in the machine operation,
operation, by using the ABOVE can operate Model BW124D, BW124PD
procedures. and BW124PDB Single Drum Rollers .
CAUTION: Do NOT check the operation of the a. Drive at a SLOW speed when nearing a slope.
drum vibration system, UNLESS the Drive at a SLOW speed and use additional CAUTION
drum of the machine is on a SOFT when operating the machine close to a slope and/or
surface, such as loose dirt or “old” when traveling “up” or “down” a slope.
tires. Damage to the drum and/or
machine can occur if the drum vibra- b. Do NOT travel “across” a slope. When on a
tion system operation is checked on a slope, TRAVEL in a “UP” or “DOWN” direction ONLY.
HARD surface. Keep AWAY from “edges” and/or “embankments”.
Use extra CAUTION when operating the machine on
“wet” or “loose” soil.
Operation of ALL instruments and indicator
lights. c. Use extra CAUTION when operating the ma-
chine near personnel and/or other machines. MATCH
a. Note that the hourmeter and ALL indicator lights the machine operating speed to area and working
are operating correctly. conditions.
3-14 11/95
Section 3
OPERATION
d. Do NOT operate a machine in need of repair. DANGER: Keep ALL personnel CLEAR of the
Report and repair ANY damage and/or operation with hitch area. Clearance between the front
faults IMMEDIATELY. and rear frames CLOSES when the ma-
chine is turned in either direction.
e. Keep CLEAR of the hitch area at ALL times dur- Serious INJURY, or DEATH, can occur
ing operation of, or service to, the machine. if caught between the frames.
WARNING
WARNING
P/N 918141
FASTEN
SEAT BELT!
IF MACHINE
TIPS:
DO NOT
JUMP!
P/N 918142
FIGURE 3-3. OPERATION AND SEAT BELT WARNING DECALS - MODEL BW124D, BW124PD
AND BW124PDB SINGLE DRUM ROLLERS .
11/95 3-15
Section 3
OPERATION
f. IMMEDIATELY after becoming seated, and BE- OPERATING THE MACHINE [See Figures 3-1, 3-2,
FORE the machine is started, ALWAYS securely fas- 3-3 and Table 3-1].
ten and tighten the seat belt across the lap. The op-
erator MUST remain seated at ALL times during ma- DANGER: ALL personnel and other machines
chine operation. Keep hands and feet INSIDE the MUST be CLEAR of the machine path
machine cockpit at ALL times. Allow NO riders on the AFTER it has been started and
machine at ANY time. BEFORE the machine is moved.
g. Do NOT suddenly stop the machine during op-

eration. a. IMMEDIATELY after being seated, place the
seat belt across the lap and SECURELY insert the
h. BEFORE getting off of the machine, ALWAYS metal end into the belt buckle. Tighten the belt fully
do the following procedures: against the body, by pulling on the loose end of the
belt.
1. Stop drum vibration. If so equipped, LOWER
the leveling blade to the ground by using the b. Release the secondary/parking brake system, by
leveling blade control foot pedal [ITEM 18]. putting the secondary/parking brake system lever
[ITEM 5] in the “OFF” [RELEASED] position.
2. Put the secondary/parking brake system
lever [ITEM 5] in the “ON” [APPLIED] position. c. If in a confined area, near personnel, or near
other machines, keep the engine throttle lever [ITEM
3. Put the travel control lever [ITEM 2] in 3] at “LOW” idle. If so equipped, raise the leveling
“NEUTRAL”. blade from the ground by moving the leveling blade
control foot pedal [ITEM 18] to the “RAISE” [#1] posi-
4. STOP the engine and remove the ignition key. tion.
WARNING: ALWAYS apply the secondary/parking WARNING: Do NOT put the engine throttle lever
brake system when the machine is to the “HIGH” idle if the machine is in
parked. The transmission system will confined area, near personnel or
NOT keep the parked machine near other machines.
“STOPPED” at ANY time. The sec-
ondary/parking brake system MUST
be used to keep the machine CAUTION: When operating the machine on the
“STOPPED” at ALL times. work surface, the engine throttle
MUST be at “HIGH” idle. When on the
work surface, put he throttle lever
i. Do NOT operate the machine, if the machine will [ITEM 3] in “HIGH” idle.
move when the secondary/parking brake system is
“ON” [APPLIED], until the fault is corrected.
d. SLOWLY move the travel control lever [ITEM 2]
TOWARD the direction the machine is desired to
WARNING: The machine must NOT move, at ANY travel, a SMALL amount.
brake system lever [ITEM 5] is in the
“ON” [APPLIED] position.
j. Do NOT operate a machine NOT having the “Op-

erating Instruction and Warning Decals” in place on
the machine. The decals MUST remain in
good condition and NOT be covered with dirt or
grease. Replace damaged, or missing, decals IMME-
DIATELY [See Machine Parts Manual].
3-16 11/95
Section 3
OPERATION
WARNING: The machine will MOVE when the g. If so equipped, use the leveling blade [Model
travel control lever is moved in BW124PDB only] to move fill, as desired, while oper-
EITHER direction [forward or back ating the compactor in the forward or reverse direc-
ward] from NEUTRAL. tion of travel.
PUSHING the lever FORWARD
selects the FORWARD direction of
machine travel. DANGER: Do NOT use the leveling blade to lift
PULLING the lever BACKWARD or transport personnel.
selects the REVERSE direction of Serious INJURY, or DEATH, can occur.
machine travel. Do NOT move other machines or
BEFORE moving the travel control vehicles with the leveling blade.
lever, from neutral, be SURE that the Serious INJURY, or DEATH, to person-
machine path is CLEAR. nel in the area can occur.
CAUTION: When changing travel direction, CAUTION: When the machine is parked, ALWAYS
during machine operation, hold the lower the leveling blade to the ground.
travel control lever in NEUTRAL for a
short time, BEFORE moving the lever
to the opposite travel direction posi- NOTE: Use the leveling blade system control foot
tion. pedal [ITEM 18] to control the operation of
Change the travel direction ONLY the leveling blade:
while the machine is STOPPED.
Position “1” - LIFT the blade.
Position “0” - STOP and HOLD the blade.
e. When the machine is in a clear area and away Position “2” - LOWER the blade.
from personnel and other machines, if desired, Position “3” - FLOAT and LOCK the blade.
SLOWLY move the travel control lever [ITEM 2] fur-
ther forward, or backward, to the full travel position.
DYNAMIC BRAKING OF THE MACHINE [See Fig-

NOTE: Full travel lever movement will give FULL ure 3-2].
machine travel speed. The machine travel
speed is proportional to the mount of the On LEVEL terrain, slowing of the machine is done by
travel lever movement in either direction. moving the travel control lever [ITEM 2] TOWARD
NEUTRAL. Complete stopping of the machine is
done by moving the travel control lever [ITEM 2] fur-
f. When on the work surface, if desired, start the ther TO NEUTRAL.
drum vibration system by pressing INWARD, and
then releasing, the vibrator “ON/OFF” push button WARNING: When nearing a slope FIRST slow the
[ITEM 6] which is installed into the end of the travel machine by moving he travel control
control lever handle [ITEM 2]. lever TOWARD NEUTRAL. SLOW the
machine further, or STOP the
machine, on a slope by moving the
DANGER: When compacting the work surface travel control lever to the direction of
near buildings, check the effect of the travel position that is OPPOSITE the
vibratory forces on the structures. direction that the machine is travel-
STOP work IMMEDIATELY if structure ing.
damage is noted. The secondary/parking brake system
MUST be used to hold a stopped, or
parked, machine at ALL times. The
CAUTION: Operate the vibration system ONLY transmission system, used for
with the engine throttle [ITEM 3] at DYNAMIC braking, will NOT hold a
“HIGH” idle. stopped, or parked, machine at
ANY time.
11/95 3-17
Section 3
OPERATION
CAUTION: BEFORE machine movement stops, MACHINE TOWING [See Figures 3-4, and 3-5].
stop the vibration system by pressing
the vibrator “ON/OFF” push button Should the machine become completely disabled or
[ITEM 6] INWARD, and then releasing the engine is not able to be started, use the following
the button. procedures to release the secondary/parking brake
system on each tire drive motor:
a. Put SOLID wood blocks behind, and in front of,

STOPPING THE ENGINE [See Figure 3-2 and BOTH drive tires.
Table 3-1].
a. SLOW, and then STOP, the machine by using DANGER: Block securely with SOLID block
DYNAMIC braking through the transmission system BEFORE releasing the secondary/
[see procedure above]. LEAVE the travel control le- parking brake system. Machine move-
ver [ITEM 2] in NEUTRAL. ment can occur if the machine is NOT
“blocked”.
CAUTION: BEFORE machine movement stops,

stop the vibration system by pressing CAUTION: To prevent machine damage, Do NOT
the vibrator “ON/OFF” push button tow the machine unless ALL of the
[ITEM 6] INWARD, and then releasing following procedures have been
the button. followed.
b. Put the secondary/parking brake system lever b. Go to either tire drive motor. Locate the motor
[ITEM 5] in the “ON” [APPLIED] position. housing and brake release piston. Find the plastic
protection plug that is snapped into the tapped hole
c. If so equipped, lower the leveling blade [ Model of the brake release piston. Remove the plug [see
BW124PDB only] to the ground by using the leveling figure 3-4].
blade control foot pedal [ITEM 18].
c. Place the brake release device [Item 3] over the
d. Move the throttle control lever [ITEM 3] “DOWN- tire drive motor housing [Item 5]. Install the
WARD” to the “LOW” idle position. Run the engine capscrew [Item 1] into the tapped hole [4] in the
for a period of three - five [3-5] minutes, at the LOW brake release piston until the final stop nut [2] is loos-
idle speed, BEFORE stopping the engine. ened.
d. Turn the nut [2] until contact with the release de-
CAUTION: Do NOT stop the engine BEFORE run- vice [3]. Use a wrench to turn the nut [2] further in-
ning at the “LOW” idle speed. ward approximately one [1] complete revolution. The
Serious engine damage can occur if secondary/parking brake, on the tire drive motor, is
the engine is stopped BEFORE waiting now released and the drive wheel must turn freely.
the three - five [3-5] minute period. Leave the release mechanism [1] in place at this
time.
e. Turn the ignition switch key [ITEM 1] to “OFF” e. Go to the second tire drive motor. Repeat steps
and stop the engine. Remove the key from the igni- "b", "c" and "d" to release the secondary/parking
tion switch [ITEM 1]. Move the vandal guard [ITEM brake on the tire drive motor.
16], into position over the instrument panel and se-
cure with a padlock, if desired. f. Use a solid towing pin to connect a tow bar to the
towing eye [Item 1], found on the rear, of the ma-
chine. Use a towing pin to connect the tow bar to a
towing vehicle, having a pulling capacity larger than
the weight of the machine [see figure 3-5].
3-18 11/95
Section 3
OPERATION
h. After the machine has reached the repair area,
put SOLID wood blocks behind, and in front of,
BOTH drive tires. Remove the tow bar from the ma-
chine and towing vehicle.
DANGER: Block securely with SOLID blocks

BEFORE removing the tow bar from
the machine, or towing vehicle. Ma-
chine movement can occur if the
machine is NOT “blocked”.
After the machine has been towed, the
secondary/parking brake system on
the tire drive motors MUST be applied.
FIGURE 3-4. SECONDARY/PARKING BRAKE
RELEASING LOCATION - ON TIRE DRIVE
MOTORS. i. Go to either tire drive motor. Turn the nut [Item 2],
found on the release device [Item 1], figure 3-4, until
the nut is away from the release device. The second-
ary/parking brakes, in the tire drive motor, are now
APPLIED. Install the protection plug into the tapped
hole in the brake release piston.
j. Go to the second tire drive motor and repeat step

"i". Put the “brake release devices” in the storage
compartment.
FIGURE 3-5. TOW BAR CONNECTION TO

MACHINE.
g. Remove ALL blocking from the wheels. Have a

driver be seated. Use the towing vehicle to SLOWLY
tow the machine to a near by service area while the
driver steers the machine.
DANGER: Tow the machine on LEVEL terrain.

Do NOT tow the machine at a speed
above 0.62 MPH [1 km/h]
Do NOT tow the machine further than a
MAXIMUM of 0.3 miles [500 m].
NOTE: Manual steering of the machine, during

towing, is required. Steering system
control effort is increased due to NO
hydraulic assist.
11/95 3-19
Section 3
OPERATION
TRANSPORTING THE MACHINE [See Figures 3-6, e. Put SOLID wood blocks under EACH drive tire,
3-7 and 3-8]. at both the front and the rear. Put SOLID wood
blocks under the drum, on BOTH sides, at both the
a. Put the engine throttle control lever [ITEM 3] at front and the rear [see figure 3-7].
“LOW” idle. CAREFULLY and SLOWLY load the ma-
chine onto the transporting truck or trailer. f. Connect the four [4] tie-down chains, with shack-
les, between the truck or trailer bed and the machine,
DANGER: Use only strong and stable loading at the locations given in the following “DANGER”.
ramps to load the machine. Tighten the tie-down load binding device to hold the
Keep ALL personnel, except the machine securely in position for transportation [see
operator, CLEAR of the area while figure 3-7].
loading the machine.
Do NOT endanger any person through
machine tipping and/or roll over. DANGER: For CORRECT transportation of the
machine, FOUR [4] tie-downs MUST be
b. Put the secondary/parking brake lever [ITEM 5] used to secure the machine to the
“ON” [APPLIED]. Put the travel control lever [ITEM 2] truck or trailer bed to prevent machine
in NEUTRAL. rolling, slipping or roll over. One [1] tie-
down lug is found behind EACH rear
c. Place the machine in a “straight ahead” position. tire, on the outside of the frame and
Slow, and then stop, the engine using the CORRECT fender. One [1] tie-down cutout is
procedures given in this section. found in EACH side of the front frame,
behind the front cross beam.
d. Move the transport lock [Item 1] into position ALWAYS use shackles, at the machine
from its stored position [see figure 3-6]. Align the tie-down points, with the chains and
through holes, in the lock, with the through hole in the load binding devices. If lifting, and
locking eye on the rear frame. Install the large lock then loading the machine, use the
pin [Item 2] through the bores and secure the lock pin same [4] areas, referenced above, as
with the spring pin [Item 3]. “lifting eyes” [see Figure 3-8].
ALWAYS use shackles on the lifting
points for lifting the machine. See
Section 2 - SPECIFICATIONS, for
machine weight specifications.
Do NOT stand, or step, under the
machine when being lifted.
g. After machine transport, move the transport lock

into the stored position and secure with the lock pin
and spring pin.
FIGURE 3-6. TRANSPORTATION LOCK

INSTALLATION.
3-20 11/95
Section 3
OPERATION
FIGURE 3-7. MACHINE TRANSPORT TIE-DOWN LOCATIONS.
FIGURE 3-8. MACHINE LIFTING LOCATIONS.
11/95 3-21
Section 3
OPERATION
NOTES
3-22 11/95
Section 4
MAINTENANCE
TABLE OF CONTENTS
PAGE
GENERAL INFORMATION ................................................................................................................... 4-4.
MAINTENANCE .................................................................................................................................... 4-4.
GENERAL INFORMATION ............................................................................................................... 4-4.
MAINTENANCE SCHEDULE ........................................................................................................... 4-4.
GENERAL INFORMATION ............................................................................................................ 4-4.
TABLE 4-1. MAINTENANCE SCHEDULE ........................................................................................... 4-6.
MAINTENANCE PROCEDURES .......................................................................................................... 4-12.
GENERAL INFORMATION ............................................................................................................... 4-12.
ENGINE MAINTENANCE ................................................................................................................. 4-12.
ENGINE LUBRICATION OIL ......................................................................................................... 4-12.
CHECKING THE ENGINE LUBRICATION OIL LEVEL ............................................................. 4-12.
CHANGING THE ENGINE LUBRICATION OIL ......................................................................... 4-12.
CHANGING THE ENGINE LUBRICATION OIL FILTER ............................................................ 4-13.
FUEL SYSTEM ............................................................................................................................... 4-14.
FUEL TANK ................................................................................................................................ 4-14.
ENGINE FUEL FILTER ............................................................................................................... 4-15.
ENGINE AIR FILTRATION ............................................................................................................ 4-16.
AIR CLEANER. ........................................................................................................................... 4-16.
11/95 4-1
Section 4
MAINTENANCE
PAGE
COOLING SYSTEM ................................................................................................................... 4-17.
CLEANING THE COOLING FINS AND THE HYDRAULIC OIL COOLER ............................. 4-17.
HYDRAULIC SYSTEM ...................................................................................................................... 4-19.
CHECKING THE HYDRAULIC OIL LEVEL AND ADDING

HYDRAULIC OIL TO THE HYDRAULIC OIL RESERVOIR ....................................................... 4-19.
CHANGING THE HYDRAULIC OIL ............................................................................................... 4-19.
HYDRAULIC PRESSURE OIL FILTER ELEMENT-

REMOVAL AND REPLACEMENT............................................................................................... 4-22.
ALTERNATOR AND COOLING FANS DRIVE BELT

INSPECTION AND REPLACEMENT PROCEDURES .................................................................. 4-23.
ELECTRICAL SYSTEM .................................................................................................................... 4-24.
CHECKING THE BATTERY "CONDITION" AND

SERVICING OF RELATED ITEMS ............................................................................................. 4-24.
ELECTRICAL WIRING INSPECTION ............................................................................................ 4-24.
DRIVE TIRES .................................................................................................................................... 4-26.
INSPECTION, AIR PRESSURE CHECK AND ADJUSTMENT .................................................... 4-26.
MISCELLANEOUS MAINTENANCE INFORMATION ..................................................................... 4-27.
GREASE LUBRICATION ............................................................................................................... 4-27.
HITCH BEARINGS ...................................................................................................................... 4-27.
LEVELING BLADE BEARINGS - MODEL BW124PDB ............................................................. 4-27.
SCRAPER ASSEMBLIES ........................................................................................................... 4-27.
OPERATOR RESTRAINT [SEAT BELT, FALLING OBJECT AND

ROLL OVER PROTECTION STRUCTURE [FOPS/ROPS] ........................................................ 4-29.
4-2 11/95
Section 4
MAINTENANCE
PAGE
PREPARING THE MACHINE FOR STORAGE ............................................................................. 4-30.
ENGINE PRESERVATION .......................................................................................................... 4-30.
BATTERY .................................................................................................................................... 4-30.
FUEL TANK ................................................................................................................................ 4-31.
AIR CLEANER, EXHAUST AND OTHER OPENINGS .............................................................. 4-31.
DRIVE TIRES .............................................................................................................................. 4-31.
EXPOSED COMPONENT RUST PREVENTION ........................................................................ 4-31.
11/95 4-3
Section 4
MAINTENANCE
GENERAL INFORMATION. MAINTENANCE SCHEDULE.
THIS section gives the necessary procedures for GENERAL INFORMATION.

CORRECT MAINTENANCE of the BOMAG Model
BW124D, BW124PD and BW124PDB Single The MAINTENANCE SCHEDULE lists the recom-
Drum Rollers. mended time intervals between machine mainte-
nance inspections and lubrication procedures. Table
Follow ALL the “MAINTENANCE SCHEDULES” 4-1 gives inspection and lubrication information for
and “MAINTENANCE PROCEDURES” for COR- the BOMAG Model BW124D, BW124PD and
RECT machine service schedules and procedures. BW124PDB Single Drum Rollers.
Most service intervals are listed by the “HOUR” and

“PERIODIC” time periods. The maintenance
MAINTENANCE. schedule begins with eight [8] hours or daily mainte-
nance intervals and continues through the 2,000
GENERAL INFORMATION. hours or every two [2] years maintenance schedule
intervals.
MAINTENANCE must be a planned program which
includes periodic machine inspection and lubrication
procedures. NOTE: If the machine is operated MORE than
eight [8] hours per day, follow the
The MAINTENANCE program must be done, based “HOUR” schedule. If the machine is oper-
on the machine “OPERATING HOURS”, recorded ated LESS than eight [8] hours per day,
on the hourmeter, or based on the “PERIODIC follow the “PERIODIC” schedules, where
SCHEDULE”, which is done at time intervals of they apply.
weekly, monthly or yearly.
The MAINTENANCE program is divided into TWO The maintenance checks, given in Table 4-1, are
[2] subsections: The MAINTENANCE SCHEDULE ALSO listed on the “Machine Maintenance Decal”,
and the MAINTENANCE PROCEDURES. found on the machine [See Figure 4-2]. Figure 4-1
shows the location of the “machine maintenance
points”.
14
5 1 9
15
17
10
18
13 6
20 4
21 19 11
16 2
12 8 3
FIGURE 4-1. MACHINE MAINTENANCE POINTS .

4-4 11/95
Section 4
MAINTENANCE
11 12 5 1 9
15
13
4
7
14 10 8 3 2
FIGURE 4-2. MACHINE MAINTENANCE DECAL.

11/95 4-5
Section 4
MAINTENANCE
TABLE 4-1. MAINTENANCE SCHEDULE.
FIG’
4-1 ITEM 8/ 250/ 500/ 1000/ 2000/ QUAN. TYPE/REMARKS
ITEM DAY 3 MO 1 YR 1 YR 2 YR
NO.
1 ENGINE OIL X C* 6.3 All temperature

Qts. Texaco - “URSA”
[6.0 L] SUPER PLUS 15W40,
or equivalent
premium motor
oil meeting CD/
SF standards.*
2 ENGINE OIL C* 1 Change at EACH

FILTER engine oil change
Use APPROVED filter
ONLY.*
3 ENGINE C* 1 Change at interval

FUEL shown.
FILTER Use APPROVED
filter ONLY.*
4 FUEL LEVEL X 10.0 #1D or #2D

- IN TANK Gal. diesel fuel. See
[38 L] Section 2 -
SPECIFICATIONS,
for complete
specifications.
5 ENGINE X C** 1 Check condition

INLET AIR indicator light.
FILTER Change element
ELEMENT as needed.**
6 ENGINE X Air Check cooling air

COOLING Path path. If required
SYSTEM clean total cooling
air path as needed.*
4-6 11/95
Section 4
MAINTENANCE
FIG’
ITEM DAY 3 MO 1 YR 1 YR 2 YR
NO.
7 HYDRAULIC X A/C+ 8.0 Check hydraulic

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

COR -
RECT
hydrau-
lic oil
ONLY***
+ A= OBTAIN AND ANALYZE OIL SAMPLE - WITH CARE.

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

SYSTEM indicator, on filter
PRESSURE head, daily. Change
OIL FILTER element when
hydraulic oil is
changed, and/or
one [1] time for
every 2,000 hours of
machine operation,
or when filter
element condition
indicator, on filter
head, shows needed.
Use APPROVED
filter element ONLY.
See Machine Spare
Parts Catalog for
CORRECT
replacement
element.
11/95 4-7
Section 4
MAINTENANCE
FIG’
ITEM DAY 1 WK 2 WK 1 YR 2 YR
NO.
9 ALTERNATOR X* 1 Check belt for

& COOLING FAN wear or damage.
DRIVE BELT Check belt for
CORRECT
adjustment.*
Replace belt, with
NEW, and adjust if
needed [see
ENGINE manual].
10 BATTERY X 1 The battery requires

minimum service.
Check the charge
and electrolyte level of
battery one [1]
time for each 100
hours of machine
operation, or every 2
weeks. Clean bat-
tery and battery
cable connectors.
Check the hold
down clamp for
tightness. Service as
required. See
THIS section.
11 SECONDARY/ X System Check OPERATION

PARKING and APPLICATION
BRAKE condition
SYSTEM of SECONDARY/
PARKING BRAKE
SYSTEM, one [1]
time for every eight
[8] hours of machine
operation, or daily,
using the procedures
given in THIS section.
4-8 11/95
Section 4
MAINTENANCE
FIG’
ITEM DAY WK 1 YR 1 YR 2 YR
NO.
12 DRIVE X 2 Check inflation

TIRES pressure each 50
hours, or weekly
with tires "COLD".
Adjust pressure
as needed [see
this section].
13 SAFETY X All Check condition.

DECALS Replace if needed.
See Machine
Spare parts
Catalog.
14 SEAT BELT X 1 Set Check condition.

Replace set if
damaged. See
Machine
Spare parts
Catalog.
15 GAUGES X All Check operation.

HORN X Repair or replace
LIGHTS X as needed.
16 DYNAMIC X Trans. Check operation.

BRAKES System Repair IF needed.
See Section 3.
17 STEERING X Steering Check operation.

System Repair if needed.
18 BACK UP X Alarm Check system

ALARM System operation.
If needed, repair
system BEFORE
machine operation.
19 HITCH C All Lubricate ALL

BEARINGS Fittings bearings through
grease fittings
with multipurpose
grease one [1] time
for each 50 hours
of machine operat-
ion, or weekly.
11/95 4-9
Section 4
MAINTENANCE
FIG’
ITEM DAY WK 1 YR 1 YR 2 YR
NO.
19 HITCH C All Lubricate ALL

grease fittings
with multipurpose
grease one [1] time
for each 50 hours
of machine operat-
ion, or weekly.
20 FALLING X Structure Inspect ALL metric

OBJECT/ M20 - grade 10.9
ROLL OVER capscrews, nuts
PROTECTIVE and washers that
STRUCTURE fasten the
[FOPS/ structure to the
ROPS] machine. They
MUST remain
tightened to the
torque of 221
ft.lbs. [300 N.m].
CAREFULLY
inspect ALL welds
for cracks, break-
age in the weld
or where the
weld joins the
components,
severe rust or
other weld re-
lated problems.
If any damage
is found in the
above inspection,
contact your
nearest Distributor
immediately.
21 LEVELING BLADE C All Lubricate ALL

grease fittings
with multipurpose
grease one
[1] time for each
50 hours of
machine operation,
or weekly.
4-10 11/95
Section 4
MAINTENANCE
CAUTION: CHECK ENGINE lubrication oil level with the engine in the “OFF and
COLD” condition.
CHECK HYDRAULIC system oil level with the engine in the “OFF”
condition and the hydraulic oil at the “OPERATING” temperature.
KEY:
X= CHECK C= CHANGE
A/C= OBTAIN OIL SAMPLE, WITH CARE, AND ANALYZE. CHANGE OIL BASED ON
RESULTS OF OIL ANALYSIS - IF REQUIRED
* = Refer to current “Operation Manual - FL 1011 Diesel

Engine ” published by Deutz Engine Company, which is
supplied with EACH machine.
** = Under VERY dusty or severe operating conditions change at 500 hours or
as need is indicated.
*** = See DECAL adjacent to hydraulic reservoir fill tube.
11/95 4-11
Section 4
MAINTENANCE
MAINTENANCE PROCEDURES. NOTE: The ABOVE procedure will help to
remove the possibility of filling the
GENERAL INFORMATION. engine with too much lubrication oil, by
allowing the oil to return to the oil pan.
The following MAINTENANCE PROCEDURES give
CORRECT instructions for performing the required
maintenance checks and show the locations for lu- WARNING: STOP the engine BEFORE checking
brication of the machine. the engine lubrication oil level. With
engine running, HOT oil can be
thrown causing serious injury.
NOTE: The instructions given in the MAINTE-
NANCE procedure subsection are given
by “machine systems” and are NOT
necessarily in the same order as listed in
Table 4-1 or as shown on the “Machine
Maintenance Decal”. They also include
some items NOT shown in the table, or
on the decal.
ENGINE MAINTENANCE.
The following ENGINE maintenance information will

cover engine maintenance procedures most often
done.
For additional ENGINE maintenance information,

see the “Operation Manual - FL 1011 Series Diesel
Engine” published by Deutz Engine Company,
which is supplied with the machine.
FIGURE 4-3. DEUTZ DIESEL ENGINE -
LUBRICATION OIL LEVEL CHECK AND FILL
LOCATIONS.
ENGINE LUBRICATION OIL.
CHECKING THE ENGINE LUBRICATION OIL

CHANGING THE ENGINE LUBRICATION OIL
LEVEL [See Figure 4-3].
[See Figure 4-4].
The engine lubrication oil MUST be kept at a level
The engine lubrication oil MUST be changed after
ABOVE the “bottom” mark but NOT above the “top”
EACH 250 hours of machine operation or according
mark on the engine lubrication oil dipstick.
to the interval given in the diesel engine
“Operation Manual - FL 1011 Series Diesel Engine”
To ACCURATELY check the engine lubrication oil
published by Deutz Engine Company and supplied
level, put the machine in a “LEVEL” position and
with the machine.
STOP the engine. Clean the area around the engine
lubrication oil dipstick BEFORE removing the dip-
NOTE: The color of the engine lubrication oil
stick from the engine. WAIT five [5] minutes
can NOT be used as an indication of the
BEFORE removing the dipstick from the engine and
need for a engine lubrication oil change.
checking the oil level.
The use of an engine lubrication oil
“analysis service” is the ONLY alternate
reason for not following the required
engine lubrication oil change schedule.
4-12 11/95
Section 4
MAINTENANCE
WARNING: Do NOT change the engine lubrica- CAUTION: Do NOT start the engine BEFORE
tion oil when the engine and lubrica- changing the engine lubrication oil
tion oil are HOT. filter. Follow the procedures given in
Change when WARM ONLY. Hot oil THIS section, and in the engine
can cause serious injury. “Operation Manual - FL 1011 Series
Diesel Engine” published by Deutz
Engine Company.
CAUTION: Do NOT change the engine lubrica-
tion oil with the engine in a
“running” condition.
Serious engine damage, or
failure will, occur.
Clean the area around the engine
lubrication oil dipstick and oil filler
cap BEFORE removing the dipstick
or oil filler cap.
With the engine “STOPPED”, and with “WARM” en-

gine lubrication oil, proceed as follows:
a. Clean the area around the engine lubrication oil

drain plug found on the engine oil pan.
b. Place a container, having a capacity greater

than 7 qts. [6.6 L], directly under the engine lubrica-
tion oil drain plug.
c. CAREFULLY remove the engine lubrication oil

drain plug. FIGURE 4-4. DEUTZ DIESEL ENGINE -
LUBRICATION OIL DRAIN PLUG LOCATION.
d. Drain ALL of the engine lubrication oil into the
container.
CHANGING THE ENGINE LUBRICATION OIL
e. Clean, install and CAREFULLY tighten the lu-
FILTER [See Figure 4-5].
brication oil drain plug.
The engine lubrication oil filter MUST be changed
after EACH 250 hours of machine operation, when
CAUTION: Do NOT overtighten the drain plug.
the engine lubrication oil is changed.
This action could cause damage to
unit.
WARNING: Do NOT change the engine lubrica-
f. Fill the engine to the CORRECT oil level, with
tion oil filter when the engine and
the CORRECT engine lubrication oil.
lubrication oil are HOT. Change the
filter when “WARM” only. Hot oil can
cause serious injury.
NOTE: See THIS section for the CORRECT
amount and type of lubrication oil.
CAUTION: Do NOT change the engine lubrica-
tion oil filter with the engine running.
g. Wash the oil filler cap and dry with compressed
Serious engine damage, or failure,
air. Install the oil filler cap and the engine lubrication
will occur.
oil dipstick.
11/95 4-13
Section 4
MAINTENANCE
With the engine “STOPPED” and filled with NEW g. Start the engine. Check to be sure there are
engine lubrication oil, proceed as follows: NO oil leaks and that the engine oil pressure light
indicates that the engine has the lubrication oil pres-
a. Use a CLEAN cloth to wipe the area around sure.
the engine lubrication oil filter element and its
mounting base.
CAUTION: STOP the engine IMMEDIATELY if
b. Place a container under the filter element. no, or low, OIL pressure is indicated
or any oil leaks are seen. CORRECT
c. Use a filter removal wrench to loosen and re- any problem noted BEFORE starting
move the filter element by turning it in a COUNTER- the engine, again.
CLOCKWISE direction of rotation. Drain and dis-
card the removed filter element.
CAUTION: Be sure the used rubber gasket is

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

head using a CLEAN lint free cloth.
e. Put CLEAN engine lubrication oil on the rubber

gasket area of the NEW filter element. Fill the NEW
filter element with CORRECT, NEW and CLEAN oil.
f. Install the NEW filter element onto the filter

head. Carefully tighten the filter element, by the
hand ONLY.
NOTE: Tighten the filter element as DIRECTED

on the filter element, by the filter manu-
facturer. FIGURE 4-5. DEUTZ DIESEL ENGINE -
LUBRICATION OIL FILTER LOCATION.
CAUTION: Do NOT overtighten the lubrication

oil filter element onto the filter head. FUEL SYSTEM.
Follow all engine lubrication oil
change and fill procedures, given in FUEL TANK [See Figure 4-6].
THIS section, and in the engine
“Operation Manual - FL 1011 Series The low fuel level light is lighted when the amount of
Diesel Engine” published by Deutz fuel in the tank is "low". Check for a low fuel amount
Engine Company., BEFORE the ONE [1] time EACH day and fill the fuel tank to
engine is started. “FULL”, as needed. Also fill the tank, to “FULL”,
BEFORE the machine is stored for the night to re-
duce the accumulation of moisture, in the tank, from
NOTE: CHECK the engine lubrication oil level at condensation.
THIS time.
4-14 11/95
Section 4
MAINTENANCE
WARNING: DIESEL FUEL IS VERY FLAMMABLE.
USE EXTRA CAUTION.
Do NOT change the fuel filter ele-
ment in an area near open flame.
Do NOT change the fuel filter
filter element with the machine
running.
Do NOT smoke while changing the
fuel filter element.
Do NOT spill fuel.
a. STOP the engine. Close the fuel supply valve.
b. Put a container under the fuel filter, BEFORE

removing the filter element.
c. Wipe the area around the fuel filter element and

the element mounting head, using a CLEAN lint free
cloth.
FIGURE 4-6. FUEL TANK FILL CAP d. Use a filter removal wrench to loosen and re-
AND SPOUT. move the element, by turning the element in a
COUNTER-CLOCKWISE direction. Drain and dis-
card the removed element.
WARNING: The operator MUST be off the ma-
chine while fuel is added.
e. Wipe the inside area of the filter head with a
NO smoking while filling the fuel
CLEAN “lint free” cloth. Fill the “NEW” fuel filter ele-
tank.
ment COMPLETELY FULL of the CORRECT and
ALL fuels for internal combustion
CLEAN fuel. Put CLEAN oil on the element rubber
engines are flammable.
gasket.
Fill the fuel tank ONLY in a desig-
nated area with good ventilation.
Have a fire extinguisher available.
NEVER fill the tank near an open
flame or near equipment that can
create sparks.
NEVER check the fuel level, or
check for leaks with an open flame.
ENGINE FUEL FILTER [See Figure 4-7].
The fuel filter element MUST be replaced one [1]

time for EACH 500 hours of machine operation, or
each year.
Replace the fuel filter element using the following

“GENERAL” procedures and those given in the en-
gine “Operation Manual - FL 1011 Series Diesel En-
gine” published by Deutz Engine Company, and
supplied with the machine.
FIGURE 4-7. FUEL FILTER LOCATION - DEUTZ
DIESEL ENGINE.
11/95 4-15
Section 4
MAINTENANCE
f. Install the “NEW” fuel filter element onto the fil- ENGINE AIR FILTRATION.
ter head, until the gasket is seated against the filter
head. Tighten the element one half [1/2] additional AIR CLEANER [See Figure 4-8].
turn by the HAND only.
The engine inlet air cleaner assembly uses two [2]
replaceable filter elements.
CAUTION: Do NOT overtighten the fuel filter
element onto the filter head. CHECK the engine inlet air restriction indicator light
DAILY. If the restriction indicator light is “ON”, the
air cleaner filter elements MUST be removed and
g. Open the fuel supply valve. Start the engine replaced IMMEDIATELY.
and check for ANY fuel leaks.
WARNING: STOP the engine IMMEDIATELY if

ANY fuel leakage is noted.
Do NOT start the engine until
the leakage problem is
CORRECTED.
WING NUT
INNER AIR FILTER

ELEMENT AIR CLEANER RUBBER SEAL
BODY BOOT
CLAMP
VACUUM
RUBBER SEAL SWITCH
FITTING
RUBBER SEAL
WING NUT
CLIP
RUBBER SEAL
CLAMP
END CUP
OUTER AIR FILTER
ELEMENT
VACUATOR
VALVE WING NUT
ENGINE INLET AIR
SUPPLY HOSE
FIGURE 4-8. AIR CLEANER ASSEMBLY - EXPLODED VIEW.
4-16 11/95
Section 4
MAINTENANCE
CAUTION: The air cleaner filter elements should j. Install the air cleaner end cup onto the air
be replaced one [1] time for EACH cleaner body.
1,000 hours of machine operation, or
yearly, for a machine which is oper- k. Install the rubber seal over the threaded end
ated under “normal” conditions, or cup and air filter element retaining rod. Install and
one [1] time for EACH 500 hours of tighten the wing nut, which holds the end cup onto
machine operation, or every six [6] the air cleaner body.
months, for a machine which is
operated under “very dusty or l. Start the engine using ALL the CORRECT start-
“severe” conditions. ing procedures given in Section 3 - OPERATION -
Do NOT service the air cleaner of THIS manual. Note that the engine inlet air re-
elements while the engine is running. striction indicator light is “OFF” and that the engine
inlet air path is NOT being restricted.
Use the following procedures to service the air

cleaner elements:
COOLING SYSTEM.
a. Loosen the wing nut which retains the end cup.
Remove the end cup from the air cleaner body. CLEANING THE COOLING FINS AND THE HY-
DRAULIC OIL COOLER [See Figure 4-9].
b. Remove the wing nut, rubber seal and end cup
from the air cleaner body. WARNING: Do NOT clean the system with the
engine running. Serious injury can
c. Remove the outer air filter element from inside result from being caught or struck
the air cleaner body and DISCARD. by the cooling fans, belt or moving
engine parts.
d. Loosen and remove the wing nut and rubber
seal which retains the inner air filter element. Re-
move the inner air filter element and DISCARD. NOTE: Also see the engine “Operation Manual -
FL 1011 Series Diesel Engine” published
e. Clean the inside of the air cleaner body with a by Deutz Engine Company, and supplied
clean cloth. with the machine.
f. Inspect ALL hose clamps for tightness and the

condition of the engine inlet air supply hose from the Dirt, particularly in the form of spilled oil and/or fuel
air filter assembly to the engine air intake. on the engine cooling fins and hydraulic oil cooler,
reduces the cooling performance.
CAUTION: Severe engine damage can occur if If oil or fuel leakage in the area of the cooling
hose clamps are in a loose condition blower, cylinders or oil cooler is noted, immediately
or if the hose is damaged. find and repair the leak source.
g. Carefully install the NEW inner air filter element

into the air cleaner body.
h. Install the rubber seal over the threaded air fil-

ter element retaining rod. Install and tighten the
wing nut, which holds the inner air filter element into
the air cleaner body.
i. Carefully install the NEW outer air filter element

over the inner air filter element and into the air
cleaner body.
11/95 4-17
Section 4
MAINTENANCE
WARNING: The compressed air supply MUST
have a pressure BELOW 30 psi.
[2 bar]. Wear safety glasses and
protective clothing.
CAUTION: Do NOT damage the hydraulic oil

cooler cooling fins during cleaning.
Clean the fin area with the com-
pressed air blown in the OPPOSITE
direction of “normal” air flow during
operation.
NOTE: If remaining contamination is oily, spray

the engine with a cold cleansing agent
and flush with water after an adequate
“soaking time”. Also see the engine
“Operation Manual - FL 1011 Series
Diesel Engine” published by Deutz
FIGURE 4-9. ENGINE COOLING FINS - Engine Company, and supplied with the
CLEANING LOCATION. machine.
After repair of the leak source, clean the cooling fins e. Put the engine cooling air cowl in position on
using the following information. the engine and snap both retaining locks closed.
a. Keep the engine STOPPED. f. Start the engine and allow the engine to warm
for a short period to help prevent corrosion.
b. Unsnap and remove the engine cooling air
cowling.
c. Using a suitable brush, remove dry dirt from the

engine cooling fins.
NOTE: Also use the brush to remove dry dirt

from hydraulic oil cooler at this time.
d. Use low pressure compressed air to blow dust

from the engine cooling fins.
NOTE: Also use compressed air to remove dry

dirt from hydraulic oil cooler at this time.
4-18 11/95
Section 4
MAINTENANCE
HYDRAULIC SYSTEM. CHANGING THE HYDRAULIC OIL [See Figures
4-10, 4-11 and 4-12].
Obtain a hydraulic oil sample from oil six [6] inches
The transmission, vibration, steering and leveling [152.4 mm] BELOW the fill neck of the hydraulic oil
blade [Model BW124PDB] systems use the same reservoir one [1] time for each 2,000 hours of ma-
hydraulic oil reservoir and hydraulic oil supply. chine operation, or every two [2] years for OIL
ANALYSIS.
Use the equipment furnished, and follow the direc-

CHECKING THE HYDRAULIC OIL LEVEL AND tions given, by the oil analysis service. CHANGE
ADDING HYDRAULIC OIL TO THE HYDRAULIC the hydraulic oil IF the oil analysis results indicate a
OIL RESERVOIR [See Figure 4-10]. change is needed.
CHECK the hydraulic oil reservoir oil level, one [1] Changing the hydraulic oil removes the
time EACH day, using the dipstick in the reservoir accumulation of dirt, water and mechanical wear
filler cap. Check the oil level when the hydraulic oil particles from the hydraulic oil reservoir and system.
is at “NORMAL” operating temperature. The chemical structure of the hydraulic oil also
changes after continuous use in the system and
NEW, CLEAN and FILTERED oil is a MUST to help
WARNING: Do NOT loosen, or remove the insure further CORRECT operation of the hydraulic
hydraulic oil reservoir filler cap system.
when the hydraulic oil is “HOT”.
ALWAYS loosen the filler cap
SLOWLY to relieve any pressure in CAUTION: Hydraulic oil which has oxidized or
the hydraulic oil reservoir. ONLY which contains contamination, of
loosen the filler cap when the oil is ANY type, can shorten the expected
at a “WARM” temperature. service life of all, or any, of the
components in the hydraulic system.
The hydraulic reservoir oil level MUST be at the

"MAX" [top] line on the dipstick. If the hydraulic oil
level is BELOW the MAX" line, the CORRECT, FIL-
TERED hydraulic oil MUST be added to the hydrau-
lic oil reservoir UNTIL the oil level is at the COR-
RECT level.
CAUTION: Do NOT over fill the hydraulic oil

reservoir.
Do NOT use unfiltered hydraulic oil.
The NEW hydraulic oil MUST be
filtered through TEN [10] micron
filtration BEFORE it enters the
hydraulic oil reservoir. The oil must
NOT have more than 400 particles
larger than 10 u. per milliliter as
installed.
KEEP the oil level of the hydraulic
oil reservoir, at the CORRECT
level. The hydraulic oil reservoir can
have a low pressure in it at system FIGURE 4-10. HYDRAULIC OIL RESERVOIR AND
operating temperatures. OIL LEVEL CHECK DIPSTICK.
11/95 4-19
Section 4
MAINTENANCE
Use the following procedures to change the c. Go to the top area of the hydraulic oil reservoir.
hydraulic oil: Remove the capscrews and washers that fasten the
hydraulic reservoir access cover to the top of the
a. STOP the engine. Allow the hydraulic oil to reservoir. Carefully remove the access cover from
cool, until it is at a WARM temperature. Wipe the oil the reservoir.
filler cap, and surrounding area with a clean cloth.
Slowly loosen, and remove, the hydraulic oil reser-
voir filler cap. Put a CLEAN, lint free cloth over the CAUTION: Use CARE to NOT damage the gasket
reservoir fill tube opening and secure it in place. between the cover and the reservoir
when removing the access cover
from the reservoir. Inspect the
WARNING: Do NOT drain the hydraulic oil from gasket, and replace gasket with NEW
the reservoir when it is HOT. Hot when the cover is installed back onto
hydraulic oil can cause serious the reservoir, if damaged.
injury. Drain at a WARM temperature
ONLY.
d. Reach through the reservoir access opening
and use CLEAN lint free cloths to remove
b. Go to the lower area of the hydraulic oil reser- any remaining oil and/or contamination from the
voir. Wipe the oil drain plug, and surrounding area bottom area of the hydraulic oil reservoir.
with a clean cloth. Place an empty container, having
a capacity of approximately 10 gallons [39 liters],
under the hydraulic reservoir drain plug. Carefully CAP
remove the oil drain plug. Allow all of the oil to drain
into the container. Install and securely tighten oil
drain plug. SCREW
CAP RETAINER
GASKET
COVER
GASKET
CAP STRAINER
SCREW FILLER
NECK
WASHER
GASKET
FIGURE 4-12. HYDRAULIC OIL RESERVOIR

ACCESS COVER AND RELATED PARTS -
LOCATIONS.
FIGURE 4-11. HYDRAULIC OIL RESERVOIR

DRAIN PLUG LOCATION.
4-20 11/95
Section 4
MAINTENANCE
e. If removed, install a new gasket onto the hy- h. Install the hydraulic oil reservoir filler cap onto
draulic oil reservoir access opening area. Install the the reservoir filler neck and tighten securely.
access cover over the gasket and onto the hydraulic
oil reservoir. Install the retaining capscrews, with i. Start the engine using the correct procedures
washers, into the tapped reservoir bores and given in Section 3 - OPERATION - of THIS manual.
tighten securely. CHECK the hydraulic system for ANY leaks.
f. CAREFULLY remove the cloth from the hydrau- WARNING: Do NOT use the hands on ANY
lic oil reservoir fill tube opening. hydraulic hose, fitting or system
component to check the system for
possible leaks.
NOTE: Also change the one [1] hydraulic Serious injury can occur from a leak
pressure oil filter element at this time. under high pressure. Hydraulic oil,
See THIS section for service procedures. under pressure, can penetrate the
skin or damage eyes. Oil leaks,
under pressure, may NOT be visible.
CAUTION: Do NOT fill the hydraulic oil reservoir Use a piece of cardboard, or wood,
with NEW hydraulic oil UNTIL the to find leaks. Wear safety goggles
pressure filter element in the ABOVE for eye protection. IF oil enters the
“NOTE” has been serviced. skin, or eye, get IMMEDIATE medical
Do NOT start the engine UNTIL the attention.
hydraulic system has been COM-
PLETELY and CORRECTLY filled with
NEW, CORRECT and FILTERED CAUTION: STOP the engine IMMEDIATELY if
hydraulic oil [see THIS section]. ANY hydraulic leak is noted.
Damage to the components of the Do NOT start the engine UNTIL any
hydraulic system can occur, if the problem noted has been corrected.
engine is started BEFORE the system
is ENTIRELY filled with NEW hydrau-
lic oil.
g. Fill the hydraulic oil reservoir with NEW, COR-

RECT and FILTERED hydraulic oil to the "MAX"
level [top mark] on the dipstick .
CAUTION: Do NOT use unfiltered hydraulic oil.

The NEW hydraulic oil MUST be
filtered through TEN [10] micron
filtration BEFORE it enters the hy-
draulic system. The oil must NOT
have MORE than 800 particles larger
than 10 u. per milliliter of oil as
installed. Fill the hydraulic oil
reservoir UNTIL the oil is at the
"MAX" level on the dipstick.
Do NOT overfill the hydraulic oil
reservoir with oil.
11/95 4-21
Section 4
MAINTENANCE
HYDRAULIC PRESSURE OIL FILTER ELEMENT -
REMOVAL AND REPLACEMENT [See Figure
4-13].
Check the condition of the hydraulic pressure oil fil-

ter element EACH day. The filter element MUST be
changed when the change indicator, found on the
filter head, indicate an element change is required.
Also change the filter element with EACH hydraulic
oil change.
CAUTION: The hydraulic system MUST be at

NORMAL operating temperature,
with the engine “running”, when the
condition of the filter element is
checked. With the engine at “HIGH”
idle, and when the filter condition
indicator WHITE sliding bar is in the
RED zone, an element CHANGE is
indicated to be needed.
FIGURE 4-13. HYDRAULIC PRESSURE OIL
FILTER ELEMENT LOCATION.
NOTE: When the hydraulic oil is “COLD” and at

machine “START UP” the filter condition
indicator WHITE sliding bar can show a CAUTION: Be sure that the old filter element
HIGHER amount of filter element restric- rubber gasket was removed and
tion. discarded, BEFORE the new filter
element is Installed.
WARNING: Do NOT loosen, or remove, the

hydraulic pressure oil filter element d. Put CLEAN hydraulic oil on the NEW filter ele-
when the engine is running or when ment rubber gasket. Completely fill the filter with
the hydraulic oil is HOT. Loosen and NEW, CORRECT and FILTERED hydraulic oil.
remove the filter element ONLY
when the engine is “STOPPED” and e. CAREFULLY install the NEW filter element
the hydraulic oil has cooled to a onto the filter head. Tighten the NEW filter element
WARM or COLD temperature. onto the filter head ONLY UNTIL the rubber gasket
contacts the filter head seal area. Tighten the NEW
filter element ONE HALF [1/2] additional turn AF-
Use the following procedure to remove and replace TER the rubber gasket contacts the filter head area.
the hydraulic pressure oil filter element:
a. STOP the engine. Allow the hydraulic oil to CAUTION: Do NOT overtighten the NEW filter
reach a WARM or COOL temperature. element. Tighten by hand ONLY.
b. Wipe the hydraulic suction oil filter head and

element using a CLEAN lint free cloth.
c. Use a oil filter removal wrench to loosen and

remove the filterx element. Drain and then discard
the removed filter element.
4-22 11/95
Section 4
MAINTENANCE
f. Fill the hydraulic oil reservoir with oil. Use ALL
the CORRECT procedures given in THIS section.
CAUTION: Do NOT start the engine BEFORE

filling the hydraulic oil reservoir.
Damage to the hydraulic system
components can occur. Fill the
reservoir and pressure oil filter
element given in THIS section
BEFORE starting the engine.
g. Start the engine using the CORRECT proce-

dures given in Section 3 - OPERATION - of THIS
manual. Check the hydraulic system for ANY oil
leaks.
WARNING: Do NOT use the hands on ANY

hydraulic hose, fitting or system
component to check the system for FIGURE 4-14. ALTERNATOR AND
possible leaks. SERIOUS injury can COOLING FANS DRIVE BELT LOCATION.
occur from a leak under high pres-
sure. Oil can be injected under the
skin by high pressure. Protect the
eyes by wearing safety glasses. a. STOP the engine.
CAUTION: STOP the engine IMMEDIATELY if WARNING: Do NOT inspect or adjust the drive
ANY hydraulic oil leak is noted. belt when the engine is running. The
Do NOT start the engine UNTIL any engine MUST be STOPPED before
problem noted has been corrected. inspecting and/or adjusting the drive
belt. Serious injury can result from
being caught or struck by the
cooling fans, belt or other moving
ALTERNATOR AND COOLING FANS DRIVE engine parts.
BELT INSPECTION ADJUSTMENT AND
REPLACEMENT PROCEDURES [See Figure
4-14]. b. Visually inspect the drive belt for cracks on the
INNER surface of the belt plies. Check the belt de-
Inspect the single drive belt one [1] time for EACH flection at the longest span of the belt. The MAXI-
50 hours of machine operation, or every two [2] MUM amount of deflection is 0.406-0.593in. [10-15
weeks, and replace the belt if needed. mm] with thumb pressure on the belt. Replace the
belt, with NEW, if any cracks or other damage is
The belt is kept under tension by an adjustable ten- noted.
sion mechanism.
Use the following procedures to inspect and adjust NOTE: If the belt requires replacement with
or inspect, replace and then adjust the drive belt: NEW, also see the engine “Operation
Manual - FL 1011 Series Diesel Engine”
published by Deutz Engine Company,
and supplied with the machine.
11/95 4-23
Section 4
MAINTENANCE
ELECTRICAL SYSTEM. WARNING: BATTERY EXPLOSION CAN OCCUR
IF THE BATTERY IS SHORTED.
CHECKING THE BATTERY “CONDITION” AND ALWAYS disconnect the NEGATIVE
SERVICING OF RELATED ITEMS [See Figure 4- [-] battery cable FIRST, and then
15]. disconnect the POSITIVE [+] battery
cable, BEFORE cleaning the termi-
WARNING: Do NOT attempt to open the battery nals or cables. NEVER make a
case, except the filler caps. The acid shorted circuit between the positive
in electrolyte can cause INJURY. If [+] terminal and negative [-] terminal
electrolyte is spilled, use water to of the battery.
FLUSH the area and make the acid ALWAYS connect the POSITIVE [+]
NEUTRAL using a WATER and battery cable to the POSITIVE
SODA solution. Acid in the EYES battery terminal FIRST, and then
MUST be FLUSHED with water connect the NEGATIVE [-] battery
IMMEDIATELY. cable to the NEGATIVE [-] battery
ALL batteries produce an EXPLO- terminal LAST.
SIVE GAS. Do NOT place ANY tools on a
Do NOT smoke near a battery. battery at ANY time.
Do NOT check with flame.
AVOID causing sparks.
Place NO tools on the battery.
Wear eye protection.
Remove the battery fill covers and check the acid

level in the battery one [1] time for EACH 100 hours
of machine operation, or every two [2] weeks. If
needed, fill the battery to the "full" level with clean
distilled water. Install the fill covers after checking.
Remove the battery and clean the battery compart-

ment with baking soda and flush with clean water.
Clean the outside of the battery with baking soda

and flush with clean water.
Install and tighten the battery hold down assembly.

The battery MUST be kept from ANY movement in
the machine.
Use a battery cable cleaning brush, baking soda

FIGURE 4-15. BATTERY MAINTENANCE ITEM
and clear water to clean the battery terminals and
LOCATIONS.
cables. Put petroleum jelly on both posts and cables
AFTER the cables are connected.
ELECTRICAL WIRING INSPECTION [See Figure

4-16].
During engine and other system maintenance in-

spections, check the electrical wiring for correct
routing and support. Inspect the wires for loose ter-
minal connections, cracks or wear in
the wiring insulation and for corrosion. Wires and
connections MUST be free of oil, dirt or grease.
4-24 11/95
Section 4
MAINTENANCE
11/95 4-25
Section 4
MAINTENANCE
WARNING: BATTERY EXPLOSION CAN OCCUR a. Remove the tire valve cap from the tire inflation
IF A BATTERY IS SHORTED. valve. Check the inflation pressure of the tire, using
ALWAYS disconnect BOTH the an accurate tire pressure gauge. Check the second
positive [+] AND the negative [-] drive tire inflation pressure. Install BOTH valve
battery cables from a battery, caps.
BEFORE ANY repair procedures are
done to the electrical wiring or
components. WARNING: ALWAYS use remote inflation
ALWAYS use APPROVED practices equipment consisting of an exten-
when performing electrical system sion hose, with clip-on filling chuck,
diagnosis procedures and doing re- and a gauge or preset pressure
pairs. regulator. When adding inflation air
NEVER make a shorted circuit to the drive tires, ALL personnel
between the positive [+] terminal MUST keep clear of the tire and rim.
and the negative [-] terminal of a Serious injury can occur if a tire is
battery. released from the wheel.
Do NOT place ANY tools on a
battery at ANY time.
CAUTION: The pressure indicated, on the tire
pressure gauge, must be 26 psi. [1.8
CAUTION: Do NOT use a wire smaller than the bar], for open faced diamond tread
size of the original factory installed tires, or 28 psi. [2.0 bar] for bar tread
wires in the electrical system. If due tires with the drive tires “cool”.
to wear or damage wires are replaced Adjust the air pressure until the
with new, use wire being replaced. pressure indicated is correct.
Do NOT overinflate the drive tires.
The drive tires will NOT absorb
shocks to the machine. Over inflated
DRIVE TIRES. tires also are more likely to cut, snag
or be punctured.
INSPECTION, AIR PRESSURE CHECK AND Do NOT under inflate the drive tires.
ADJUSTMENT [See Figure 4-17]. The drive tires will be too soft and
will over deflect. This condition can
Check each tire for the correct inflation pressure build excess heat and can cause
one [1] time for each 50 hours of machine operation breaks in the tire body cords.
or weekly. ALWAYS install a tire valve cap, onto
the tire valve stem, after checking
Also, inspect each tire for cuts or other serious dam- and/or adjusting the drive tire infla-
age at this time. tion pressure.
If tire damage is found, use an authorized tire ser-

vice to remove the tire/wheel assembly, repair, or NOTE: Do NOT check the drive tire pressure
replace, the damaged tire and install the tire/wheel when the tires are warm. Check the tire
assembly onto the machine. inflation pressure only when the drive
tires are “cool”.
Check each drive tire inflation pressure and adjust
as needed, using the following procedures:
4-26 11/95
Section 4
MAINTENANCE
FIGURE 4-17. DRIVE WHEEL TIRE, INFLATION FIGURE 4-18. HITCH BEARINGS - LUBRICATION
AIR PRESSURE CHECK, AND FILL LOCATIONS. LOCATIONS.
MISCELLANEOUS MAINTENANCE LEVELING BLADE BEARINGS - MODEL

INFORMATION. BW124PDB [See Figure 4-19].
GREASE LUBRICATION. a. Park the machine on a level surface. Put the

secondary/parking brake system “ON” [APPLIED].
Use the following information to lubricate the given STOP the engine.
locations on the machine with LITHIUM HIGH
PRESSURE GREASE one time for each 50 hours b. Go to the front center of the machine. Find the
of machine operation, or weekly. leveling blade cylinder, two [2] leveling blade cylin-
der bearings and bearing lubrication grease zerks.
c. Wipe the two [2] cylinder bearing lubrication

HITCH BEARINGS [See figure 4-18]. grease zerks with a CLEAN cloth.
a. Park the machine on a level surface. Put the d. Give each zerk approximately five [5] grease
secondary/parking brake system “ON” [APPLIED]. gun pumps to lubricate the bearing.
STOP the engine.
b. Go to the hitch area. Wipe the three [3] hitch

bearing lubrication grease zerks with a CLEAN
cloth.
c. Give each grease zerk approximately five [5]

grease gun handle pumps to lubricate the bearing.
11/95 4-27
Section 4
MAINTENANCE
NOTE: On Model BW124D, loosen the one [1]
capscrew which fastens the adjustable
cleaner bar to the frame at each end.
Adjust the cleaner bar to contact the
drum surface. Tighten the capscrews to a
torque of 65 ft. lbs. [88 N.m]. On Models
BW124PD and BW124PDB, loosen the
capscrews that fasten the scrapers to the
cross member. Center EACH scraper BE-
TWEEN the drum feet and adjust EACH
scraper to drum surface clearance to 0.25
in. [7 mm]. Tighten all capscrews to a
torque of 91 ft. lbs. [123 N.m].
FIGURE 4-19. LEVELING BLADE BEARINGS -

LUBRICATION LOCATIONS.
BOLT
SCRAPER ASSEMBLIES [See Figures 4-20 and
4-21].
FIGURE 4-20. SCRAPER
Check for broken or loose scraper components one ASSEMBLIES - MODEL BW124D ROLLER.
[1] time for each 50 hours of machine operation, or
weekly. Replace broken or missing parts as
required. Keep all mounting fasteners correctly
tightened at all times.
WARNING: Scrapers can become very sharp, on

the lower edge when worn.
Serious injury can occur if contact
is made with a sharp edge.
CAUTION: Do NOT operate a machine having

missing or damaged scraper compo-
nents. Replace ALL missing or
damaged scraper components FIGURE 4-21. SCRAPER ASSEMBLIES -
IMMEDIATELY. MODEL BW124PD AND BW124PDB ROLLERS.
4-28 11/95
Section 4
MAINTENANCE
OPERATOR RESTRAINT [SEAT BELT], FALLING DANGER: If ANY structure damage is found
OBJECT AND ROLL OVER during the inspection process, do
PROTECTION STRUCTURE [FOPS/ROPS] SYS- NOT operate the machine. Remove
TEMS [See Figure 4-22]. the ignition key and place a tag on the
steering wheel saying; “DO NOT
One [1] time for each eight [8] hours of machine op- OPERATE”. Contact your nearest
eration, or daily check the condition of the operator Distributor and/or Compaction
restraint [seat belt] system. America, Kewanee, Illinois, USA, for
repair or replacement instructions.
The anchor end of each half belt MUST be securely
fastened [bolted] to the machine. Securely tighten
any retaining bolt, found to be in a loosened condi-
tion, to a torque of 37 ft. lbs. [50 N.m].
Each retaining bolt MUST be in a good condition

and NOT be rusted, broken or otherwise damaged.
If needed, replace, and then securely tighten the
bolt, with NEW of the SAME type and strength
[grade], that shows ANY damage.
Each belt half MUST be in good condition. The belt

material must NOT be cut, rotted or torn. Carefully
inspect the latch/release mechanism for full and cor-
rect latch engagement and release actions.
Replace the COMPLETE operator restraint [seat
belt] SET, with NEW, if ANY damage or malfunction
is noted.
One [1] time for each eight [8] hours of machine op-
eration, or daily check the condition of the falling ob-
ject and roll overprotection structure [FOPS/ROPS]
to machine retaining capscrews and nuts.
Each of the structure retaining capscrew and nut

MUST remain FULLY tightened to the CORRECT
torque of 221 ft.lbs. [300 N.m] at ALL times.
Each retaining capscrew MUST be in a good condi-

tion and NOT be rusted, broken or otherwise dam-
aged. Replace, and then securely tighten, ANY
capscrew, with NEW of the SAME type and strength
[M16 - grade 10.8], that shows ANY damage.
Tighten ALL capscrews and nuts to a CORRECT
torque of 221 ft.lbs. [300 N.m], AFTER replacement.
At the SAME time, also inspect ALL of the CRITI-

CAL structural members [Uprights, Cross members,
Tubes or Gussets] for broken welds, severe rust
and/or damage to the materials.
11/95 4-29
Section 4
MAINTENANCE
FIGURE 4-22. OPERATOR RESTRAINT [SEAT BELT], FALLING OBJECT/ROLL OVER PROTECTION
STRUCTURE [FOPS/ROPS] SYSTEM COMPONENTS.
PREPARING THE MACHINE FOR STORAGE. BATTERY.
Use the following information as a “general guide” If the machine is to be stored for a period of MORE
ONLY to prepare the machine for storage. If than 30 days, remove the battery from the machine.
desired, Manufacturers of component parts, used Wash the battery with baking soda and water solu-
on the machine, can also be contacted for specific tion, rinse with clear water and permit to air dry.
information about components manufactured by Service the battery as required [see THIS Section].
them.
Fully charge the battery BEFORE it is placed into
storage. Charge the battery, again, one [1] time for
every 30 days which the battery is stored.
ENGINE PRESERVATION.
Keep the battery stored in a wood surface in a
See the engine “Operation Manual - FL1011 Series COOL and DRY storage area.
Diesel Engine” published by Deutz Engine Com-
pany, and supplied with the machine for engine
storage preservation procedures that are suggested CAUTION: Do NOT store the battery on a con-
by the engine manufacturer. crete surface. Store the battery on a
WOOD surface ONLY. Be sure the
battery electrolyte will NOT freeze.
4-30 11/95
Section 4
MAINTENANCE
FUEL TANK. EXPOSED COMPONENT RUST PREVENTION.
FILL the fuel tank to a COMPLETELY full condition, Put a heavy grease, or equivalent, onto the exposed
using the CORRECT, CLEAN fuel, BEFORE the area of the hydraulic cylinder rod. Put a rust preven-
machine is placed in storage [see THIS section]. tative oil [such as L.P.S. #s 2 or 3] on ALL control
linkages, control cable ends, hinges or other moving
parts.
CAUTION: Do NOT leave the fuel tank ONLY part
filled. Moisture can condense inside Put ALL covers and access plates in their correct
the fuel tank, while in storage, and position and secure in place with the retaining
can cause fuel system component capscrews.
damage during storage and/or when
the machine is placed back into use.
AIR CLEANER, EXHAUST AND OTHER

OPENINGS.
Put a cap, tape or otherwise seal ALL openings to

prevent the entrance of moisture, or other forms of
contamination, while the machine is in storage.
DRIVE TIRES.
Check and adjust the air pressure of the drive tires

to the CORRECT cold pressure [see this section].
Us e a jack, having a capacity of 5 tons [4.5 t] to
carefully lift BOTH sides of the machine REAR
frame assembly enough, so that BOTH drive tires
are ABOVE the ground a SMALL amount. Put solid
wood blocks under BOTH sides of the REAR frame,
to keep the machine drive tires above the ground.
Lower the machine onto the blocks. Remove the
jack. Cover the drive tires to keep direct sun light
from them.
WARNING: Keep CLEAR of the jack, frame and

blocks while lifting, blocking and
lowering the machine. Serious injury
can occur if caught by the above
items. Block the rear machine frame
SECURELY using solid wood block-
ing.
11/95 4-31
Section 4
MAINTENANCE
NOTES
4-32 11/95
Section 5
FRAME, HITCH and FALLING OBJECT/
ROLL OVER PROTECTION STRUCTURE
TABLE OF CONTENTS
PAGE
GENERAL INFORMATION ........................................................................................................................... 5-2

DESCRIPTION OF THE FRAMES AND THE HITCH ................................................................................... 5-2
REMOVAL OF THE HITCH ASSEMBLY ....................................................................................................... 5-3
INSTALLATION OF THE HITCH ASSEMBLY ............................................................................................... 5-5

FALLING OBJECT/ROLL OVER PROTECTION STRUCTURE [FOPS/ROPS] .......................................... 5-7
CHECKS AND SERVICE PROCEDURES .................................................................................................... 5-7
TROUBLE ANALYSIS FOR THE FRAME AND HITCH .............................................................................. 5-10
6/96 5-1
Section 5
GENERAL INFORMATION. The hitch assembly permits movement of the TWO
[2] frames. The hitch includes a VERTICAL support,
This section describes the FRAMES, HITCH and which gives a total of, 60 degrees of machine steer-
FALLING OBJECT/ROLL OVER PROTECTION ing, full left to full right.
STRUCTURE [FOPS/ROPS] used on Model BW
124D, BW 124PD, and BW 124PDB Single Drum The HORIZONTAL joint cross shaft gives the
Rollers [see figure 5-1]. machine a total of 13 degrees oscillation between
the FRONT and REAR frames. Frame and hitch
Hitch removal and disassembly, inspection of com- loads are held on bushing and thrust bearing
ponents, assembly, and installation information is assemblies.
also given in this section.
The VERTICAL hitch coupling is made of the
Information about inspection and maintenance of the following items: two [2] pillow blocks each installed
falling object/roll over protection structure is also onto the rear frame weldment by four [4] hex bolts,
found in this section. four [4] discs, and four [4] hex nuts. Two [2] bearing
covers attached to the outside surface of each pil-
low block casting by [6] hex bolts. One [1] hitch sup-
port
DESCRIPTION OF THE FRAMES AND THE HITCH has an upper assembly and a lower assembly. The
[See Figures 5-1 and 5-2]. upper assembly consisting of the following items:
one [1] sealing ring, one [1] spherical bearings, three
The machine uses a FRONT frame and a REAR [3] supporting discs, one [1] internal circlip, and one
frame weldment. The FRONT and REAR frame [1] external circlip.
weldments are connected by the HITCH assembly.
FRONT WELDMENT
REAR WELDMENT
OSCILLATION
HITCH
FIGURE 5-1. LOCATION OF THE HITCH AND FRAMES.
5-2 6/96
Section 5
The lower assembly consisting of the following c. Go to the steering cylinder to hitch connection
items: one [1] sealing ring, one [1] spherical bear- point. Remove the cotter pin from the steering cylin-
ings, two [2] supporting discs, and one [1] internal der to hitch gudgeon. Remove the pin and move the
circlip. Also used are; two [2] grease nipples. One steering cylinder away from the hitch.
grease nipple is installed on the front of each pillow
block. d. Support the hitch assembly with a mobile jack.
The HORIZONTAL hitch coupling is made of the fol- e. While insuring that both the front and rear frame
lowing items: one [1] bearing housing, one [1] joint weldments are supported on all four [4] corners, re-
cross shaft, two [2] tapered roller bearings, two [2] move the eight [8] hex bolts attaching the bearing
sealing rings, one [1] supporting disc, one [1] housing to the front weldment.
belleville spring, and one [1] tension nut.
f. Go to the rear frame weldment, locate both the
Also used are, one [1] cylinder loop attached to the upper and lower pillow blocks. Remove the four [4]
rear of the hitch support by six [6] hex bolts, and six hex bolts while holding the hex nuts with a wrench
[6] discs. One [1] cylinder attached to the cylinder from each of the pillow blocks. Set aside the hex
loop by two [2] supporting discs, one [1] spherical bolts, discs, and hex nuts.
bearing, one [1] disc, one [1] gudgeon, one [1] screw
plug, and one cotter pin. The rear of the g. Balance the hitch while removing. Lift the hitch
cylinder is attached to the cylinder bearing by assembly to an appropriate work place.
two [2] supporting discs, one [1] spherical bearing,
one [1] disc, one [1] gudgeon, one [1] screw plug, h. Locate the bearing cover on the upper pillow
and one cotter pin. The cylinder support is mounted block and remove the six [6] hex bolts and set aside.
through the plate of the rear frame by four [4] hex Remove the bearing cover and set aside. Remove
bolts, eight [8] tightening washers, and four [4] hex the external circlip and the supporting disc.
nuts.
i. Locate the bearing cover on the lower pillow
block and remove the six [6] hex bolts and set aside.
Remove the bearing cover and set aside.
REMOVAL OF THE HITCH ASSEMBLY
[See Figures 5-1 and 5-2].
NOTE: Discard all spherical bearings and sealing
Use the following procedure for removal of the hitch rings. Contact an authorized distributor
assembly. and purchase replacement bearings, seal-
ing rings, and any other components
a. Support BOTH the front and rear frames, under showing wear and/or damage. If severe
ALL four [4] corners of each frame, with SOLID wear or damage is noted in all major com-
wood blocks. ponents (bearing housing, cylinder sup-
port, joint cross shaft), replace the com-
plete hitch assembly with new.
WARNING: Block SECURELY under ALL four [4]
corners of BOTH the FRONT and
REAR frame sections. The frame j. Use a puller and remove both pillow blocks from
halves will NOT balance and MUST the vertical support. Remove the seal ring and sup-
be supported under ALL four cor- port disc from each pillow block. Remove the inter-
ners of EACH frame section. nal circlips and supporting disc from each pillow
block.
b. Completely clean the hitch and frame areas,
with All-Purpose Degreaser, part number 178297, k. Use a suitable mandrel to press the spherical
and permit to air dry.
6/96 5-3
Section 5
SPERICAL
BEARING COVER
BEARING
PILLOW BLOCK
GREASE NIPPLE
EXTERNAL CIRCLIP CYLINDER

SUPPORTING DISC BEARING
SPERICAL BEARING
SUPPORTING DISC
INTERNAL CIRCLIP
SUPPORTING DISC
SEALING RING
CYLINDER
JOINT CROSS
SHAFT
CYLINDER LOOP
SEALING RING
SUPPORTING DISC
SUPPORT INTERNAL CIRCLIP
SUPPORTING DISC
SPERICAL BEARING
PILLOW BLOCK
TAPER
ROLLER BEARING
BEARING
HOUSING
BEARING COVER
GREASE NIPPLE
TAPER ROLLER BEARING

SUPPORTING
BELLEVILLE SPRING
DISC
TENSION NUT
SEALING RING
FIGURE 5-2. COMPONENTS OF THE HITCH ASSEMBLY.
5-4 6/96
Section 5
bearing out of each pillow block. b. Slide a NEW sealing ring and new supporting
disk onto the jointed cross shaft. Fit a new tapered
l. Secure the hitch support to allow parts removal roller bearing and press it on until the final stop. Fill
from the horizontal hitch assembly. Locate and re- the bearing well with lithium-soaped high pressure
move the sealing ring found on the back side of the grease.
bearing housing.
m. Use a pin wrench to remove the tension nut c. Press both outer races of the bearing into the
from the jointed cross shaft. bearing housing until final stop.
n. Remove and set aside, the Belleville spring. d. Carefully fit the bearing housing over the cross
shaft; when doing so, insert the inner seal ring into
o. Use a puller to pull the bearing housing from its the bearing housing.
seat and remove it.
e. Fill the outer tapered roller bearing with lithium-
p. Pull the tapered roller bearing inner race and soaped high pressure grease and fit it in position.
the supporting disc, from the jointed cross shaft.
f. Fit the Belleville spring with the convex side fac-
q. Drive the inner race and both outer races of the ing inwards.
tapered roller bearing, out of the bearing housing.
g. Screw on a new tension nut with the large outer
r. Check the condition of the jointed cross shaft for diameter facing inwards and tighten it with a pin
wear and/or damage. If necessary, detach and set wrench until the dimension 11.4 [± 0.1 mm] is ob-
aside both the jointed cross shaft, sealing ring and tained [SEE FIGURE 5-3].
the cylinder loop from the vertical support.
s. Go to the steering cylinder and remove the NOTE: Measurement is made through the inner
screw plug, cotter pin, grudgeon, spherical bearing, bores in the tension nut. When tighten-
disc, and two [2] supporting discs located at the rear ing, rotate the jointed cross shaft to en-
of the cylinder and set them aside. Place the cylin- sure that the individual rollers support
der in a secure position. the load equally.
CAUTION: Ensure the cylinder will not damage

other internal components.
11.4 +/- 0.1 mm
t. Examine all components for wear and/or dam-
age. Discard all spherical bearings and sealing
rings. Contact an authorized distributor and pur-
chase replacement bearings, sealing rings, and any
other components showing wear and/or damage.
INSTALLATION OF THE HITCH ASSEMBLY [See

Figures 5-1 and 5-2].
a. If necessary, attach the jointed cross shaft to

the vertical support.
FIGURE 5-3. DIMENSION MEASUREMENT

LOCATION.
6/96 5-5
Section 5
h. Secure the set tension nut by striking twice with s. Install the two [2] hex bolts with discs through
a punch at opposite sides. the left center and right center holes of the bearing
housing, and then into the threaded holes in the
i. Place the sealing ring into the bearing housing, front frame.
over the tension nut.
t. Install the six [6] hex bolts with discs through
j. Install the internal circlip and then the supporting both the upper and lower: left, center, and right
disc into both pillow blocks. holes of the bearing housing, and then into the
threaded holes in the front frame.
k. Press a spherical bearing into each pillow block,
until the final stop. u. Tighten all hex bolts connecting the bearing
housing to the front frame to a torque of 221 ft. lbs.
l. Lubricate all parts with a lithium-soaped high [300 N.m].
pressure grease.
v. Move the steering cylinder into position to be
m. Install the sealing ring, onto each vertical sup- mounted onto the cylinder support. Press one [1]
port pin located on the cylinder support. spherical bearing into the cylinder support. Install
one [1] supporting disc on each side of the spherical
n. Press the pillow blocks onto the upper and bearing. Place the steering cylinder onto the cylinder
lower vertical support pins, install support disc and support and install one [1] gudgeon through the top
external circlip onto the upper and lower vertical of the cylinder eyelet, place one [1] supporting disc
support pins. onto the gudgeon. Put one [1] cotter pin through the
gudgeon pin and bend the cotter pin. Install the
o. Fill bore in the bearing cover with a lithium- screw plug into the top of the gudgeon.
soaped high pressure grease. Install the bearing
cover on both the upper and lower pillow blocks with w. Move the steering cylinder into position to be
six [6] hex bolts each. Torque each of the hex bolts mounted onto the cylinder loop. Place one [1]
to 30 ft. lbs. [45 N.m]. spherical bearing into of the cylinder loop. Install
one [1] supporting disc on each side of the cylinder
p. Place the hitch assembly onto the mobile jack in loop. Place the steering cylinder onto the cylinder
such a position as to allow mobility and support the loop and install one [1] gudgeon through the top of
articulated joint. Return the hitch assembly to the the cylinder eyelet, place one [1] supporting disc
rear frame. Raise the hitch and align the through onto the gudgeon. Put one [1] cotter pin through the
holes of the lower pillow block with the through holes gudgeon pin and bend the cotter pin. Install the
located on the rear frame. screw plug into the top of the gudgeon.
q. Install the four [4] hex bolts through both the x. Use a hydraulic jack, having a capacity MORE
lower pillow block and the rear frame. Place the four than 5,000 lbs. [2270 kg], to lift the frame near each
[4] discs and the four [4] hex bolts while, and tighten block. Carefully remove ALL support blocking from
the hex bolts while holding the hex nuts with a under the machine and lower the machine. Go to the
wrench. remaining blocked areas and remove the blocking.
r. Install the four [4] hex bolts through both the up-
per pillow block and the rear frame. Place the four WARNING: Keep CLEAR of the jack, frame area
[4] discs and the four [4] hex nuts, and tighten the and blocking while lifting the ma-
hex bolts while holding the hex nuts with a wrench. chine, removing the blocking and
After installation, the hex bolts on both pillow blocks lowering the machine to the ground.
must be torqued to 221 ft. lbs. [300 N.m]. Serious injury can occur if caught by
the above items.
5-6 6/96
Section 5
y. Start the engine and check the hitch for func- a. Inspect ALL hardware that fastens the STRUC-
tion. TURE to the machine. They MUST remain tightened
to a torque of 221 ft. lbs. [300 N.m]. If replacement
hardware is needed, select the correct item having
DANGER: KEEP CLEAR of the hitch area. Clear- the SAME specifications. Install and then tighten the
ance closes between the front and hex bolts and nuts to the CORRECT torque using a
rear frames during a right or left large capacity torque wrench.
turn of the machine.
Serious INJURY, or DEATH, can occur
if caught between the frames at the WARNING: If the protective structure has been
hitch area. removed from the machine and isbe-
ing installed again, Inspect each
piece of mounting hardware for wear
or damage. Replace worn, or dam-
FALLING OBJECT/ROLL OVER PROTECTION aged, hardware items with NEW.
STRUCTURE [FOPS/ROPS] [See Figure 5-4]. Install, and then tighten, all mounting
hardware as directed in step "a"
The steel components of the FALLING OBJECT/ above.
ROLL OVER PROTECTION STRUCTURE [FOPS/ NEVER replace any mounting hard-
ROPS] are welded together using material welding ware item with an item NOT having
practices that produce a strong integrated structure. equal, or better, rating.
The protection structure with brackets is fastened to

the machine on EACH side of the REAR frame by a b. Carefully inspect ALL welds for cracks, severe
total of twelve [12] hex bolts, twenty-four [24] tighten- rust, breakage in the weld and/or where the weld
ing washers, and twelve [12] hex nuts. joins the metal of the structure steel components.
DANGER: An improperly mounted, or damaged, WARNING: If ANY damage is found, contact your
structure may not provide operator nearest Distributor IMMEDIATELY for
protection in the event of a machine replacement or repair instructions.
tip over. Follow the inspection Do NOT use the machine until
procedures below. contact and the directed repairs, or
protective structure replacement,
has been done.
Do NOT add anything to the protec-
CHECKS AND SERVICE PROCEDURES [See Fig- tive structure. NEVER "heat" or weld
ure 5-4]. any "add on" item onto the structure.
Do NOT operate a machine AFTER a
Use the following information to check the ROLL roll over situation HAS occurred. If a
OVER PROTECTION STRUCTURE components for roll over situation has occurred,
breakage or other damage and correct tightening at REMOVE the protective structure
LEAST one [1] time for each eight [8] hours of ma- from the machine only AFTER
chine operation, or daily and to do minor surface rust contact has been made with your
removal and painting on the structure. nearest Distributor and/or Compac-
tion America. Assistance in the
repair, or replacement, of the system
will be offered.
NEVER weld on, or replace, a protec-
tive structure component BEFORE
obtaining instructions, per the
ABOVE information.
6/96 5-7
Section 5
c. If surface rust on components is found, remove
rust from ALL welds and structure components. Ap-
ply paint primer and top coat paint to the complete
protective structure, as directed by the paint manu-
facturer.
d. A seat belt system is included with the protec-

tive structure to help restrain the operator in the
event of machine tipping. Carefully inspect the seat
belt. The latch MUST catch and release correctly.
The belt material MUST be clean and not torn, rotted
or damaged. The belt anchor bolts MUST remain
tightened securely, to the seat riser, at a CORRECT
torque of 37 ft. lbs. [50 N.m]. Replace the COM-
PLETE belt SET, with NEW, if ANY damage is
found.
WARNING: IMMEDIATELY after becoming

seated, FASTEN and then TIGHTEN,
the seat belt BEFORE starting the
engine. During machine operation, if
the machine tips, do NOT jump.
NEVER operate a machine having a
worn, damaged or malfunctioning
seat belt. Repair or replace the seat
belt IMMEDIATELY.
5-8 6/96
Section 5
ROPS
HEX BOLT
TIGHTENING
WASHER
CONSOLE
LEFTHAND
CONSOLE
RIGHTHAND
HEX NUT
HEX BOLT
TIGHTENING
WASHER
FIGURE 5-4. FALLING OBJECT/ROLL OVER PROTECTIVE STRUCTURE [FOPS/ROPS] AND

OPERATOR RESTRAINT - MAJOR COMPONENT LOCATIONS
6/96 5-9
Section 5
TROUBLE ANALYSIS FOR THE FRAME AND HITCH
TROUBLE CAUSE CORRECTIVE ACTION
NOISE IN HITCH AREA Worn or damaged parts in the Disassemble hitch. Inspect
DURING OSCILLATION hitch assembly parts for wear or damage.
AND/OR TURN Replace parts, with NEW, as
found needed.
STEERING ACTION Binding of the upper and/or Disassemble hitch. Inspect

NOT SMOOTH lower pin on the vertical parts for wear or damage.
support Replace parts, with NEW, as
found needed.
Worn or damaged spherical Disassemble hitch. Inspect

bearing[s] in the hitch parts for wear or damage.
Replace parts, with NEW, as
found needed.
5-10 6/96
Section 6
ENGINE
TABLE OF CONTENTS
PAGE

DESCRIPTION ............................................................................................................................................... 6-2
REMOVAL OF THE ENGINE ASSEMBLY .................................................................................................... 6-2
INSTALLATION OF THE ENGINE ASSEMBLY ............................................................................................ 6-4
6/96 6-1
Section 6
ENGINE
GENERAL INFORMATION. REMOVAL OF THE ENGINE [See Figure 6-2].
This section contains information about the DEUTZ a. Remove the side covers, from the side of the
diesel engine used in the Model BW 124D, BW engine compartment. Remove the air inlet hose as-
124PD, and BW 124 PDB Single Drum Rollers. sembly from the engine inlet air connection point.
Remove the lift shockfrom it's location at the fender
This section also contains REMOVAL and INSTAL- mount. Remove the engine hood assembly retaining
LATION information about the engine. nuts, washers and cap screws. Disconnect the
backup alarm harnes from alarm and remove harnes
from hood. Remove the hood assembly from the ma-
chine.
DESCRIPTION.
b. FIRST remove the NEGATIVE [-] battery cable
The Model BW 124D, BW 124PD, and BW 124 PDB from the NEGATIVE [-] terminal of the battery, and
Single Drum Rollers are powered by the DEUTZ then remove the POSITIVE [+] battery cable from
Model F3L 1011, oil and air cooled engine the POSITIVE [+] terminal of the battery. Disconnect
[see figure 6-1]. BOTH the NEGATIVE [-] and the POSITIVE [+] bat-
tery cables from their connections to the engine. Re-
For engine OPERATION and general manufacturer move the battery from the machine and place in a
MAINTENANCE procedures, see the DEUTZ Model suitable location.
F3L 1011 “OPERATION and MAINTENANCE
MANUAL”, which is supplied with EACH machine. CAUTION: Do NOT place the battery on a con-
crete surface. Store the battery on a
For major engine repair requirements contact the WOOD surface ONLY.
nearest DEUTZ Engine Dealer for assistance about
major repair procedures, in dealer shop repairs and/
or engine parts. WARNING: BATTERY EXPLOSION CAN OCCUR
IF A BATTERY IS SHORTED.
Remove the NEGATIVE [-] battery
cable FIRST.
Do NOT smoke OR cause a spark
while removing the battery cables
from the battery.
BATTERY MAY CONTAIN EXPLO-
SIVE GAS.
ALWAYS use APPROVED practices
when performing electrical system
diagnosis procedures and doing re-
pairs.
NEVER make a shorted circuit
between the positive [+] terminal
and the negative [-] terminal of a
battery.
Do NOT place ANY tools on a battery
at ANY time.
c. Loosen the clamp at the exhaust pipe to flexible

exhaust tube. Remove the exhaust pipe from the
FIGURE 6-1. DEUTZ Model F3L 1011 Engine. flexible exhaust tube.
6-2 6/96
Section 6
ENGINE
d. Disconnect the fuel supply AND return lines l. Install one [1] engine lifting eye into each tapped
from the engine. Put a cap or a plug into EACH line lifting inset hole, located on top of engine. SE-
AND onto EACH engine fitting. CURELY fasten a chain and a lifting device, having
a capacity MORE than 1,000 lbs. [454 kg], to the
e. Detach the throttle cable from the engine. Dis- two [2] engine lifting eyes. Tighten the lifting device.
connect the choke cable from the engine.
f. Disconnect the transmission system direction WARNING: Use a lifting device and chain ca-
control cable from the transmission pumps control pable of lifting at LEAST a weight of
lever. 1,000 lbs. [454 kg].
Fasten SECURELY.
g. Put an identification tag on EACH hose and
EACH fittingof the transmission pumps, steering/vi-
bration pump, or if so equipped, the steering/vibra- m. Remove the cap screws, nuts and washers
tion/leveling blade system pump. Then disconnect which hold the engine to the frame weldment at ALL
ALL hydraulic supply and return hoses from the hy- FOUR [4] connection points.
draulic oil cooler. Put caps or plugs in ALL hoses
and on ALL fittings IMMEDIATELY after the hoses
are disconnected. NOTE: The DEUTZ diesel engine is mounted
into the frame at a TOTAL of four [4] en-
h. Disconnect the governor [throttle] control cable gine mount to frame connection points -
from the engine governor control lever and anchor [two [2] FRONT and two [2] REAR].
bracket.
i. Disconnect ALL hydraulic supply and return n. Check AGAIN, to be sure that ALL the hoses,
hoses from the hydraulic oil cooler. Put caps or lines and electrical wire and cable connections have
plugs in ALL hoses and on ALL fittings IMMEDI- been disconnected and removed from the engine.
ATELY after the hoses are disconnected. Remove Also check for removal of these items from other
the fan gaurd from the hydraulic oil cooler. Remove components being removed WITH the engine, as an
the hydraulic oil cooler from the machine and place assembly.
component away from the machine.
j. Put an identification tag on EACH electrical wire CAUTION: Do NOT remove the engine assembly
and EACH electrical wire connection terminal on the before loosening and removing ALL
engine. Loosen and remove ALL electrical wires items connected to the engine, or
which are connected to the engine. fastened to any component being
removed with the engine.
k. Put an oil drain pan under the engine lubrication
oil drain plug. Wipe the area around the drain plug,
using a clean cloth. Remove the drain plug and drain
the engine of lubrication oil. Replace and tighten the
drain plug AFTER the engine is COMPLETELY
drained of oil.
WARNING: Do NOT drain the engine lubrication

oil while the oil is HOT. Drain the oil
ONLY when WARM or COOL. HOT oil
can cause serious injury.
6/96 6-3
Section 6
ENGINE
o. CAREFULLY and SLOWLY lift the engine, clear INSTALLATION OF THE ENGINE ASSEMBLY
of the frame, a SMALL amount. Move the engine as- [See Figure 6-2].
sembly “back” and toward the REAR of the machine,
a SMALL amount. CAREFULLY and SLOWLY con- a. If needed install one [1] engine lifting eye into
tinue to lift the engine assembly, “UPWARD” and each tapped lifting insert hole located on top of
“OUT” of the frame, UNTIL the engine assembly is ingine. SECURELY fasten a chain and a lifting de-
away from the frame and machine. vice, having a capacity MORE than 1,000 lbs. [454
kg], to the engine lifting eyes.
WARNING: KEEP CLEAR of the engine assembly

while it is being lifted and removed WARNING: Use a lifting device and chain having
from the frame. Serious injury can a capacity larger than 1,000 lbs.
occur if caught between the engine [454 kg].
and frame areas. Fasten SECURELY.
p. CAREFULLY lower the engine onto an engine b. CAREFULLY and SLOWLY lift the engine as-
stand or other engine support device. sembly a SMALL amount.
c. CAREFULLY and SLOWLY lift the engine as-

WARNING: KEEP CLEAR of the engine assembly sembly to a position ABOVE the frame. SLOWLY
while being lowered after removal begin to lower the engine assembly “DOWNWARD”
from the frame. Serious injury can toward the frame. Align ALL the engine mount holes
occur if caught between the engine with the holes located in the frame weldment, as the
and support device. engine assembly reaches the frame.
WARNING: KEEP CLEAR of the engine assembly

while it is being installed. Lower the
engine assembly SLOWLY into the
frame.
Check for ANY interference between
components at ALL times during
engine installation.
d. Install ALL four [4] of the engine mount to frame

retaining cap screws - with washers, into the frame
and engine mount holes. Install one [1] washer and
one [1] nut onto each capscrew. Tighten each en-
gine mount weldment to frame retaining capscrew to
a torque of 65ft. lbs. [88 N.m] or until rubber is com-
pressed. Remove the chain from the engine lifting
eyes. Remove the lifting eyes from the engine.
e. Fill the engine with NEW engine lubrication oil

[see Section 4 - MAINTENANCE]. Install the hydrau-
lic oil resevoir, battery support, and battery.
6-4 6/96
Section 6
ENGINE
TORQUE TO
37ft. lbs.[50 n.m]
TORQUE COUPLER
CAPSCREW TO
45ft. lbs.[ 61 n.m]
TORQUE TO
43ft. lbs. [59 n.m]
ENGINE MOUNT
ENGINE
MOUNT
FUEL TANK
FRAME
FIGURE 6-2. DEUTZ DIESEL ENGINE - INSTALLATION INTO FRAME.
f. CAREFULLY connect ALL electrical wires, EX- i. Remove ALL caps and plugs from ALL the
CEPT the POSITIVE [+] and NEGATIVE [-] battery hoses and fittings which fasten to, or are on, the
cables, to the CORRECT engine wire connection transmission pump, steering/vibration pump, or if so
terminal, as shown by the identification tags, and equipped, the steering/vibration/leveling blade sys-
tighten securely. tems pump and the vibrator pump. Install EACH
hose onto the CORRECT fitting of the above pumps
as shown by the identification tags. Securely tighten
WARNING: Do NOT connect EITHER battery each hose onto each fitting.
cable to the battery at THIS time.
Serious injury can occur if a j. Remove ALL caps and plugs from ALL hoses
"shorted" electrical condition is and fittings which fasten to, or are on, the hydraulic
caused during component connec- oil cooler. Install EACH hose onto the CORRECT oil
tion and installation. cooler fitting and securely tighten each hose fitting.
k. Remove the caps and plugs from the fuel supply

g. Connect the governor [throttle] control cable to and return hoses and engine fittings. Connect the
the engine governor and anchor bracket. fuel supply and return hoses to the engine fittings.
Securely tighten each hose fitting. Install the fan
h. Connect the transmission direction control cable gaurd onto the hydraulic oil cooler.
to the transmission pump control lever. Adjust the
direction control cable linkage if needed [see Section l. Remove ALL caps and plugs from ALL the
8 - TRANSMISSION for the procedure]. hoses and fittings which fasten to, or are on, the hy-
draulic oil reservoir assembly, ONE [1] at a time. In-
stall EACH hose onto the CORRECT fitting of the
hydraulic reservoir as shown by the identification
tags. Securely tighten EACH hose onto EACH fitting.
6/96 6-5
Section 6
ENGINE
m. Add NEW, CLEAN and FILTERED hydraulic oil s. Carefully connect the POSITIVE [+] battery
to the hydraulic oil reservoir UNTIL the oil level is at cable terminal to the POSITIVE [+] terminal of the
the proper level on the dipstick [see Section 4 - battery and tighten FIRST. Then, carefully connect
MAINTENANCE]. the NEGATIVE [-] battery cable to the NEGATIVE [-]
terminal of the battery and tighten.
CAUTION: Do NOT start the engine UNTIL ALL of WARNING: Do NOT connect the NEGATIVE [-]
the transmission system start up battery cable to the NEGATIVE [-] ter-
procedures have been completed. minal of the battery BEFORE con-
Be SURE the charge pump has necting the POSITIVE [+] battery
FILLED with oil and IS developing cable to the POSITIVE [+] terminal of
charge pressure BEFORE the engine the battery.
is started [See section 8 - TRANSMIS- Do NOT smoke or cause a spark
SION SYSTEM - for the CORRECT while connecting the battery cable
procedures]. terminals to the battery.
BATTERY MAY CONTAIN EXPLO-
SIVE GAS.
n. Connect BOTH the POSITIVE [+] and the
NEGATIVE [-] battery cables to their connections on t. Inspect ALL hose, line, wire and cable connec-
the engine. tions for CORRECT connection locations and tight-
ness. Check for ANY leak of fuel, oils or coolant, at
o. Carefully install the hood assembly - with air this time.
cleaner onto the machine. Install the hood retaining
cap screws, washers and nuts. Securely tighten all u. AFTER making sure, AGAIN, that the transmis-
cap screws and nuts. Install the wiring harness insu- sion system start procedures have been completed,
lated clamps and harness onto the rear cowl, inside start the engine, using the CORRECT engine start-
the service access area. Connect ALL electrical ing procedures given in Section 3 - OPERATION.
wires to the back up alarm and the hydraulic oil tem- Check ALL machine systems for correct operation
perature sender as indicated by the identification and function.
tags. Install the lift cylinders to the fender mounts.
p. Connect the air intake hose assembly onto the ANY machine system does NOT have
engine inlet air connection point. Install and securely CORRECT operation.
tighten the retaining band clamp. Do NOT start the engine again UNTIL
the system problem has been cor-
CAUTION: Severe engine damage can occur if rected.
hose clamps are in a loose condition
or if intake hose is damaged.
q. Install new exhaust pipe to exhaust manifold

gaskets. Install exhaust pipe to engine exhaust
minifold. Install exhaust pipe to muffler and place
exhaust clamps into position. Tighten clamps to se-
curely.
r. Install the engine side shields. Install the side

shields retaining cap screws, washers and nuts. Se-
curely tighten all cap screws and nuts.
6-6 6/96
Section 7
ELECTRICAL
TABLE OF CONTENTS
PAGE

SYSTEM DESCRIPTION ............................................................................................................................... 7-2
DESCRIPTION - ELECTRICAL SYSTEM MAJOR COMPONENTS ............................................................ 7-2

BATTERY ................................................................................................................................................. 7-2
STARTER MOTOR ................................................................................................................................... 7-2
GENERATOR ........................................................................................................................................... 7-2

SWITCHES ............................................................................................................................................... 7-2
RELAYS AND CIRCUIT BREAKERS ...................................................................................................... 7-3
INSTRUMENTS AND INDICATOR LIGHTS ............................................................................................ 7-4

INSTRUMENTS .................................................................................................................................. 7-4
INDICATOR LIGHTS .......................................................................................................................... 7-4
CABLES AND WIRES .............................................................................................................................. 7-5

CABLES ............................................................................................................................................. 7-5
WIRES ................................................................................................................................................ 7-5
CIRCUITS ...................................................................................................................................................... 7-5

START - STOP ( PRIMARY CIRCUIT) ..................................................................................................... 7-5
SECONDARY CIRCUITS ......................................................................................................................... 7-5
CHARGING CIRCUIT .......................................................................................................................... 7-9

VIBRATION CIRCUIT .......................................................................................................................... 7-9
FUEL SUPPLY CIRCUIT ................................................................................................................... 7-11
WARNING CONTROL INDICATOR LIGHT CIRCUIT ...................................................................... 7-11

TROUBLE ANALYSIS INFORMATION AND PROCEDURES ................................................................... 7-13
TROUBLE ANALYSIS FOR THE ELECTRICAL SYSTEM ........................................................................ 7-15
6/96 7-1
Section 7
ELECTRICAL
GENERAL INFORMATION. GENERATOR.
This section describes the OPERATION of the The 60 amp generator is used to convert mechanical
electrical system and contains DESCRIPTIONS of energy into electrical energy. It supplies electrical
the items included in the system used on the Model current to the electrical circuits and keeps the battery
BW124D, BW124PD, and BW 124PDB Single “charged” when the engine is “running”.
Drum Rollers.
“TROUBLE ANALYSIS” for the electrical system is WARNING: NEVER smoke, or cause a spark,
found at the rear of this section. near ANY battery.
ALWAYS loosen and remove the
NEGATIVE [-] battery cable from the
SYSTEM DESCRIPTION [See Figures 7-1, 7-2 NEGATIVE [-] battery terminal
and 7-3]. BEFORE loosening and removing
the POSITIVE [+] battery cable from
The electrical system contains the following major the POSITIVE [+] battery terminal.
components: NEVER cause a shorted circuit
condition in ANY CIRCUIT.
1. BATTERY. USE EXTRA CAUTION when
2. STARTER MOTOR. checking ANY circuit using ANY
3. GENERATOR. electrical testing instrument.
4. SWITCHES. BATTERY MAY CONTAIN
5. SOLENOID CONTROLS [of fuel system and EXPLOSIVE GAS.
vibration system control valves].
6. RELAYS and CIRCUIT BREAKERS
7. INSTRUMENT and INDICATOR LIGHTS.
8. CABLES and WIRES. SWITCHES.
a. Ignition Key Switch.
DESCRIPTION - ELECTRICAL SYSTEM MAJOR The ignition key switch is the main control switch for
COMPONENTS [See Figures 7-1, 7-2 and ALL electrical circuits. The switch is a three [3]
7-3]. position switch which permits the engine to be
started, put in a “running” condition and stopped.
The following information describes the MAJOR One [1] ignition key switch is used in the electrical
electrical components used in the electrical system system.
of the Model BW124D, BW124PD, and
BW124PDB Single Drum Rollers. b. Neutral Start Switch.
The neutral start switch is used to stop the engine

BATTERY. from being started when the travel control [F-N-R]
hand lever and the transmission system is NOT in
The battery supplies direct current to crank the “NEUTRAL”. One [1] neutral start switch is used in
engine and operate electrical circuits until the the engine start circuit.
generator is able to supply current. One [1] 12 volt,
580 CCA hour battery, is used in the electrical c. Low Engine Oil Pressure Switch.
system for this purpose.
The oil pressure switch is used to close the electrical
STARTER MOTOR. circuit between the ignition switch and the oil pres-
sure control light indicator. The switch is normally
open when the engine has been started and is
The starter motor is used to convert electrical energy "running". If the switch is closed it also activates the
into mechanical energy to crank and start the warning buzzer failure indicator.
engine. One [1] 12 volt, negative ground starter
motor is used in the start circuit.
7-2 6/96
Section 7
ELECTRICAL
d. High Engine Oil Temperature Switch. RELAYS AND CIRCUIT BREAKERS.
The oil temperature switch is used to close the a. Neutral Start Relay.
electrical circuit between the ignition switch and the
oil temperature control light indicator. The switch is The neutral start relay is used to supply electrical
normally open when the engine has been started current from the neutral start switch to the starter
and is "running". If the switch is closed it also solenoid. When the transmission system is in
activates the warning buzzer failure indicator. "NEUTRAL", electrical current is supplied to the
relay from the neutral start switch. Current then
e. Engine Air Cleaner Vacuum Switch. closes the relay and flows through the relay to the
starter solenoid and energizes the solenoid to allow
The engine inlet air restriction indicator switch is the starter to crank and start the engine.
used to complete the electrical GROUND circuit if
the engine inlet air flow path becomes restricted. b. Back Up Alarm Relay.
One [1], normally open, vacuum closed, switch is
used in the electrical circuit of the engine inlet air The back up alarm relay is used to supply electrical
system. current to the back up alarm. When the transmission
is in "REVERSE", electrical current is supplied to the
f. Horn Button Switch. relay from the back up alarm switch. Current then
closes the relay and flows to the back up alarm and
The horn button switch is used to close the electrical sounds the alarm.
circuit and supply electrical current to the horn. One
[1], normally open, dash installed button switch is c. Vibrator System Relay.
used in the electrical circuit of the warning horn
system. The vibrator system relay is used to supply electrical
current from the vibrator "On/Off" control switch to
g. Low Fuel Level Switch the vibrator solenoid. When the vibrator system "On/
Off" switch is in the "ON" position, current flows from
The fuel level switch is used to complete the circuit the "On/Off" switch to the relay. Current flows
and electrically indicate a low fuel level exists within through the relay to the vibrator solenoid on the
the fuel tank. One [1] low fuel level switch, having a vibrator control valve. The solenoid then moves the
float assembly, mechanically closes the circuit flow control spool, in the valve body, and directs high
ground to the machine frame. When the circuit pressure hydraulic oil flow to the vibrator motor.
ground is closed, the low fuel level indicator light, on
the dash, is lighted, indicating a low fuel level exists
in the tank.
h. Vibrator System On/Off Switch
The vibrator system on/off solenoid is energized

when the control lever installed vibrator “on/off”
switch is in the “ON” position. The solenoid moves
the oil flow control spool, in the vibrator valve body,
and permits high pressure oil to flow to the hydraulic
vibrator motor.
6/96 7-3
Section 7
ELECTRICAL
d. Ten [10] Amp Circuit Breakers. INSTRUMENTS, AND INDICATOR LIGHTS.
Ten [10], ten [10] amp circuit breakers are used in INSTRUMENTS.
the electrical system.
a. Engine Hourmeter.
The first circuit breaker is used in the circuit which
supplies current to the: electrical charging system The engine hourmeter indicates the amount of time
indicator light, engine hourmeter, and the generator. the engine has operated and is given in time divi-
sions of tenths, units, tens, hundreds and thousands
The second circuit breaker is used in the circuit of hours. The engine hourmeter is “on” when the
which supplies current to the: high engine oil ignition key switch is “on” and/or when the engine is
temperature control light, high engine oil tempera- “running”.
ture switch.
The third circuit breaker is used in the circuit which

INDICATOR LIGHTS.
supplies current to the: relay warning buzzer failure
indicator, buzzer. a. Engine Inlet Air Restriction Indicator Light.
The forth circuit breaker is used in the circuit which The engine inlet air restriction indicator light is
supplies current to the: oil pressure switch - brake, lighted if the engine inlet air route is restricted. The
secondary/parking brake system condition indicator red lens covered light will be lighted when the
light. ignition key switch is “on” and with the engine
"running " and the inlet air route restricted.
The fifth circuit breaker is used in the circuit which
supplies current to the: low engine oil pressure b. Secondary/Parking Brake System Condition
switch - engine, and the low engine oil pressure Indicator Light.
light.
With the ignition key switch “on”, the secondary/
The sixth circuit breaker is used in the circuit which parking brake system condition indicator red lens
supplies current to the: horn switch, and the horn. covered light is lighted when the secondary/parking
brake system is "on" [applied].
The seventh circuit breaker is used in the circuit
which supplies current to the: drum vibrator toggle c. High Engine Oil Temperature Light
switch (on/off), and the vibration relay.
The engine oil temperature light is lighted if the oil
The eighth circuit breaker is used in the circuit which temperature exceeds safe conditions. The red lens
supplies current to the: air cleaner vacuum switch covered light can also be lighted when the ignition
and the air cleaner restriction control light. key switch is “on”, and at machine “start up”.
The ninth circuit breaker is used in the circuit which d. Low Engine Oil Pressure Light
supplies current to the: low fuel control light, and the
low fuel level switch. The engine oil pressure light is lighted if the oil
pressure is below the minimal limit. The red lens
The tenth circuit breaker is used in the circuit which covered light can also be lighted when the ignition
supplies current to the: backup alarm proximity key switch is “on”, and at machine “start up”.
switch, backup alarm relay, and the backup alarm
buzzer. e. Low Fuel Level Indicator Light
e. One half [1/2] Amp Circuit Breaker. The low fuel level indicator light is lighted if the fuel
level is low enough to activate the low fuel level
One [1], one half [1/2] amp circuit breaker is used in switch located at the fuel tank. The red lens covered
the electrical system. The circuit breaker supplies light can also be lighted when the ignition key switch
current to the low fuel level switch and is supplied is “on”, and at machine “start up”.
current from the ninth, ten [10] amp circuit breaker
within the same circuit.
7-4 6/96
Section 7
ELECTRICAL
f. Electrical Charging System Indicator Light A SECONDARY circuit is an electrical circuit depen-
dent upon a PRIMARY circuit for electrical current.
The electrical charging system indicator light is
lighted if the battery is not being charged by the The electrical system consists of the following
generator system. The red lens covered light can circuits:
also be lighted when the ignition key switch is “on”,
and at machine “start up”. 1. START - STOP (PRIMARY CIRCUIT)
A. POWER CIRCUIT
B. CONTROL CIRCUIT
a. OFF [STOP]
b. START
CABLES AND WIRES. c. ON - [RUN].
2. SECONDARY CIRCUITS
CABLES. A. CHARGING.
B. VIBRATION.
a. Positive [+] and Negative [-] Battery Cables. C. FUEL SUPPLY.
D. WARNING.
The positive [+] and negative [-] battery cables
connect the positive [+] and negative [-] terminals of
the battery to the engine starter motor and the
system ground at the engine. The cables carry high START - STOP CIRCUIT [See Figures 7-1,
amperage electrical current for the engine starter 7-2 and 7-3].
motor and current from the generator to the battery.
The START - STOP circuit contains two [2] separate
WIRES. circuits within it, the POWER circuit and the
CONTROL circuit.
a. Circuit Wires.
A. POWER CIRCUIT
The wires used in the electrical system connect the
components and form the circuits which the electri- The battery, cables, generator, and engine starter
cal current flows through. The wire assemblies motor make up the POWER circuit.
contain different size [gauge] wires and connection
terminals. The wire assemblies are covered with a B. CONTROL CIRCUIT
protective plastic tape, which is wound around the
wires of the assembly, to form the wire harness. The CONTROL circuit includes the ignition switch,
neutral start switch, starter relay, starter motor
CIRCUITS. solenoid, and the wires which carry the electrical
current in the circuit.
The components of the electrical system is a combi-
nation of CIRCUITS, each of which is composed of In the CONTROL CIRCUIT, constant current is
one, or more, of the following: wiring, switches, supplied to the ignition switch by current running
control relays, fuses, indicator lights, and other from the positive battery post into the positive battery
electrical components. cable.
The electrical system is comprised of both a PRI- The positive [+] battery cable is connected to the
MARY circuit and a variety of SECONDARY circuits. battery positive [+] post, and connects to position
thirty [30] on the starter motor solenoid. Current then
The PRIMARY circuit is an electrical CIRCUIT not flows from position thirty [30] on the starter motor
dependent upon another circuit for power. A solenoid to pin position eight [8] on connector block
PRIMARY circuit may, or may not, feed current to X21.
SECONDARY circuits.
Current flows from pin position eight [8], on the X21
6/96 7-5
Section 7
ELECTRICAL
connector block, to pin position two [2], on the X21 NOTE: If the directional control lever is not in
connector block. Current then flows from pin position neutral, current will NOT travel through
two [2], on the X21 connector block, to pin position the neutral start switch and the machine
three [3], on the X21 connector block. Current flows will not start.
from pin position three [3], on the X21 connector
block, to position 30, on the ignition switch.
Current flows from terminal BLACK [BK] to the X11
The ignition key switch has three [3] positions: connector block. Current flows from the X11 connec-
tor block to pin position one [1], on the X20 connec-
a. “OFF” [STOP]. tor block. Current flows from pin position one [1,] on
b. “START”. the X20 connector block, to pin position four [4], on
c. “ON” [RUN]. the X20 connector block. Current flows from pin
position four [4], on the X20 connector block, to
Each of the three [3] positions will be discussed terminal 85, located on the neutral starter relay.
separately:
When current is present in terminal 85, of the neutral
a. OFF [STOP] POSITION. start relay, the current closes the relay and allows
current to flow through the relay from position three
With the ignition key switch in the OFF position [3], on the X21 connector block, to terminal 30 of the
current flow to ALL SECONDARY circuits is termi- starter relay.
nated. With the ignition key switch in the ON position
current flows to ALL SECONDARY circuits requiring Current flows through terminal 87, located on the
power during running and/ or starting conditions from neutral start relay, into pin position seven [7], on the
the PRIMARY circuit. X20 connector block. Current flows from pin position
seven [7], on the X20 connector block, to pin posi-
When the ignition switch key is turned to “OFF”, tion six [6], on the X20 connector block. Current
electrical current no longer will flow from the flows from pin position six [6], on the X20 connector
“ignition” terminal of the ignition switch, through block to terminal 50, on the starter solenoid. Current
pin position one [1], on the X21 connector block. energizes the starter solenoid and allows the starter
Current then flows through the wire, which loops to to crank and start the engine.
pin position four [4], on the X21 connector block.
Current flows from pin position four [4], on the X21 c. ON [RUN] POSITION.
connector block, into the wire connected to the
solenoid of the fuel shut-off valve, found on the When the engine has been started, and the ignition
engine. key is released, the ignition switch will return to the
“on” [RUN] position by spring pressure.
The lack of electrical current permits the fuel shut-off
valve spool to “close”, stopping the fuel flow through
the engine fuel system. NOTE: See each SECONDARY circuit for
information about each individual circuit.
b. START POSITION.
When the ignition switch key is turned to the 2. SECONDARY CIRCUITS [See Figures 7-1,
“START” position, electrical current flows from 7-2 and 7-3].
position 50, on the ignition switch, to pin position two
[2], on the X21 connector block.
Current then flows from pin position two [2], on the
X21 connector block, to pin position three [3,] on the
X21 connector block. Current then flows from pin
position three [3], on the X21 connector block, to pin
position six [6], on the X21 connector block.
Current flows from pin position six [6] to pin position
seven [7], on the X21 connector block, to pin posi-
tion seven [7] on the X21 connector block. Current
then continues to flow through the BLACK wire to
the X11 connector block. Current flows from the X11
connector block to the BROWN [BR] terminal, on the
neutral start switch, found above the displacement
control of the transmission pump assembly.
With the transmission in "neutral", current flows
through the neutral start switch and into terminal
BLACK [BK],
7-6 6/96
Section 7
ELECTRICAL
u t
l d O
F o ! ! ! !
a g e ! ! ! !
2 P R E
E H E
US line
K e y
FIGURE 7-1. ELECTRICAL SYSTEM SCHEMATIC.
6/96 7-7
Section 7
ELECTRICAL
u t
l d O
F o ! ! ! !
a g e ! ! ! !
2 P R E
S E eH E
U lin
K e y
FIGURE 7-2. ELECTRICAL SYSTEM WIRE

IDENTIFICATION GAGE SIZES, COLORS AND LENGTHS.
7-8 6/96
Section 7
ELECTRICAL
Most SECONDARY circuits receive current through two [2], on the X30 connector block.
the fuse block located on the instrument panel as-
sembly. The main power connection for the fuse Then the current travels from pin position two [2] on
block is the "B" block (see FIGURE 7-2). You can the X30 connector block to the D+ terminal on the
determine the position by examining the instrument generator.
either from the UNDERSIDE, or the TOPSIDE.
Current then flows from the B [+] terminal, located
From the UNDERSIDE of the Instrument panel, with on the generator, down to terminal 30, on the starter
the fuse block located in the upper RIGHT hand cor- solenoid. From terminal 30, on the starter solenoid,
ner, position "A" is the top far RIGHT, up to, and in- the generator output current flows through the
cluding "F", which is the top far LEFT. Position "1" is positive [+] battery cable to the positive [+] terminal
the bottom far RIGHT, up to, and including "6", of the battery.
which is the bottom far LEFT.
B. VIBRATION CIRCUIT [See Figures 7-1,
From the TOPSIDE of the instrument panel, with the 7-2 and 7-3].
fuse block located in the upper LEFT hand corner,
position "A" is the top far LEFT, up to, and including, The vibration circuit electrically controls the machine
"F" , which is the top far RIGHT. Position "1" is the vibration system by turning the system on and off.
bottom far LEFT, up to, and including, "6", which is
the bottom far RIGHT. The vibration system relay has a constant current
supplied from the terminal position 15/54, on the
A. CHARGING CIRCUIT [See Figures 7-1, ignition switch, to pin position one [1], on the X21
7-2 and 7-3]. connector block.
After the engine has started and is “running”, the Current is then routed to pin position 4 on the X21
generator output voltage increases above the connector block to the ten [10] amp fuse [F3] in the
battery voltage. fuse block located on the instrument panel assem-
bly.
Current to the generator is supplied from terminal
position 15/54, on the ignition switch, to pin position The current then travels from the ten [10] amp fuse
one [1], on the X21 connector block. [F3] in the fuse block located on the instrument
panel assembly to terminal 30 on the vibration
Current then flows to pin position 4, on the X21 system toggle relay.
connector block, to the ten [10] amp fuse [F2], in the
fuse block, located on the instrument panel assem- Current then flows from terminal 30, on the vibration
bly. system toggle relay, to terminal 56, on the vibration
system toggle relay.
Current then flows from the ten [10] amp fuse, in the
fuse block, into the charge control indicator light. If the vibration system toggle relay is grounded,
current flows through the relay to terminal 56b.
The charge control indicator light has two [2] wires Current flows from terminal 56b to pin position two
leading from it. [2], on the X20 connector block.
The first wire supplies current to the hourmeter Current then flows from pin position two [2,] on the
through the positive terminal. X20 connector block, to pin position three [3], on the
X20 connector block.
The second wire supplies current through the diode Current is then routed from pin position three [3], on
into pin position eight [8], on the X20 connector the X20 connector block, to terminal one [1], on the
block. solenoid of the vibration valve. The solenoid is
The current then flows from pin position eight [8], on
the X20 connector block, to pin position five [5].
Current flows from pin position five [5] to pin position
6/96 7-9
6/96
ELECTRICAL
Section 7
7-10
FIGURE 7-3. INSTRUMENT AND CONTROL PANEL ELECTRICAL WIRING DIAGRAM.
Section 7
ELECTRICAL
grounded through terminal two [2], on the vibration The solenoid moves the control valve spool to the
valve. “open” position and high pressure hydraulic oil flow
is sent to the vibrator motor.
The vibrator "on/off" control switch, found on the
travel control lever, completes the ground for the C. FUEL SUPPLY CIRCUIT.
vibration circuit.
When the ignition switch key is turned to “ON”,
When the "on/off" control switch is "off", the ground electrical current flows from the “ignition” terminal of
is not complete. When in the "off" position, the the ignition switch. Current flows to pin position one
vibration system toggle relay is NOT supplied [1], on the X21 connector block, through the wire
current. that loops to pin position four [4], on the X21 con-
nector block. Current flows from pin position four [4],
When the "on/off" control switch is "on", the ground on the X21 connector block, into the wire connected
is completed, and closes the toggle relay. to the solenoid, of the fuel shut-off valve found on
the engine.
This ground is achieved by having a closed circuit
through the "on/off" control switch. The ground Electrical current permits the fuel shut-off valve
connection leads from terminal S, on the vibrator spool to “open”, allowing fuel to flow through the
system toggle relay, to pin position three [3], on the engine fuel system.
X20 connector block.
D. WARNING CONTROL INDICATOR LIGHT
The ground is continued from pin position three [3], CIRCUITS See Figures 7-1, 7-2 and 7-3].
on the X20 connector block, to pin position two [2],
on the X20 connector block. A WHITE wire lead runs a. SECONDARY/PARKING BRAKE CIRCUIT
from pin position two [2], on the X20 connector
block, to the X12 connector block. The secondary/parking brake electrical circuit is a
warning system that indicates activity by a warning
The WHITE wire connecting to the X12 connector indicator light mounted upon the instrument panel
block is connected to the GREEN wire. assembly
The ground continues through the "on/off" control When the ignition switch is “on”, current flows from
switch into a second GREEN wire and back to the 15/54 terminal, on the ignition switch to pin
second position, on the X12 connector block. position one [1], on the X21 connector block.
A BROWN wire leads from the X12 connector block Current is then routed to pin position four [4], on the
connection to the frame of the machine and X2 connector block, to the ten [10] amp fuse [F2], in
completes the circuit ground. the fuse block, located on the instrument panel
assembly.
When the ground is completed, current flows
through the vibrator system toggle relay, as The current then flows from the ten [10] amp fuse, in
discussed earlier. the fuse block, into the secondary/parking brake
control indicator light.
When the vibrator system relay system is supplied
current, is grounded and is closed, current flows into The secondary/parking brake control indicator light
wire BS. Current flows to the vibrator system sole- will illuminate when the ground is complete. The
noid, on the vibrator system control valve block. ground is complete when the secondary/parking
brake lever is move into the “on” position. When in
the “on” position, the lever manually toggles the oil
NOTE: The vibrator system "on/off" switch must pressure switch-brake. The switch then grounds
be toggled to the "ON" to operate the vi- itself to the machine frame.
bration system.
6/96 7-11
Section 7
ELECTRICAL
b. BACKUP ALARM CIRCUIT Ground continues from terminal 86 to pin position

two [2], on the X22 connector block, to pin position
The backup alarm circuit has a constant current three [3], on the X22 connector block. From pin
supplied from the terminal position 15/54, on the position three [3] on the X22 connector block,
ignition switch, to pin position one [1], on the X21 ground continues to both the BL [BLUE] terminal, on
connector block. the backup alarm proximity switch to the machine
frame ground.
Current is then routed to pin position four [4], on the
X21 connector block, to the ten [10] amp fuse [F5], c. HORN CIRCUIT
in the fuse block, located on the instrument panel
assembly. The horn circuit has a constant current supplied from
the terminal position 15/54, on the ignition switch to
The current then travels from the ten [10] amp fuse pin position one [1], on the X21 connector block.
[F5], in the fuse block located on the instrument
panel assembly. Current flows to terminal 30, on the Current is then supplied to pin position four [4], on
backup alarm relay, and pin position four [4], on the the X21 connector block, to the ten [10] amp fuse
X22 connector block. Current then flows to pin [F4], in the fuse block located on the instrument
position one [1], on the X22 connector block and to panel assembly.
the BN [brown] terminal, on the backup alarm
proximity switch at the same time. The current then travels from the ten [10] amp fuse
[F4], in the fuse block located on the instrument
The backup alarm relay is dependent upon the panel assembly, to terminal 4, on the push button
backup alarm proximity switch for actuation. When horn.
the backup alarm proximity switch is activated, by
placing the directional control switch in the "reverse" When the horn push button is depressed it allows
position, it allows current to flow from the BL [black] current to flow through terminal 3, on the horn push
terminal to pin position two [2], on the X22 connector button, to pin position eight [8], on the X21 connec-
block. Current flows to pin position three [3,] on the tor block to pin position five [5], on the X21 connec-
X22 connector block, from pin position three [3], on tor block, to the positive [+] terminal, on the horn.
the X22 connector block, to terminal 85, on the
backup alarm relay. The ground circuit is completed by a frame ground
from the negative [-] terminal, located on the horn.
When current is supplied through terminal 85, on the
backup alarm relay, the circuit is activated through d. LOW FUEL WARNING CIRCUIT
terminal 87A, on the backup alarm relay.
The low fuel warning circuit has a constant current
The current then flows from terminal 85 to pin supplied from the terminal position 15/54, on the
position six [6], on the X22 connector block, to pin ignition switch, to pin position one [1], on the X21
position seven [7], on the X22 connector block. connector block.
Current flows from pin position seven [7], on the X22
connector block, to the X1 connector and then from Current is then routed to pin position four [4], on the
the X1 connector to the positive terminal, of the X21 connector block, to the ten [10] amp fuse [F2],
backup alarm buzzer. in the fuse block located on the instrument panel
assembly.
The ground circuit is then completed through the
negative terminal of the backup alarm buzzer to the The current then travels from the ten [10] amp fuse
X6 connector. Ground continues from the X6 con- [F2], in the fuse block located on the instrument
nector to pin position eight [8], on the X22 connector panel assembly, to positive [+] terminal, on the low
block, to pin position five [5], on the X22 connector fuel indicator light. Current flows from the negative [-]
block. Ground continues from pin position five [5], on terminal to pin position one [1], on the X23 connec-
the X22 connector block, to terminal 86, on the tor block, to pin position four [4], on the X23 connec-
backup alarm relay. tor block, from pin position four [4], on the X23
connector block to the [F10] 1/2 amp in-line fuse.
7-12 6/96
Section 7
ELECTRICAL
The in-line fuse is used to reduce the current flowing TROUBLE ANALYSIS INFORMATION AND
into the low fuel level switch positive [+] terminal. PROCEDURES.
The low fuel indicator light will illuminate when the The following “TROUBLE ANALYSIS” information
ground circuit is completed by the frame ground. The tables are about the individual ELECTRICAL circuits
low fuel level switch consists of a float assembly, used on the machine. The tables give the most
which mechanically moves. common problems that can be found, the probable
cause of the problem and the usual corrective action
When a low fuel level status exists in the tank, the that should restore the machine to a normal
float assembly completes the circuit ground. operating condition.
The circuit ground is completed from the negative ALWAYS follow the four basic principles of GOOD
terminal of the low fuel level switch, to the X5 systematic trouble shooting:
connector and from the X5 connector to the machine
frame. 1. KNOW the system;
e. AIR SUPPLY WARNING CIRCUIT 2. DETERMINE the symptoms;
Current flows from the ten [10] amp fuse [F2,] in the 3. LIST the possible causes; AND
fuse block located on the instrument panel assem-
bly, to positive [+] terminal, on the air cleaner 4. TAKE the CORRECT ACTION.
restriction control light. Current then flows from the
negative [-] terminal to pin position one [1], on the
X22 connector block, to pin position four [4], on the WARNING: NEVER smoke, or cause a spark,
X22 connector block. From pin position four [4,] on near ANY battery.
the X22 connector block, current flows to the air ALWAYS loosen and remove the
cleaner vacuum switch, positive [+] terminal. NEGATIVE [-] battery cable from the
NEGATIVE [-] battery terminal BE-
The air cleaner restriction control light will illuminate FORE loosening and removing the
when the ground circuit is completed by a frame POSITIVE [+] battery cable from the
ground. The vacuum will occur, at the air cleaner POSITIVE [+] battery terminal.
vacuum switch, if the air flow is obstructed. When NEVER cause a shorted circuit
this occurs the switch is toggled, and closes the condition in any circuit.
circuit ground. USE EXTRA CAUTION when check-
ing ANY circuit using ANY electrical
The circuit ground goes from the negative [-] termi- testing instrument.
nal of the air cleaner vacuum switch to the machine BATTERY MAY CONTAIN EXPLO-
frame. SIVE GAS.
CAUTION: IMPROPER trouble shooting methods

waste time and can cause further
system problems.
When trouble shooting ANY system circuit problem,

FIRST determine IF the problem noted is confined to
ONLY that system circuit or common to ALL system
circuits.
6/96 7-13
Section 7
ELECTRICAL
Use STANDARD voltage, ohms and continuity If the problem affects ALL system circuits, then the
testing instruments to aid in trouble shooting ALL problem must be caused by malfunctions in circuits,
system circuit problems. For correct test instrument or components, COMMON to ALL system circuits
use and procedures follow ALL of the testing and the thought process and procedures should be
instrument MANUFACTURES written instructions, related to those areas.
which are supplied with the above test instruments.
Determine WHICH system factor, where they apply,
is causing the problem: Electrical, Mechanical or
WARNING: Do NOT use ANY testing instrument Hydraulic.
BEFORE reading ALL manufactures
instructions for the instrument and Only AFTER the CAUSE of the problem has been
procedures to be used to trouble determined can the SPECIFIC damaged circuit item
shoot ANY circuit problem. Serious be removed, repaired, or replaced.
injury and/or system circuit damage
can occur.
If the problem is confined to ONLY one system

circuit, the trouble shooting thought process and
procedures should be confined to ONLY the circuits
and components which affect that system circuit.
7-14 6/96
Section 7
ELECTRICAL
TROUBLE ANALYSIS FOR THE ELECTRICAL SYSTEM.

[See Figures 7-1, 7-2 and 7-3].
PRIMARY CIRCUIT
PROBLEM CAUSE CORRECTION
ENGINE WILL NOT CRANK Battery is damaged [dead] - G1 Charge or replace battery.
Initiator [neutral start] switch not Adjust, or replace, switch
in closed position - B10 See Section 8]
Damaged ignition switch - SO Replace ignition switch.
Damaged starter relay - K5 Replace relay.
Damaged starter solenoid - M1 Replace starter solenoid.
Damaged circuit wire -10/11/5/6/7 Repair, or replace, wire.
Damaged battery cables - 5/6/7 Clean, or replace, battery

cables.
ENGINE CRANKS SLOWLY Damaged starter motor - M1 Repair, or replace, starter motor.
Battery not fully charged - G1 Charge battery.
Low ambient temperatures Warm area around machine.
Incorrect engine lubrication oil Remove oil and replace with

in engine correct oil.
ENGINE CRANKS BUT Fuel shut-off solenoid not Check current flow. Repair, or
WILL NOT START energized - on engine assembly replace, fuel shut-off solenoid
and/or valve.
No fuel in tank Add correct fuel.
Fuel pre-cleaner, strainer and/or Replace pre-cleaner, strainer

filter "plugged" and/or filter with new.
Air in fuel supply system "Bleed" air from system.
Damaged fuel pump Replace pump.
Incorrect injector pump timing Set timing.
Damaged injector pump Replace pump.
6/96 7-15
Section 7
ELECTRICAL

SECONDARY CIRCUITS
BATTERY IS OVERCHARGED Voltage regulator in generator Replace regulator, or generator.

damaged - G2
BATTERY IS NOT CHARGED Voltage regulator in generator Replace regulator, or generator.

damaged - G2
Damaged generator G2 Repair or replace generator.
Damaged wire[s] in circuit - 2/3 Repair, or replace, wires.
HOURMETER DOES NOT Generator not suppling current Check for current output. Repair,
INDICATE HOURS AS to the hourmeter - G2 or replace, generator.
ENGINE OPERATES
Damaged wire[s] in circuit - 1/2 Check circuit for current flow.
Correct problem as needed.
Damaged hourmeter- PO Replace hourmeter.
HOURMETER INDICATES Meter circuit in hourmeter is Replace hourmeter.

ERRATIC HOURS "open"- PO
ENGINE LOW LUBRICATION Low oil pressure closing switch Replace low oil pressure closing
OIL PRESSURE INDICATOR damaged - B6 switch with new.
LIGHT DOES NOT ILLUMINATE
Damaged bulb in light - H9 Replace bulb with new.
Damaged circuit fuse - F2 Replace fuse with new.
No current flowing to indicator Check circuit for current flow.

light in circuit - 18 Correct problem as needed.
Damaged wire[s] in circuit - 18 Repair, or replace, wire[s] as

needed.
7-16 6/96
Section 7
ELECTRICAL

SECONDARY CIRCUITS
HIGH ENGINE TEMPERATURE High temperature closing switch Replace high temperature
INDICATOR LIGHT DOES NOT damaged - B30 closing switch with new.
ILLUMINATE
Damaged bulb in light - H4 Replace bulb with new.
No current flowing in indicator Check circuit for current flow. light

circuit - 12 Correct problem as needed.

needed.
LOW GENERATOR VOLTAGE Damaged bulb in light - H8 Replace bulb with new.
INDICATOR LIGHT DOES NOT
ILLUMINATE Damaged circuit fuse - F2 Replace fuse with new.

needed.
Generator damaged - G2 Repair, or replace, generator.
LOW FUEL LEVEL Damaged bulb in light - H24 Replace bulb with new.
INDICATOR LIGHT DOES NOT
ILLUMINATE Damaged circuit fuse[s] - F2/F10 Replace fuse[s] with new.
Damaged fuel sending unit - S53 Replace fuel sending unit.
Damaged wire[s] in circuit - 24 Repair, or replace, wire[s]
SECONDARY/PARKING Damaged bulb in light - H1 Replace bulb with new..

BRAKE SYSTEM CONDITION
INDICATOR LIGHT DOES NOT Brake system oil closed switch Replace switch with new.
ILLUMINATE WHEN SYSTEM damaged - B5
IS "ON"
Damaged wire[s] in circuit - 17 Repair, or replace, wire[s]
SECONDARY/PARKING Damaged wire[s] in circuit - 17 Repair, or replace, wire[s].

BRAKE SYSTEM WARNING
BUZZER DOES NOT Warning system buzzer relay Replace relay with new.
SOUND WHEN SYSTEM damaged - K33
IS "ON"- INDICATOR LIGHT
ILLUMINATES Buzzer damaged - H10 Replace buzzer with new.
6/96 7-17
Section 7
ELECTRICAL

SECONDARY CIRCUITS
ENGINE INLET AIR Damaged bulb in light - H15 Replace bulb with new.
RESTRICTION INDICATOR
LIGHT DOES NOT ILLUMINATE Damaged circuit fuse - F2 Replace fuse with new.
Damaged vacuum switch - B3 Replace switch with new.
No current flowing in circuit - 22 Check circuit for current flow.


needed.
VIBRATION SYSTEM Damaged circuit fuse - F3 Replace fuse with new.

DOES NOT OPERATE
WITH "ON/OFF" BUTTON IN Damaged wire[s] in circuit - 20/21 Repair, or replace, wire[s] as
"ON" POSITION needed.
Damaged relay - K4 Replace relay with new.
No ground in circuit - 20/21 Check circuit for ground.

Damaged push button switch - Replace switch with new.

S13
Damaged solenoid valve - Y7 Replace solenoid valve with new.
BACKUP ALARM DOES NOT Damaged circuit fuse - F5 Replace fuse with new.
SOUND WHEN MACHINE IN
REVERSE DIRECTION OF Damaged wire[s] in circuit - 26/27 Repair, or replace, wire[s] as
TRAVEL needed.
Damaged proximity switch - B32 Replace switch with new.

Damaged relay- K26 Replace relay with new.
Damaged alarm - H14 Replace alarm with new.
7-18 6/96
Section 7
ELECTRICAL

SECONDARY CIRCUITS
HORN DOES NOT Damaged circuit fuse - F4 Replace fuse with new.
SOUND WHEN BUTTON IS
PUSHED Damaged wire[s] in circuit - 13/19 Repair, or replace, wire[s] as
needed.
Damaged horn button switch - S3 Replace switch with new.

ßCorrect problem as needed.
Damaged horn assembly - B11 Replace horn with new.
6/96 7-19
Section 7
ELECTRICAL
NOTES
7-20 6/96
Section 8
TRANSMISSION SYSTEM
TABLE OF CONTENTS
PAGE
GENERAL INFORMATION ...................................................................................................................... 8-3
EXCHANGING THE TRAVEL PUMP ASSEMBLY .................................................................................. 8-3
EXCHANGING THE TRAVEL PUMP COUPLING ................................................................................... 8-6
SEPARATING THE TRAVEL PUMPS ...................................................................................................... 8-7
TRAVEL PUMPS ...................................................................................................................................... 8-8
GENERAL NOTES FOR REPAIRS ...................................................................................................... 8-8
SEALING THE TRAVEL PUMP DRIVE SHAFT .................................................................................. 8-9
SEALING THE MOUNTING FLANGE AND PIVOT FOR 1ST TRAVEL PUMP ................................. 8-10
SEALING THE MOUNTING FLANGE AND PIVOT FOR 2ND TRAVEL PUMP ................................ 8-11
SEALING THE TRAVEL PUMP VALVES .......................................................................................... 8-12
REMOVING AND INSTALLING THE DRIVE ...................................................................................... 8-13
REMOVING THE DRIVE ................................................................................................................ 8-13
INSTALLING THE DRIVE .............................................................................................................. 8-16
EXCHANGING THE DRUM MOTOR ...................................................................................................... 8-16
EXCHANGING THE TIRE DRIVE TRAVEL MOTORS ........................................................................... 8-17
REPAIRING THE TRAVEL MOTOR - WITH AND WITHOUT BRAKE .................................................. 8-18
TRAVEL MOTOR WITH BRAKE - DISMANTLING THE BRAKE ...................................................... 8-18
DISMANTLING THE TRAVEL MOTOR - WITH/WITHOUT BRAKE .................................................. 8-22
6/96 8-1
Section 8
TRANSMISSION SYSTEM
PAGE
FILLING THE HYDRAULIC SYSTEM .................................................................................................... 8-30
FLUSHING OF THE DRUM DRIVE TRAVEL CIRCUIT - GENERAL INFORMATION .......................... 8-32
FLUSHING OF THE DRUM DRIVE TRAVEL CIRCUIT ...................................................................... 8-34
INSTALLING THE FLUSHING SYSTEM ............................................................................................. 8-34
BLEEDING ........................................................................................................................................... 8-35
FLUSHING THE LINES FOR THE FRONT DRUM MOTOR ............................................................... 8-36
FLUSHING THE DRUM MOTOR ......................................................................................................... 8-36
FLUSHING THE WHEEL DRIVE TRAVEL CIRCUIT ............................................................................. 8-37
GENERAL INFORMATION .................................................................................................................. 8-37
FLUSHING OF THE WHEEL DRIVE TRAVEL CIRCUIT .................................................................... 8-39
INSTALLING THE FLUSHING SYSTEM ............................................................................................. 8-39
BLEEDING ........................................................................................................................................... 8-40
FLUSHING THE LINES FOR THE REAR TRAVEL MOTORS ........................................................... 8-41
FLUSHING THE LEFT-HAND AND RIGHT-HAND TRAVEL MOTORS ............................................. 8-41
FUNCTIONAL CHECK ............................................................................................................................ 8-42
MAINTENANCE OF THE FLUSHING FILTER UNIT .............................................................................. 8-42
PRESSURES IN THE WHEEL AND DRUM DRIVE TRAVEL CIRCUITS .............................................. 8-42
CHECKING THE PRESSURES IN THE WHEEL DRIVE CIRCUIT ..................................................... 8-42
CHECKING THE PRESSURES IN THE DRUM DRIVE CIRCUIT ....................................................... 8-43
HIGH PRESSURE TEST OF TRAVEL PUMPS .................................................................................. 8-44
TRAVEL PUMP, WHEEL DRIVE ..................................................................................................... 8-44
TRAVEL PUMP, DRUM DRIVE ....................................................................................................... 8-44
TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM .............................................................. 8-45
8-2 6/96
Section 8
TRANSMISSION SYSTEM
GENERAL INFORMATION. 1. Detach the lever for the parking brake

(Fig. 1/1 ). Unscrew the bolts (Fig. 1/2) for the brake
This section gives information about the TRANSMIS- actuation valve. Unscrew the bolts and nuts for the
SION system (Fig. A) used on the machine. console (Fig. 1/3), and pull the console to the front.
This section also includes information for removal,

disassembly, inspection, assembly and installation of
the major TRANSMISSION system components,
including the secondary/parking brake
components, which are integral with the drum drive
motor.
“Trouble Analysis” for the TRANSMISSION system

is found at the rear of this section.
EXCHANGING THE TRAVEL PUMP

ASSEMBLY.
FIGURE 1.
CAUTION: Remove the complete pump assembly
from the machine, only after correctly
and fully checking the pumps. Use
pressure check and flow rate test
procedures that will indicate internal
component damage which require the
pumps be removed for repair, or
replacement.
Major transmission repairs will effect
warranty. See your nearest
Distributor and refer to the "Policies
and Procedures" before removing the
transmission pumps, or doing major
repair procedures to the pumps.
NOTE: The transmission pump is an assembly FIGURE 2.

with the vibration and steering/
charge pump. After pump installation,
2. Detach the travel actuation cable (Fig. 2/1 ) from
and BEFORE starting the engine, do the
the travel lever.
following:
Flush and bleed the transmission circuit
completely.
NOTE: For Installation check and set the travel
Flush and bleed the vibration circuit
actuation cable, see troubleshooting
completely.
chart.
Perform ALL pre-charge procedures.
After start up, perform ALL high pressure
checks [refer to respective sections for
3. Unscrew all mounting screws (Fig. 3/2) from
procedures].
the backstop (Fig. 3/1), remove the backstop with
attached travel actuation cable and place it to one
side.
6/96 8-3
Section 8
TRANSMISSION SYSTEM
FIGURE A. HYDRAULIC SYSTEM SCHEMATIC.
8-4 6/96
Section 8
TRANSMISSION SYSTEM
FIGURE 3. FIGURE 5.
4. Unscrew the cap nuts (Fig. 4) of the hydraulic 6. Unscrew all bolts (Fig. 5/1 ) from the bell
oil hoses from the connections, and immediately housing (Fig. 5/2).
plug the connections and hydraulic oil hoses.
7. Carefully pull the travel pump to the front.
CAUTION: Collect the hydraulic oil and dispose

of it so as to prevent pollution. WARNING: Risk of inquiry.
NOTE: For Installation, fit the coupling hub

(Fig. 6/1 ) of the travel pump into the
coupling flange (Fig. 6/2).
FIGURE 4.
5. Attach lifting tackle to the pump.
CAUTION: Weight is approximately 50 kg. FIGURE 6.
8. Place wooden beams under the travel pump so

as to prevent accidents and then lower the travel
pump.
9. Remove the lifting tackle, move it to the front of

the crosspiece and place it around the pump again.
6/96 8-5
Section 8
TRANSMISSION SYSTEM
10. Lift out the travel pump assembly. EXCHANGING THE TRAVEL PUMP COUPLING.
11. To exchange the pump, detach both travel 1. Remove the travel pump assembly, [see THIS
levers (Fig. 7/1 and 2) with rod (Fig. 7/3). section].
2. Pull off the coupling element (Fig. 1/1 ).
FIGURE 7.
FIGURE 1.
12. Detach the coupling hub (Fig. 8/1 ).
3. Remove the coupling bolts (Fig. 1/2) by un-

screwing them.
NOTE: For Installation, Torque 50 Nm.
4. Loosen the clamping screws (Fig. 2/1) of the

coupling hub (Fig. 2/2) and pull the coupling hub
from the pump shaft.
5. Fit the coupling flange and coupling hub, install

the travel pump and perform a trial run.
FIGURE 8.
13. Unscrew the bolts (Fig. 8/2) and remove the

bell housing (Fig. 8/3).
14. Unscrew all the double-end unions.
FIGURE 2.
8-6 6/96
Section 8
TRANSMISSION SYSTEM
SEPARATING THE TRAVEL PUMPS. 5. Unscrew the bolts (Fig. 3/1) on both sides and
separate the travel pumps.
1. Remove the travel pumps [see THIS section].
2. Detach the coupling from the travel pump [see NOTE: For Installation, fit a new O-ring
THIS section]. (Fig. 4/1) into the groove and apply a thin
coat of grease. Grease the pivot (Fig. 4/2)
3. Detach the bell housing. To do so, unscrew the and insert it.
bolts (Fig. 1/1 ) and lift off the bell housing.
FIGURE 3.
FIGURE 1.
4. Detach both travel levers (Fig. 2/1 and 2) with

rod (Fig. 2/3).
FIGURE 4.
6. To detach the intermediate flange, unscrew the

FIGURE 2. Allen screws and remove the flange (Fig. 5/1 ).
NOTE: For Installation, use a new O-ring

(Fig. 6/1 ). Fit the dowel pins (Fig. 6/2)
into the bores in the cover (Fig. 6/3).
Ensure that the coupling element
(Fig. 6/4) is fitted correctly.
6/96 8-7
Section 8
TRANSMISSION SYSTEM
GENERAL NOTES FOR REPAIRS.
CAUTION: To help insure cleanliness and obtain

acceptable service life after repair,
ALWAYS observe the following notes
when repairing hydraulic
components.
1. Close ALL ports on hydraulic components [see

figure 1].
FIGURE 5.
FIGURE 1.
2. Remove and discard ALL seals and gaskets.

Replace with NEW during assembly [see figure 2 ].
FIGURE 6.
TRAVEL PUMPS.
The travel pump assembly contains the following

items, which can be resealed, or removed and
replaced, as a "minor repair":
1. Drive shaft seal.

2. Mounting flange and pivot [both pumps].
3. Travel pump valves [both pumps].
CAUTION: Opening the travel pumps for

"major repairs" causes loss of
warranty and/or policy adjustment
claims.
FIGURE 2.
NOTE: The following repair procedures follow

economical and technical guidelines. 3. Examine ALL sealing and sliding surfaces for
Repairs, other than those given, are NOT wear or damage [see figure 3].
recommended.
8-8 6/96
Section 8
TRANSMISSION SYSTEM
SEALING THE TRAVEL PUMP DRIVE SHAFT.
1. Remove the circlip (Fig. 1/1) and press off the

locking ring (Fig. 1/2).
NOTE: For Installation, check that the circlip is

fitted correctly.
FIGURE 3. 2. Remove the radial seal (Fig. 1/4).
4. Fill the hydraulic components with NEW, filtered 3. Check the groove and O-ring (Fig. 1/3) of the
hydraulic oil before system start up [see cover; check the condition of the drive shaft
figure 4]. (Fig. 1/5) and the housing bore.
4. Press the new radial seal with suitable sleeve

into the cover so it is positioned correctly.
NOTE: For Installation, before assembling the

cover, grease the dust and sealing lips.
FIGURE 4.
1 CIRCLIP
2 LOCKING RING
3 O-RING
4 RADIAL SEAL
5 DRIVE SHAFT
4
3
2
1
FIGURE 1.
6/96 8-9
Section 8
TRANSMISSION SYSTEM
SEALING THE MOUNTING FLANGE AND PIVOT 6. To remove the pivot (Fig. 1/12), remove the
FOR 1ST TRAVEL PUMP. circlip (Fig. 1/8).
1. Mark the mounting flange (Fig. 1/1 ) and detach

it. NOTE: For installation, check that the circlip is
fitted correctly.
2. Check the condition of the groove and the
contact face of the connecting plate (Fig. 1/7) or
mounting flange (Fig. 1/1 ). 7. Press off the locking ring (Fig. 1/10)
3. Remove the sealing washer (Fig. 1/5). 8. Remove the O-rings (Fig. 1/9 and 1/11 ).
4. Check the condition of the bushing 9. Check the condition of the running face of the
(Fig. 1/3), the running face of the coupling element pivot, the sealing face of the housing (Fig. 1/13) and
(Fig. 1/4) and both sides of the sealing washer. the grooves of the locking ring.
5. Exchange defective parts; use new O-rings.

NOTE: For installation, grease the O-rings
before installation.
NOTE: For installation, grease the O-ring before
installation.
2
1
3
4
6 5
8 2
7
9
10
12
11
13
1 MOUNTING FLANGE 8 CIRCLIP
2 O-RING 9 O-RING
3 BUSHING 10 LOCKING RING
4 COUPLING ELEMENT 11 O-RING
5 SEALING WASHER 12 PIVOT
6 PIN 13 HOUSING
7 CONNECTING PLATE
FIGURE 1.
8-10 6/96
Section 8
TRANSMISSION SYSTEM
SEALING THE MOUNTING FLANGE AND PIVOT NOTE: For installation, check that the circlip is
FOR 2ND TRAVEL PUMP. fitted correctly.
1. Mark the cover (Fig. 1/1 ) and detach it.

6. Press off the locking ring (Fig. 1/10).
2. Check the condition of the groove and the
contact face of the connecting plate (Fig. 1/7) and 7. Remove the O-rings (Fig. 1/2 and 1/9).
cover (Fig. 1/1 ).
8. Check the running face of the pivot, the sealing
3. Check the condition of the bushing (Fig. 1/3). face of the housing (Fig. 1/13) and the O-rings and
grooves of the locking ring.
4. Exchange defective parts, use new O-rings.
NOTE: For installation, grease the O-rings

NOTE: For installation, grease the O-rings before installation.
before installation.
5. To remove the pivot (Fig. 1/12), remove the

circlip (Fig. 1/8).
1
2
8 7 2 3
9
10
12
11
1 COVER 9 0-RING
2 O-RING 10 LOCKING RING
3 BUSHING 11 O-RING
7 CONNECTING PLATE 12 PIVOT
8 CIRCLIP 13 HOUSING
FIGURE 1.
6/96 8-11
Section 8
TRANSMISSION SYSTEM
SEALING THE TRAVEL PUMP VALVES. NOTE: For installation, stick the valve cone and
spring together with grease before
1. Unscrew the screw plug (Fig. 1/4) of the charge assembly.
pressure relief valve with spring (Fig. 1/6) and
unscrew the O-ring (Fig. 1/5).
3. Remove the two charge valves (Fig. 1/1 ).
NOTE: For installation, wind adhesive tape 4. Use new O-rings (Fig. 1/2 and 1/3).
around the thread of the screw plug
before fitting the new O-ring in order
to prevent damage to the seal ring. NOTE: For installation, wind adhesive tape
around the thread of the charge valves
before fitting the new O-rings in order to
2. Remove the valve cone (Fig. 1/7). prevent damage to the seal rings.
1
2
3
4 5
6 7
1 CHARGE VALVE 5 O-RING

2 O-RING 6 SPRING
3 O-RING 7 VALVE CONE
4 SCREW PLUG
FIGURE 1.
8-12 6/96
Section 8
TRANSMISSION SYSTEM
REMOVING AND INSTALLING THE DRIVE. 6. Check the condition of the locating pin, bore
and contact face of the valve plate, as well as the O-
REMOVING THE DRIVE. ring (Fig. 1/5), seal ring (Fig. 1/6) and grooves in the
housing.
1. Mark the position of the cover (Fig. 1/1), mount-
ing flange (Fig. 1/13) and valve plate (Fig. 1/3) 7. Detach the locking ring (Fig. 1/10), see appro-
relative to the housing (Fig. 1/11). Disassemble the priate section.
parts, see appropriate section.
8. Swivel the pump housing until the cylinder (Fig.
2. Remove the coupling element (Fig. 1/2). 1/8) with the piston and pullback device
(Fig. 3/6) slip out.
3. Detach the valve plate (Fig. 1/3).
9. Place the parts on a soft, clean base.
4. Lift off the valve plate.
10. Remove the locking ring (Fig. 2/1) from the
5. Lift off the control plate (Fig. 1/7), paying drive shaft (Fig. 2/2).
attention to the locating pin (Fig. 1/4) and bore in the
timing disc. 11. Drive out the drive shaft.
3 12
5 4
7
10 8
a
6 13
2
9
11
1 COVER 9 PISTON
2 COUPLING ELEMENT 10 LOCKING RING
3 VALVE PLATE 11 HOUSING
4 LOCATING PIN 12 O-RING
5 O-RING 13 MOUNTING FLANGE
6 SEAL RING a 1ST TRAVEL PUMP
7 CONTROL PLATE b 2ND TRAVEL PUMP
8 CYLINDER
FIGURE 1.
6/96 8-13
Section 8
TRANSMISSION SYSTEM
12. Remove the drive shaft with cylinder roller 17. Check the condition of the toothing and
bearing (Fig. 2/4). running faces of the drive shaft and exchange the
drive shaft if necessary.
13. Remove the pivot (Fig. 2/8).
14. Press off the upper bearing (Fig. 2/6) with the NOTE: Fits must have no rust. The drive shaft
bearing cup (Fig. 2/5). must not show any run-in marks from the
radial seal.
15. Remove the screw plug (Fig. 2/3) and press
off the lower bearing (Fig. 2/6) with bearing cup (Fig.
2/7). 18. Check the condition of the bushing (see THIS
section), exchange if necessary and fit new O-rings.
CAUTION: Thoroughly clean all parts and put 19. Check the condition of the sliding races,
them down, so that they cannot be running faces and sliding face of the pivots (Fig. 2/
damaged. 8). They must not show any signs of scoring; if
necessary exchange the pivots.
16. Exchange all bearings/bearing cups.
8
5 6
9
4
3
1 6 BEARING
1 LOCKING RING
2 DRIVE SHAFT 7 LOWER BEARING CUP
3 SCREW PLUG 8 PIVOT
4 CYLINDER ROLLER BEARING 9 CIRCLIP
5 UPPER BEARING CUP
FIGURE 2.
8-14 6/96
Section 8
TRANSMISSION SYSTEM
20. Check the condition of the pullback device 21. Check the condition of the piston
(Fig. 3/6) with ball (Fig. 3/5). If one of these parts is (Fig. 3/7), cylinder (Fig. 3/2) and control plate
worn, both parts must be exchanged together. (Fig. 3/1 ).
NOTE: The pullback device and ball must not NOTE: The piston running faces must not show
show any signs of scoring or run-in any signs of scratches or metal
marks. inclusions. The cylinder toothing must
not be damaged. Cylinder bores and
cylinder slide faces must not show any
signs of scoring or inclusions. If there
are signs of wear always exchange
piston and control plate.
2
3
4
5
6
7 1 CONTROL PLATE
8 2 CYLINDER
3 SHIM
4 BELLEVILLE SPRING
5 BALL
6 PULL-BACK DEVICE
7 PISTON
8 SLIPPER PAD
FIGURE 3.
6/96 8-15
Section 8
TRANSMISSION SYSTEM
INSTALLING THE DRIVE. EXCHANGING THE DRUM MOTOR.
1. Heat the cylinder roller bearing (Fig. 2/4) to Installation Weight:

80˚ C, slide it on and secure with a circlip (Fig 2/9). Drum motor approx. 80 kg
1. Remove the drum, see corresponding section.

NOTE: Check that the circlip is fitted correctly.
2. Detach the console (Fig. 1/7) from the drum
motor (Fig. 1/9).
2. Fit the bearings (Fig. 2/6) and bearing cups
(Fig. 2/5 and 2/7). 3. Attach the drum motor to the lifting tackle.
Weight approx. 80 kg.
3. Fit the pivot (Fig. 2/8) and press in the drive
shaft (Fig. 2/2). 4. Unscrew the nuts (Fig. 1/8) from the rubber
buffers.
4. Fit the locking ring (Fig. 2/1) with new radial
seal and new O-ring, (see THIS section). 5. Pull the drum motor with attached drive disc
(Fig. 1/3) from the rubber buffers.
5. Preassemble the cylinder assembly (Fig. 3/2,3,
4, 5, 6 and 7), ensuring that the Belleville springs
(Fig. 3/4) and shim (Fig. 3/3) are fitted correctly. NOTE: Check the condition of all rubber buffers
and exchange if necessary.
6. Oil the slipper pad (Fig. 3/8).
7. Insert the cylinder assembly into the housing, 6. To exchange the drum motor, unscrew the
and engage the toothing by turning the drive shaft bolts (Fig. 1/5) and remove the drive disc from the
slightly. drum motor.
8. Grease the new O-rings (Fig. 1/5 and 1/12) and

insert into the grooves. NOTE: For installation, before connecting the
hydraulic oil hoses into the opening of
9. Stick the control plate (Fig. 3/1 ) onto the valve the double-end union (Fig. 2) for the
plate (Fig. 1/3) using grease. leakage hose, pour in oil until the level
no longer drops and remains at the
upper edge.
NOTE: Ensure that the control plate and locating
pin are fitted correctly.
CAUTION: Fill the hydraulic system and flush,
otherwise the new units may be
10. Oil the cylinder slide face (Fig. 3/2), and fit the destroyed (see THIS section).
valve plate (Fig. 1/3) in accordance with the marking.
11. Fit the coupling element (Fig. 1/2).
12. Fit the cover/mounting flange with new

O-rings.
13. Fit the pivot locking ring.
8-16 6/96
Section 8
TRANSMISSION SYSTEM
4
7
3 1
2
6 5
1 WASHER 9
2 WASHER
3 DRIVE DISC
8
4 ALLEN SCREW
5 ALLEN SCREW 2
6 HEXAGON NUT
7 CONSOLE
8 HEXAGON NUT
9 DRUM MOTOR
FIGURE 1.
EXCHANGING THE TIRE DRIVE TRAVEL

MOTORS.
Installation Weight: Approx. 50 kg
Tools: Jack, wooden block
1. Loosen the wheel bolts, on the side in of the

machine having the motor removed.
2. Jack up the rear of the machine until the wheel

is free.
FIGURE 2. DANGER: Support the machine, so as to prevent

accidents (Fig. 1).
6/96 8-17
Section 8
TRANSMISSION SYSTEM
5. Attach lifting tackle to the travel motor. Weight
approx. 50 kg.
6. Unscrew the mounting screws (Fig. 2/2) and

pullout the travel motor.
REPAIRING THE TRAVEL MOTOR - WITH AND

WITHOUT BRAKE.
1. Remove the travel motor (see THIS section).
2. Remove the plugs from the connection bores

FIGURE 1. of the hydraulic hoses and drain the oil.
3. Unscrew the wheel bolts and remove the wheel.

NOTE: For installation, pour in oil via the filler
4. Mark the hydraulic oil lines (Fig. 2/1 ). Unscrew bore (Fig. 1/1 ) until at the lower edge and
the cap nuts from the connections, and plug the fit plugs (Fig. 1/arrow).
connections and hydraulic oil lines.
CAUTION: Collect the draining hydraulic oil so

as to prevent pollution.
NOTE: For Installation, pour oil into the

connection socket for the leakage hose
until the level no longer drops but
remains at the upper edge.
CAUTION: Fill the hydraulic system and flush it,

otherwise the new units may be
destroyed (see THIS section).
FIGURE 1.
TRAVEL MOTOR WITH BRAKE - DISMANTLING

THE BRAKE.
1. Remove the circlip (Fig. 2/65) and washer

(Fig. 2/52).
2. Remove the cylinder head screws (Fig. 3/62)

from the stop ring and remove the parts.
NOTE: For Installation, tighten the bolts

crosswise. Align the openings
FIGURE 2. (Fig. 3/arrows) to each other.
8-18 6/96
Section 8
TRANSMISSION SYSTEM
4. Use a brass mandrel to loosen the brake piston
(Fig. 5/51) from its seat and remove the piston from
the stop ring (Fig. 5/47).
FIGURE 2.
FIGURE 5.
NOTE: For installation, use new O-rings

(Fig. 6/59 and 6/57).
FIGURE 3.
3. Drive the drive (Fig. 4/48) out of the stop ring

(Fig. 4/67).
FIGURE 6.
5. Remove the Belleville spring (Fig. 7/64), O-ring

(Fig. 7/56) and washer (Fig. 7/50) from the drive
(Fig. 7/48).
NOTE: For installation, fit a new O-ring

(Fig. 7/56) into the inner groove
(Fig. 7/arrow).
FIGURE 4.
6/96 8-19
Section 8
TRANSMISSION SYSTEM
FIGURE 7. FIGURE 9.
6. Remove the spacer (Fig. 8/55), shaft 8. Remove the disc (Fig. 10/34).
(Fig. 8/49), plates (outer) (Fig. 8/53) and plates
(inner) (Fig. 8/54).
NOTE: For installation, 14 plates (outer),

13 plates (inner). Fit parts, beginning with
plate (outer). Measure spacer, see Figs.
11 and 12.
FIGURE 10.
NOTE: For installation, the disc must fit flush.

Measure the spacers; to do this, place
the drive (Fig. 11/48) on the plate
assembly (14 outer plates, 13 inner
plates) (Fig. 11/53 and 11/54) and disc
FIGURE 8. (Fig. 11/34). Measure height.
Dimension “a”
Nominal value 49.3 mm
7. Unscrew the cylinder head screws - Dimension “a” 48.0 mm
(Fig. 9/62) and remove the base plate (Fig. 9/45). = remainder 1.3 mm
Measure the spacers (Fig. 12/55) and fit
1.3 mm thick spacers when installing the
plates (Fig. 10).
8-20 6/96
Section 8
TRANSMISSION SYSTEM
FIGURE 11. FIGURE 13.
DISMANTLING THE TRAVEL MOTOR - WITHOUT

BRAKE.
1. Unscrew the Allen screws (Fig. 14/36) and

remove the cover plate (Fig. 14/35).
NOTE: For installation, Use a new O-ring

(Fig. 14/31).
FIGURE 12.
9. Remove the radial seal (Fig. 13/61) from the

groove.
NOTE: For installation, use a new o-ring.
FIGURE 14.
6/96 8-21
Section 8
TRANSMISSION SYSTEM
DISMANTLING THE TRAVEL MOTOR - WITH/ 2. Use an M5x20 bolt (Fig. 17/a) to pull the stop
WITHOUT BRAKE. pin (Fig. 17/23) out of its seat.
NOTE: After detaching the brake, or cover plate,

further assembly operations are the NOTE: For installation, use a new O-ring
same. (Fig. 17/29).
1. Unscrew the socket-head cap screws

(Fig.15/33) and completely remove the rear housing
(Fig. 15/21).
FIGURE 17.
3, Use a brass mandrel of dia. 8 mm to press the

distributor ring (Fig. 18) out of the rear housing
FIGURE 15. (Fig. 18/21).
NOTE: For Installation, fit the connections

(Fig. 16/a) of the housing so that they
point to the type plate and type number
(Fig. 16/b). Use a new O-ring (Fig. 16/33).
FIGURE 18.
4. Fit the distributor ring (Fig. 19/22) with the

narrower groove (Fig. 19/a) pointing to the bore
for the stop pin (Fig. 19/23).
FIGURE 16.
8-22 6/96
Section 8
TRANSMISSION SYSTEM
5. Remove the springs (Fig. 20/24) from the bores

of the distributor ring (Fig. 20/22).
FIGURE 22.
FIGURE 20.
6. Exchange the seals (Fig. 21/26, 27 and 28).
7. Completely remove the cylinder block

(Fig.22/15) from the front housing (Fig. 22/2).
8. Completely remove the rollers (Fig. 23/16) and

piston (Fig. 23/17) from the cylinder block
(Fig. 22/15).
NOTE: For installation, check the parts FIGURE 23.

(Fig. 23/16 and 17) and use new parts if
necessary. a = bearing cup
b = piston
c = piston ring
6/96 8-23
Section 8
TRANSMISSION SYSTEM
9. Remove the cam housing (Fig. 24/19). NOTE: For installation, measure the bearing
pretension. Fit the disc (Fig. 26/9) and
circlip (Fig. 26/10).
NOTE: For installation, use a new O-ring Use a feeler gauge to measure
(Fig. 24/32). Fit the cam housing so that dimension “a”.
the type plate (Fig. 24/a) is aligned with Determine the thickness of the spacers,
the stamped-in numbers (Fig. 24/b). dimension “a” + 0.1 mm pretension
= thickness of spacers.
Measure the spacers and fit them during
installation.
FIGURE 24.
10. Remove the circlip (Fig. 25/10) and remove FIGURE 26.
the disc (Fig. 25/3) and spacer (Fig. 25/9).
11. Press the shaft (Fig. 27/1 ) out of the bearings.
FIGURE 25.
FIGURE 27.
NOTE: For installation, fit the preassembled

shaft (Fig. 28/1 ) into the preassembled
front housing (Fig. 28/2), then fit the
shaft bearing (Fig. 28/7).
8-24 6/96
Section 8
TRANSMISSION SYSTEM
12. Drive out the bearing cups (Fig. 29/7 and 6)

and radial seal (Fig. 29/12).
FIGURE 31.
14. Check all parts for wear, replace damaged

parts and all seal rings.
FIGURE 29.
13. Pull the shaft bearing (Fig. 30/6) and sealing

flange (Fig. 30/11 ) from the shaft.
NOTE: For installation, first fit the sealing flange

(Fig. 31/11), then the shaft bearing
(Fig. 31/6).
6/96 8-25
Section 8
TRANSMISSION SYSTEM
2 19
11
1 16
17
15
10
a 9
6
12
e
7 i
b c 32
21 33 f 55
j 47
69
39
24
54 60
h
53 50
34 52
22 65
70
56
61 49
57
26 48
51
45
29
23 59
62
64 63
27 28 k
l
FIGURE A.
8-26 6/96
Section 8
TRANSMISSION SYSTEM
LEGEND
a) Grease labyrinth region 21 Rear housing
b) Grease bearing 22 Distributor ring
c) Fill gap between lips with grease 23 Stop pin
Note: Use lithium-based grease (e.g. BP 24 Spring
Energrease L.2) suitable for vehicles 26 Seal
e) Use appropriate distance ring so that the 27 Seal
bearing has a pretension of 0...0.1. 28 Seal
f) Torque 117...122 Nm 29 O-ring
h) Make sure that disc SK 1960 is fitted in order to 32 O-ring
limit piston movement (from the chamber to 33 Socket-head cap screw
the drive). 34 Washer
i) Use appropriate spacer to obtain the neces- 39 Transport plug
sary assembly height. 45 Base plate
j) Assembly height 47 Stop ring
k) Torque 47...51Nm 48 Drive
l) Torque 23...27 Nm 49 Shaft
Front housing subassembly, consisting of 50 Washer
parts 1... 12. 51 Brake piston
1 Shaft 52 Washer
2 Front housing 53 Plate, outer
3 Washer 54 Plate, inner
6 Front bearing 55 Spacer
7 Rear bearing 56 O-ring
9 Spacer 0.1 57 O-ring
10 Circlip 59 O-ring
11 Gasket,flat 60 Seal
12 Radial seal 61 Radial seal
Rotating subassembly,consisting of parts 62 Cylinder head screw
15...17 63 Cylinder head screw
15 Cylinder block 64 Belleville spring
16 Roller 65 Circlip
17 Piston subassembly. consisting of 69 Transport plug
Piston 70 Transport plug
Support
Piston ring
19 Cam
Rear housing subassembly, consisting of
parts 21...29
LEGEND TO FIGURE A.
6/96 8-27
Section 8
TRANSMISSION SYSTEM
2
19
11
1
16
15 17
10
3
a g
6
12
e
b 7 32
c
21 33
39
24
35
34
22
31
26
36
23 29 g
27 28
FIGURE B.
8-28 6/96
Section 8
TRANSMISSION SYSTEM
LEGEND
a) Grease labyrinth region
b) Grease bearing
c) Fill gap between lips with grease
Note: Use lithium-based grease (e.g.BP
Energrease L.2) suitable for vehicles
e) Use appropriate distance ring so that the
bearing has a pretension of 0...0.1.
g) Torque 40....45Nm
Front housing subassembly, consisting of
parts 1...12.
1 Shaft
2 Front housing
3 Washer
6 Front bearing
7 Rear bearing
9 Spacer 0.1
10 Circlip
11 Gasket,flat
12 Radial seal
Rotating subassembly,consisting of parts
15...17
15 Cylinder block
16 Roller
17 Piston subassembly, consisting of
Piston
Support
Piston ring
19 Cam
Rear housing subassembly, consisting of
parts 21...29
21 Rear housing
22 Distributor ring
23 Stop pin
24 Spring
26 Seal
27 Seal
28 Seal
29 O-ring
31 O-ring
32 O-ring
33 Socket-head cap screw (torque 117...122 Nm)
34 Washer
35 Cover plate
36 Allen screw
39 Transport plug
LEGEND TO FIGURE B.
6/96 8-29
Section 8
TRANSMISSION SYSTEM
FILLING THE HYDRAULIC SYSTEM.
NOTE: Using the filling and flushing unit to fill

the hydraulic system ensures that all
hydraulic components are filled and bled
with clean hydraulic oil.
1. The travel motors and drum motor must be

filled with hydraulic oil.
2. Detach the pressure hose (Fig. 1/1) from the

vibration valve and connect to the pressure hose of
the filling and flushing unit.
3. Plug the vibration valve connection. FIGURE 2.
4. Hold the other hose of the filling and flushing

unit in the bag filled with clean hydraulic oil or in a
filled oil container.
FIGURE 3.
8. Jack up the vehicle at the front and rear, so

that the drums can rotate freely.
FIGURE 1.
5. Loosen the cap nuts (Fig. 2) and (Fig. 3) of the DANGER: Do NOT stand under loads which are
high-pressure hoses on the drum motor and travel being lifted. Risk of injury.
motors.
6. Switch on the filling and flushing unit and 9. Connect a pressure gauge to the charge-
ensure that the pressure has been set to at least 25 pressure test connection on the travel pump (Fig. 4).
bar (read off from the built-in pressure gauge).
7. Do not tighten the cap nuts (Fig. 2) and

(Fig. 3) until oil emerges at the appropriate point.
Proceed in the same way with the remaining cap
nuts.

of it so as to prevent pollution.
8-30 6/96
Section 8
TRANSMISSION SYSTEM
FIGURE 4. FIGURE 6.
10. Move the travel lever to neutral and the 13. Start the engine and let it idle until hydraulic
throttle lever to the stop position. Actuate the ignition oil flows out of both Minimess hoses without bubbles
switch, taking care that the engine does not start. (Fig. 6).
Actuate the starting switch for 10 seconds, at
intervals of 10 seconds. Repeat this process until the 14. Carefully move the travel lever in both direc-
charge pressure shown on the pressure gauge is tions until no more air emerges from the two
reached (Fig. 4). Minimess hoses.
11. Detach the pressure gauge. 15. Lower the machine onto the drums.
12. Connect a Minimess hose to each of the 16. Move the travel lever to neutral and turn the
M inimess connections MB and MA (Fig. 5) and run steering several times from one final stop to the
the other ends into the hydraulic oil container other with the engine idling.
(Fig. 6).
17. Check the hydraulic oil level during and after
filling. Unscrew the cover with dipstick (Fig. 7) from
CAUTION: Collect the hydraulic oil and dispose the hydraulic oil tank, wipe it with a clean, lint-free
of it so as to prevent pollution. cloth and insert it again until it bottoms. The oil level
must lie between the two marks “”MIN”’ and “”MAX”.
If the oil level is lower than these marks, top up with
oil.
FIGURE 5.
FIGURE 7.
6/96 8-31
Section 8
TRANSMISSION SYSTEM
FLUSHING OF THE DRUM DRIVE TRAVEL NOTE: The flushing filter must be fitted in the
CIRCUIT - GENERAL INFORMATION (FIG. 1). pump return line on the low-pressure
side. This results in the travel pump
CAUTION: Always flush the closed circuit after moving forwards.
changing a unit. Otherwise, any
particles remaining in the circuit may
quickly lead to further unit failure. Flushing the hoses.
1. Remove the travel motor from the circuit;

With strong oil contamination (scurf). connect the high pressure lines for this purpose.
1. Open and clean the remaining units. Flushing the entire system.
2. Exchange the high pressure hoses. 1. Connect the travel motor and relieve the load
on the drum for flushing.
3. Also flush the wheel drive travel circuit and
vibration circuit. Bleeding.
Before flushing. 1. Always bleed the hydraulic circuit when the

lines in the closed circuit are removed or
1. Exchange the hydraulic oil filter connected.
2. Clean the hydraulic oil tank.
3. Filter the hydraulic oil.
NOTE: Use the flushing unit to filter the oil.

Pump away the contents of the tank
through a 6uJ filter into the oil bag or a
container.

NOTE: Change oil if there is strong

contamination, if oil is discolored if oil
change intervals are almost reached.
Filter installation (Fig. 1).
1. Filter output “OUT” to the pump.
2. Filter input “IN” to the hose from the front travel

motor.
8-32 6/96
Section 8
TRANSMISSION SYSTEM
7
1
4
6
3
2
1 Junction socket 16 S 5 Travel pump (tandem pump)
2 Flushing filter 6 Junction socket 16 S
3 Reducer 25 S/16 S (2x) 7 Flushing hose
4 Drum motor
FIGURE 1.
6/96 8-33
Section 8
TRANSMISSION SYSTEM
FLUSHING THE DRUM DRIVE TRAVEL CIRCUIT.
INSTALLING THE FLUSHING SYSTEM.
1. Detach the engine hood, battery (Fig. 1/1) and

retaining plate (Fig. 1/2). Remove the hydraulic oil
tank cover (Fig. 1/3) and transfer the contents of the
hydraulic oil tank with a filter unit into a clean con-
tainer or oil bag.

of It so as to prevent pollutlon.
FIGURE 2.
3. Detach the upper high pressure hose on the

CAUTION: Before installing the flushing filter, rear travel pump for the drum drive (Fig. 3/1 ) from
check the hoses and connections for the side.
dirt and clean THEM IF NECESSARY.
FIGURE 3.
FIGURE 1.
4. Connect the flushing hose from the “IN” con-

nection of the flushing filter with the hose of the drum
CAUTION: Detach the rod (Fig. 2/1) between the motor (Fig. 4/1 ),
pump control lever.
5. Connect the flushing hose (Fig. 4/2) from the
”OUT” connection of the flushing filter to the open
connection of the travel pump,
8-34 6/96
Section 8
TRANSMISSION SYSTEM
FIGURE 4. FIGURE 6.
6. Detach the high pressure hoses from the drum 8. Connect a 60-bar pressure gauge (Fig. 7) to
motor and connect them to the junction socket (Fig. the charge pressure test connection and let the
5). engine idle for max. 15 seconds. Repeat the proce-
dure after 30 seconds until the pressure gauge
shows a constant pressure of 14 -16 bar.
FIGURE 5.
FIGURE 7.
BLEEDING.
7. Connect the test hose to the charge-pressure

test point (Fig. 6) and run the open end into a
container.
CAUTION: Crank the diesel engine with the

starter for max. 10 seconds. Repeat
the cranking process after waiting
one minute. Then repeat the process
as often as necessary until oil
emerges from the test hose.
Collect the hydraulic oil and dispose
6/96 8-35
Section 8
TRANSMISSION SYSTEM
9. Perform all these measures with the travel 2. Move the trave lever forwards by hand (fig. 8).
pump at neutral. Bleeding can be started as soon as
the charge pressure is present. For bleeding, move
the travel lever to the front by hand (Fig. 8). CAUTION: Move the travel lever only in travel
direction "forwards".
CAUTION: Move the travel lever only in travel

direction “forwards”. 3. Flush for approximately 15 minutes with the
diesel engine running at different speeds. Shut down
the diesel engine.
NOTE: Perform bleeding without loading the
pump or motor. Pressures over 100 bar
must be avoided at all costs. FLUSHING THE DRUM MOTOR.
1. Lift, or jack, the machine at the front until the

10. After 1 - 2 minutes running time with the diesel drum can rotate freely (Fig. 9).
engine idling, wait for approx. 1 minute. This waiting
period is necessary to allow air bubbles to escape
via the pump's leakage oil return line or via the DANGER: Risk of injury.
flushing unit. Repeat this process until the charge
pressure indicated on the low-pressure gauge (Fig,
7) drops immediately to ) when the diesel engine is
shut down. When this happens, the travel circuit has
been fully bled.
FIGURE 9.
2. Secure the rear wheels with wedges.

FIGURE 8.
3. Repeat bleeding.
4. Start the diesel engine and let it idle.

FLUSHING THE LINES FOR THE FRONT DRUM
MOTOR.
5. Move the travel lever in the direction "forwards".
1. Start the diesel engine and let it idle at
approximately 1400 rpm.
CAUTION: Move the travel lever only in travel
direction “forwards”.
8-36 6/96
Section 8
TRANSMISSION SYSTEM
6. Flush for approximately 15 minutes with the Filter installation (Fig. 1).
diesel engine running at different speeds.
1. Filter output “OUT” to the pump.
7. Shut down the diesel engine.
2. Filter input “IN” to the hoses from the travel
motors.
FLUSHING THE WHEEL DRIVE TRAVEL CIRCUIT.
GENERAL INFORMATION. NOTE: The flushing filter must be fitted in the

pump return line on the low-pressure
CAUTION: Always flush the closed circuit after side. This results in the travel pump
changing a unit. Otherwise, any moving forwards.
particles remaining in the circuit may
quickly lead to further unit failure.
Flushing the hoses.
With strong oil contamination (scurf). 1. Remove the travel motors from the circuit one
after the other; connect the high pressure lines for
1. Open and clean the remaining units. this purpose.
2. Exchange the high pressure hoses. Flushing the entire system.
3. Always flush the vibration circuit. 1. Connect the travel motors and relieve the load
on the wheels for flushing.
Before flushing.
Bleeding.
1. Exchange the hydraulic oil filter.
1. Always bleed the hydraulic circuit when the
2. Clean the hydraulic oil tank. lines in the closed circuit are removed or connected.

Pump away the contents of the tank
through a 6 u filter into the oil bag or a
container.

NOTE: Change oil if there is strong

contamination if oil is discoloured if oil
6/96 8-37
Section 8
TRANSMISSION SYSTEM
3 1
1 Junction socket
2 Filter
7
5 3 Travel motor,right
4 Travel motor,left
5 Travel pump (tandem pump)
6 6 Junction socket 16 S
8 7 Flushing hose
8 Reducer 25 S /16 S (2x)
7
8
2
FIGURE 1.
8-38 6/96
Section 8
TRANSMISSION SYSTEM
FLUSHING THE WHEEL DRIVE TRAVEL
CIRCUIT.

tank cover (Fig. 1/3) and transfer the contents of the
hydraulic oil tank with a filter unit into a clean con-
tainer or oil bag.

FIGURE 2.
4. Connect the flushing hose from the “IN”

CAUTION: Before installing the flushing filter, connection of the flushing filter with the hose to the
check the hoses and connections for travel motors (Fig. 3/1 ).
dirt and clean them if necessary.
5. Connect the flushing hose (Fig. 3/2) from the
“OUT”” connection of the flushing filter to the open
connection of the travel pump.
1
FIGURE 1.
3. Detach the upper high pressure hose on the FIGURE 3.

front travel pump (Fig. 2/1 ) from the side.
6/96 8-39
Section 8
TRANSMISSION SYSTEM
6. Disconnect the high-pressure hoses from the 9. Connect 60-bar pressure gauge (Fig. 6) to the
two rear travel motors and connect them to the charge pressure test connection and let the engine
junction socket. Seal the openings (Fig. 4). idle for max. 15 seconds. Repeat the procedure after
30 seconds until the pressure gauge shows a
constant pressure of 14... 16 bar.
10. Perform all these measures with the travel

lever at neutral! Bleeding can be started as soon as
the charge pressure is present. For this purpose
move the pump control lever in travel direction
“‘forwards” by hand.
CAUTION: Move the pump control lever only in

travel direction “forwards”. Perform
bleeding without loading the pump
and motors. Pressures over 100 bar
must be avoided at all costs.
FIGURE 4.
BLEEDING.
7. Connect the test hoses to the high pressure

test points (Fig. 5) and run the open ends into a
container.
8. Start the diesel engine with the starter for max.

10 . Repeat the starting process after waiting
one minute. Then repeat the process as often as
necessary until oil emerges from the test hose.

of it so as to prevent pollution. FIGURE 6.
11. After 1 - 2 min running time with the diesel

engine idling, wait for approx. 1 minute. This waiting
period is necessary to allow air bubbles to escape
via the pump’s leakage oil return line, or via the
flushing unit. Repeat this process until the charge
pressure indicated on the low-pressure gauge
(Fig. 6) drops immediately to "0" when the diesel
engine is shut down. When this happens, the travel
circuit has been fully bled.
FIGURE 5.
8-40 6/96
Section 8
TRANSMISSION SYSTEM
FLUSHING THE LINES FOR THE REAR TRAVEL
MOTORS.
1. The travel circuit has been bled.
CAUTION: The rod must have been unhooked.
3. Move the pump control lever in travel direction

”forwards” by hand (Fig. 7).
FIGURE 8.
travel direction “forwards”.
FLUSHING THE LEFT-HAND AND RIGHT-HAND

4. Flush for approx. 15 min with the diesel engine TRAVEL MOTORS.
running at different speeds.
1. Lift or jack up the rear of the machine until the
5. Shut down the diesel engine, left-hand wheel can turn freely (Fig. 9).
6. Reconnect the high pressure hoses to the left-

hand travel motor DANGER: Risk of accidents.
2. Secure the drum with wedges.
4. Move the pump control lever by hand in travel

direction “forwards”’.

travel direction “forwards”.
FIGURE 7.
7. The high pressure hoses on the right-hand

travel motor remain connected with each other
(Fig. 8).

of it so as to prevent pollutlon.
FIGURE 9.
6/96 8-41
Section 8
TRANSMISSION SYSTEM
5. Flush for approx. 15 minutes with the diesel 3. Reattach the pump control lever. Check that the
engine running at different speeds. travel lever is at neutral. Lower the machine.
6. Shut down the diesel engine. 4. Perform a test run; when doing so, load the
travel drive during forwards and reverse travel, e.g.
7. Reconnect the high pressure hoses of the by hill driving, or starting on slopes.
right-hand travel motor (Fig. 10).
5. Recheck the hydraulic connections for leaks
8. Raise up the rear of the machine and support (visual inspection).
the frame so there is no danger of accidents.
MAINTENANCE OF THE FLUSHING FILTER UNIT.

DANGER: Risk of accidents.
1. Exchange the flushing filter element if the red
control pin of the contamination indicator is pressed
out.
9. Flush the right-hand travel motor in the same
way as the left-hand one.
NOTE: Also possible with very cold oil.
10. Remove the flushing filter and reconnect the
high pressure hoses to the travel pump. Repeat
bleeding. 2. Clean the hoses and connections and keep the
flushing filter system in a protected place to prevent
it being contaminated.
of it so as to prevent pollution. 3. Exchange the filter cartridge of the filter unit if
the red control pin of the contamination indicator is
pressed out.
PRESSURES IN THE WHEEL AND DRUM DRIVE

TRAVEL CIRCUITS.
CHECKING THE PRESSURES IN THE WHEEL

DRIVE CIRCUIT.
Tools: Two, 600 bar pressure gauges, 60-bar

pressure gauge, test hoses.
1. Connect the 60-bar pressure gauge to the

charge pressure test connection of the hydraulic oil
filter (Fig. 1 ).
FIGURE 10.
FUNCTIONAL CHECK.
1. Check the hydraulic oil level in the tank and top

up if necessary.
2. Check all connections for leaks with the diesel

engine running (visual inspection).
8-42 6/96
Section 8
TRANSMISSION SYSTEM
CHECKING THE PRESSURES IN THE DRUM
DRIVE CIRCUIT.
1. Connect a 600 bar pressure gauge to each of

MA and MB on the rear travel pump.
2. Secure the drum/wheels by means of wedges.
3. Start the diesel engine and move the travel

lever a short distance.
4. Read off the value on the pressure gauge.
NOTE: Nominal value; Charge pressure 14 - 16

FIGURE 1. bar. High pressure approx. 300 - 320 bar
2. Connect a 600 bar pressure gauge to each port DANGER: Do not stand in the machine’s
MA and MB on the front travel pump (Fig. 2). articulation area.
3. Secure the drum/wheels by means of wedges.

NOTE: Measurement evaluation; If the pressures
4. Start the diesel engine and move the travel are not reached, perform troubleshooting
lever a short distance. in accordance with the troubleshooting
chart.
NOTE: Nominal value; Charge pressure 14 -16

bar. High pressure approx. 300 - 320 bar
DANGER: Do not stand in the machine’s

articulation area.
FIGURE 2.
6/96 8-43
Section 8
TRANSMISSION SYSTEM
HIGH PRESSURE TEST OF TRAVEL PUMPS (2 TRAVEL PUMP, DRUM DRIVE.
per pump).
1. Detach the T-pieces from connections A and
TRAVEL PUMP, WHEEL DRIVE. Band plug pump connections A and B (Fig. 2).
Tools: Two, 600 bar pressure gauges, two, test

hoses and two, plugs. CAUTION: Pressure test max. 3 seconds.
1. Detach the T-pieces from connections A and B

and plug pump connections A and B (Fig. 1 ).
2. Repeat pressure test.
CAUTION: Pressure test max. 3 seconds.

are not reached, perform troubleshooting
in accordance with the troubleshooting
2. Repeat the pressure test. chart.

are not reached, perform troubleshooting
in accordance with the troubleshooting
chart.
FIGURE 2.
FIGURE 1.
8-44 6/96
Section 8
TRANSMISSION SYSTEM
TROUBLE ANALYSIS FOR THE TRANSMISSION SYSTEM
TRANSMISSION PUMP
MACHINE DRIVES WITH Pumps not in neutral [stroked] Check linkage at pump[s]
TRAVEL CONTROL LEVER IN displacement control for correct
NEUTRAL fork to arm alignment.
Adjust control cable if needed.
Pumps mechanical neutral (0) Check the mechanical

position NOT correct neutral position [see this section.
Pumps hydraulic (0) position NOT Check the hydraulic neutral

correct position [see this section].
Displacement control has Replace displacement control

damage with new.
Transmission pumps worn or Replace transmission pumps

damaged with new.
MACHINE WILL NOT OPERATE Secondary/parking brake system Release brake system.
IN EITHER DIRECTION "on".
Solenoid coil not energized or Check electrical circuit for

is damaged current flow. Repair circuit, if
needed. Check solenoid for
operation. Replace with new, if
damaged.
Hydraulic system oil level low Check oil level in reservoir. Add
oil. Find and correct cause of low
oil level.
Control linkage damaged or Repair or replace control
linkage not connected to the Connect linkage to the
transmission pumps. transmission pump.
Both transmission charge Remove, inspect, clean or

pressure check valves in "open" replace as needed.
position
Air being drawn into the system Check all fittings and hoses for
correct tightness. Tighten as
needed.
Cold, or wrong, oil in system Permit system to warm. See

Section 4 for correct oil.
6/96 8-45
Section 8
TRANSMISSION SYSTEM
TRANSMISSION PUMP
MACHINE WILL NOT OPERATE High pressure relief valves in Remove, inspect clean, adjust
IN EITHER DIRECTION "open" position or replace and adjust valves.
[continued]
Wheel drive and drum drive Remove, repair or replace
motors damaged motors.
MACHINE OPERATES IN ONE Transmission pumps linkage has Check control system for
DIRECTION ONLY damage connection, binding or missing
parts. Correct and adjust as
needed.
Displacement control valves Replace valves with new.

damaged
One charge pressure check valve Identify check valve. Remove,

damaged clean or replace as needed.
Wheel and drum drive Remove motors. Repair, or

motors damaged replace as needed.
Hoses carrying "high" pressure in Locate "stopped" hose. Remove,

a "stopped" condition clean or replace as needed.
NEUTRAL POSITION DIFFICULT Pumps control linkage has Check control system for
OR NOT ABLE TO BE damage connection, binding or missing
FOUND parts. Correct and adjust as
needed.
Displacement control valves Replace valves with new.

damaged
Both pumps displacement Adjust control cylinders or

control cylinder not adjusted replace and adjust cylinders as
correctly, or is damaged needed.
SYSTEM OPERATES IN A "HOT" Hydraulic system oil level "low" Check oil level in reservoir. Add
CONDITION oil. Find and correct cause of low
oil level.
"Stopped" pressure oil filter Replace filter element with new.

element
System being operated at a Eliminate cause of excessive

pressure over "high" relief pressure, or adjust "high" relief
pressure setting.
8-46 6/96
Section 8
TRANSMISSION SYSTEM
TRANSMISSION PUMP
SYSTEM OPERATES IN A Pumps have internal leakage Remove, inspect, repair or

"HOT" CONDITION replace pumps.
[continued]
CAUTION: Clean the entire
hydraulic system
AFTER a failure.
TRANSMISSION PUMPS AND Hydraulic system oil level low Check oil level in reservoir. Add
SYSTEM NOISY DURING oil. Find and correct cause of low
OPERATION oil level.
Hose or fitting loose, allowing air Check all fittings and hoses for
to be drawn into the system correct tightness. Tighten as
needed.
Pumps have internal wear or Remove, repair or replace

damage pumps.

hydraulic system
AFTER a failure.
Hoses not correctly insulated from Check hose routings. They must
vibration or not positioned as not touch any metal that can
needed increase natural hydraulic
system "hum".
MACHINE ACCELERATION Air being drawn into system See " System Noisy During
AND/OR DECELERATION Operation - Air In System".
SLOW
Low charge pressure Adjust charge pressure to
correct amount. Disassemble,
repair or replace steering/charge
pump and then adjust, if
needed.
Displacement control valves orifice Remove displacement control

partially "stopped" valve. Remove, clean or replace
orifice. Install control valve.
Pumps have internal wear or Remove and repair or replace

damage pumps as needed.
6/96 8-47
Section 8
TRANSMISSION SYSTEM
TRANSMISSION PUMP
MACHINE ACCELERATION Engine not operating at correct Set engine at correct "high" idle
AND/OR DECELERATION speed - low RPM RPM.
IS SLOW [continued]
High pressure relief valve open, or Remove, inspect, clean or

damaged replace valve as needed. Check
pressure adjustment.
TRANSMISSION MOTORS
WHEEL DRIVE MOTORS Secondary/parking brake system Release brake system.

AND DRUM DRIVE MOTOR "on"
WILL NOT ROTATE IN EITHER
DIRECTION Wires to secondary/parking brake Check wire connections and
system switch reversed change as needed.
Hydraulic system oil level low Check oil level in reservoir. Add
oil. Find and correct cause of
low oil level.
No output from transmission See "Machine Will Not Operate

pumps In Either Direction" - in the
Transmission Pumps "Trouble
Analysis".
Secondary/parking brakes on Check brake release hydraulic

wheel drive motors not releasing. pilot pressure. Check release
piston operation on wheel drive
motors. Repair, or replace,
components as needed.
Wheel drive motors and drum Remove, repair or replace

drive motor have damage motors with new as needed.

hydraulic system
AFTER a failure.
8-48 6/96
Section 8
TRANSMISSION SYSTEM
TRANSMISSION MOTORS
WHEEL DRIVE MOTORS Pumps displacement control Adjust control linkage or

AND DRUM DRIVE MOTOR linkage not adjusted correctly or replace damaged linkage and
WILL ROTATE IN ONE is damaged then adjust correctly.
DIRECTION ONLY
Displacement controls valve have Replace control valves with new.

damage
Motors have internal damage Remove, repair or replace

motors with new.
Hoses carrying "high" pressure Remove hoses. Clean or

oil for direction NOT rotating replace as needed.
"stopped"
WHEEL DRIVE MOTORS Excessive loading of hydraulic Reduce system loading.

AND/OR DRUM DRIVE MOTOR system
OPERATING IN A "HOT"
CONDITION Low oil flow reaching wheel drive See "TRANSMISSION PUMP"
and/or drum drive motor[s] from - "System Operates In A Hot
transmission pumps. Condition".
Incorrect type oil used in Drain and flush system. Fill

hydraulic system with correct type oil
[see Section 4].
Motor[s] have internal damage Remove motor[s] and repair or

replace with new as needed.

hydraulic system
AFTER a failure.
6/96 8-49
Section 8
TRANSMISSION SYSTEM
WHEEL DRIVE MOTORS MULTI-DISC BRAKES
BRAKES WILL NOT RELEASE No charge pressure available Check charge pressure. Correct
within system cause of low ,or no, charge pilot
pressure to brake valve as
needed.
Secondary/parking brake system Remove and replace valve

control valve damaged with new.
Brake valve solenoid damaged Remove and replace solenoid.
Low or no charge pilot pressure Check charge pilot pressure

flowing from brake valve to brake from brake valve. Correct
release pistons cause of low, or no, charge
pressure, from brake valve, as
needed.
Brake release pistons, or seals, Remove motors. Disassemble

worn, or damaged and inspect brake parts. Replace
worn or damaged parts as
needed.
BRAKES WILL NOT APPLY Brake release valve damaged - Remove and replace valve
spool in open flow position with new.
Charge pilot pressure being Check for correct brake release

supplied to brake release pistons oil supply hose routing. Change
at all times routing if needed.
Multi-disc brakes worn or Replace ALL discs with new.

damaged
BRAKES WILL NOT APPLY Brake release pistons remaining in Remove release pistons.
Replace damaged parts, with
new.
Belleville [brake application] Remove washers and replace

washers have reduced tension, or with new.
other damage
8-50 6/96
Section 8
TRANSMISSION SYSTEM
WHEEL DRIVE MOTORS MULTI-DISC BRAKES
BRAKES WILL NOT HOLD Multi-disc brakes worn or damaged Replace ALL discs with new.
MACHINE WHEN APPLIED
Brakes not shimmed correctly Shim brakes to correct
specifications.
Belleville [brake application] Remove washers and replace

washers have reduced tension, or with new.
other damage
Brake release pistons not fully Remove motors. Disassemble

returning to the retracted position and inspect pistons and seals.
when brakes are applied Replace damaged parts with
new.
6/96 8-51
Section 8
TRANSMISSION SYSTEM
NOTES
8-52 6/96
Section 9
BRAKE SYSTEM
TABLE OF CONTENTS
PAGE
GENERAL INFORMATION ....................................................................................................................... 9-2
DYNAMIC BRAKING ................................................................................................................................ 9-3
BASIC OPERATION .............................................................................................................................. 9-3
SECONDARY/PARKING BRAKE SYSTEM ............................................................................................ 9-3
BASIC OPERATION ............................................................................................................................. 9-3
REMOVING AND REPLACING THE SECONDARY/PARKING BRAKE SYSTEM

HYDRAULIC SYSTEM CONTROL VALVE ASSEMBLY ....................................................................... 9-4
6/96 9-1
Section 9
BRAKE SYSTEM
GENERAL INFORMATION [See Figure 1]. Repair procedures for the SECONDARY/PARKING
BRAKE system components, within the wheel drive
THIS section describes the operation of the motors, are included in Section 8 - TRANSMISSION
DYNAMIC [hydrodynamic, through the transmission SYSTEM.
system] and the SECONDARY/PARKING [spring
applied, hydraulically released, [SAHR] braking Trouble analysis information for the secondary/
systems. parking brake system is found in Section 8 -
TRANSMISSION for the wheel drive motor assembly
SECONDARY/PARKING BRAKE components are contained components.
included within each wheel drive motor.
FROM CHANGE PUMP
MOTOR
BRAKE RELEASE PRESS
BRAKE SYSTEM
CONTROL VALVE
BRAKE RELEASE PRESS
MOTOR
TO TANK
FIGURE 1. SECONDARY/PARKING BRAKE SYSTEM - RELEASE OIL FLOW PATH.
9-2 6/96
Section 9
BRAKE SYSTEM
DYNAMIC BRAKING. SECONDARY/PARKING BRAKE SYSTEM.
BASIC OPERATION. BASIC OPERATION [See Figure 1].
During operation, SLOWING, or STOPPING, of the The SECONDARY/PARKING brake system is used
machine is done by using the TRANSMISSION to hold the machine in a “stopped” condition after it
system. Control of the transmission system is has been stopped through the use of DYNAMIC
through the travel control lever, found to the right braking. During machine operation the system will
side of the seat. During machine operation, moving also be “APPLIED” if the machine has a loss of
the lever FROM either the FORWARD, or hydraulic system charge pressure or if there is a
REVERSE, position TOWARD the NEUTRAL stoppage of the engine.
position causes the oil flow through the transmission
system to be reduced and/or then stopped. This Control of the SECONDARY/PARKING brake system
slows, and then stops, the machine. is accomplished by using the secondary/parking
brake system control handle found on the left side of
the machine.
WARNING: When approaching, and then
traveling down, a slope use a SLOW Putting the brake system control valve handle at the
speed. ADDITIONAL slowing of the “ON” [APPLIED] position, will cause the manually
machine is done by moving the moved spool, found in the brake valve, to stop the
travel control lever PAST neutral, to flow of release oil to the multi-disc brake release
the direction OPPOSITE the direction piston in the each wheel drive motor. The application
of machine travel. pressure plate will then APPLY the one set of multi-
The SECONDARY/PARKING BRAKE disc brakes contained within each wheel drive motor.
SYSTEM MUST be used to hold the
machine in a “stopped” condition at
ALL times. WARNING: The machine MUST NOT move, at
The transmission system, used for ANY time, when the secondary/
the “DYNAMIC” braking of the parking brake system control switch
machine, will NOT hold and keep the is in the “ON” position.
machine in a “stopped” condition. Do NOT operate the machine, IF the
machine WILL move when the
SECONDARY/PARKING brake system
NOTE: Repair of the DYNAMIC braking system is is in an “ON” [APPLIED] condition.
done through service to the Notify repair personnel and repair the
TRANSMISSION system [See Section 8 - machine IMMEDIATELY.
TRANSMISSION SYSTEM].
Putting the secondary/parking brake system control

valve handle at the “OFF” [RELEASED] position, will
cause the manually moved spool, found in the brake
valve, to permit the supply of charge pressure oil to
the multi-disc brake release piston in each wheel
drive motor, RELEASING the multi-disc secondary/
parking brakes.
6/96 9-3
Section 9
BRAKE SYSTEM
REMOVING AND REPLACING THE SECONDARY/ 4. Remove the brake valve handle retaining
PARKING BRAKE SYSTEM HYDRAULIC SYSTEM capscrew and remove the handle from the valve
CONTROL VALVE ASSEMBLY [See Figure 1]. actuation shaft.
Use the following information to remove and replace

the brake system hydraulic control valve assembly. NOTE: For installation, install handle onto the
valve actuation shaft. Install and tighten
1. Stop the engine. Open the engine hood and the the handle retaining capscrew.
access panel above the brake system hydraulic
control valve assembly. Wash the control valve and
hose and fitting areas to remove dirt accumulations. 5. Remove the brake valve assembly to panel
retaining capscrew and remove the valve assembly
2. Put an identification tag on each hose and each from the machine. Remove one [1] fitting at a time,
valve fitting. Remove each hose from each control from the removed valve assembly. Clean the
valve fitting. Immediately put a cap on each valve threaded area of the fitting. Put teflon tape on the
fitting and a plug in each hose fitting. threaded area of the fitting. Exchange the fitting to
the SAME port in the new control valve assembly.
Transfer the remaining fittings, using the above
NOTE: For installation, remove the plug from information.
each hose fitting and the cap from each
control valve fitting. Install and tighten
each hose onto each correct valve fitting NOTE: For installation, install brake valve into
per the identification tags. the machine and position it against the
panel. Install the valve retaining
capscrews and washers and tighten the
3. Disconnect the two [2] electrical wires at the retaining capscrews.
connection points, below the brake system condition
indicator pressure actuated switch. 6. Start the engine. Check the secondary/parking
brake valve operation.
NOTE: For installation, connect the two [2]

electrical wires at the connection points.
BRAKE VALVE HANDLE CONTROL VALVE

(ON VALVE ACTUATION SHAFT)
PANEL
ACCESS PANEL
HOSE
HOSE
HOSE
HOSE
ELECTRICAL WIRES
FIGURE 1.
9-4 6/96
Section 10
STEERING SYSTEM
TABLE OF CONTENTS
PAGE
DESCRIPTION ......................................................................................................................................... 10-2
SYSTEM OPERATION ............................................................................................................................. 10-3
EXCHANGING THE STEERING, CHARGING AND VIBRATION PUMP ............................................... 10-3
REPAIRING THE STEERING, CHARGING AND VIBRATION PUMP.................................................... 10-3
EXCHANGING THE CONTROL VALVE ................................................................................................. 10-6
REMOVING AND INSTALLING THE STEERING UNIT ......................................................................... 10-6
DISMANTLING THE STEERING CONTROL UNIT ................................................................................ 10-9
DISMANTLING THE DOUBLE SHOCK VALVES .............................................................................. 10-9
DISMANTLING THE PRESSURE RELIEF VALVE ........................................................................... 10-11
DISMANTLING THE PRESSURE RELIEF VALVE (CARTRIDGE) .................................................. 10-11
ASSEMBLING THE STEERING CONTROL UNIT ................................................................................ 10-12
ASSEMBLING THE O-RING/KIN RING ............................................................................................. 10-13
ASSEMBLING THE TWO REFILL VALVES ..................................................................................... 10-13
ASSEMBLING THE PRESSURE RELIEF VALVE ............................................................................ 10-14
ASSEMBLING THE DOUBLE SHOCK VALVES ............................................................................. 10-14
REMOVING AND INSTALLING THE STEERING CYLINDER ............................................................ 10-14
REPAIRING THE STEERING CYLINDER ........................................................................................... 10-16
DISMANTLING .................................................................................................................................. 10-16
ASSEMBLY ........................................................................................................................................ 10-16
CHECKING AND SETTING THE STEERING PRESSURE ................................................................ 10-17
TROUBLE ANALYSIS FOR THE STEERING SYSTEM ....................................................................... 10-18
6/96 10-1
Section 10
STEERING SYSTEM
GENERAL INFORMATION. Trouble analysis for the STEERING SYSTEM is
found at the rear of THIS section.
THIS section contains a description of the steering
system operation.
Removal, disassembly, inspection, assembly, instal- DESCRIPTION [See Figure 1]

lation and pressure check procedures, for the
selected system components are also found in THIS The steering system is a hydraulic operated, manu-
section. ally controlled system with provisions for manual
steering IF the engine is in a stopped condition. The
steering system has a natural feel to the operator by
providing a direct relationship between the steering
wheel and the drum of the machine.
STEERING UNIT
STEERING CYLINDER
TO VIBRATION FILTER
MOTOR
FROM VIBRATION
MOTOR
CONTROL VALVE
CHARGE/STEERING/VIBRATION
PUMP
ENGINE
FROM VIBRATION MOTOR
BREATHER FILTER
TANK
FIGURE 1. STEERING SYSTEM - HYDRAULIC SCHEMATIC.
10-2 6/96
Section 10
STEERING SYSTEM
MAJOR steering system components are: When NO steering function, using the steering
control unit, is being used the oil flow entering the
a. Steering/charging and vibration gear pump [see unit passes through the unit and is directed to the
THIS section]. return oil [low pressure] side of the steering system
and returns back to the hydraulic oil reservoir.
b. Steering control unit, with integral relief valve.
c. Steering cylinder, double acting. NOTE: Return oil from the steering cylinder is
directed through the steering control
d. Hoses and fittings. unit, to the return oil [low pressure] side
of the steering system.
SYSTEM OPERATION [See Figure 1].

EXCHANGING THE STEERING, CHARGING AND
The engine mounted steering, charging and vibra- VIBRATION PUMP.
tion pump assembly contains the gear pump that
supplies the steering, transmission and vibration 1. Open the engine hood.
systems with hydraulic oil. The hydraulic oil is drawn
from the hydraulic oil reservoir.
NOTE: For Installation, check the hydraulic oil
The oil is then pulled into, and through, the pump level and engine oil level and top up.
gear section. The pump section generates hydraulic
oil flow for the steering, transmission and vibration
systems. 2. Remove the battery.
Hydraulic oil flows from the pump gear section and 3. Unscrew the cap nuts (Fig. 1/3) of the
through steering, transmission charging and vibra- hydraulic oil hoses from the connections and
tion pump. immediately plug the connections and hydraulic oil
hoses.
Oil for the steering system flows from the steering,
charging and vibration pump through the pressure oil 4. Unscrew four mounting screws (Fig. 1/2) from
filter and to the steering control unit. the pump (Fig. 1/1 ) and remove the latter.
When any steering function, using the steering

control unit, is required [ANY turning of the machine CAUTION: Collect the draining oil and dispose
to either the left, or right] the oil flow entering the of It so as to prevent pollution.
steering control unit is directed internally through the
unit to the steering cylinder supply hose.
NOTE: For installation, place a new O-ring (Fig.
The steering cylinder supply hose then supplies the 2/3) over the collar of the pump.
cylinder with oil. Oil is supplied to the ROD end of
the cylinder to turn the machine to the RIGHT turn
direction, and the BASE end of the cylinder to turn
the machine to the LEFT turn direction.
6/96 10-3
Section 10
STEERING SYSTEM
NOTE: For installation, use a new O-ring

(Fig. 3/3). Check the hydraulic oil level
and engine oil level and top up, as
needed.
FIGURE 1.
5. To exchange the pump, unscrew the nut (Fig.

2/2) and pull off the pinion (Fig. 2/1 ).
FIGURE 3.
REPAIRING THE STEERING, CHARGING AND

VIBRATION PUMP.
Special Tools: Centering plate.
1. Remove the steering, charging and vibration

pump and detach the control valve, see appropriate
section.
2. Mark the two covers (Fig. 1/1 and 7) relative to

the pump housing and unscrew the mounting screws
(Fig. 1/13).
NOTE: For installation, align the cover on the

drive side with the centering plate and
FIGURE 2. tighten the two mounting screws.
6. Unscrew the bolts (Fig. 3/2) and remove the

flanged connector (Fig. 3/1 ).
10-4 6/96
Section 10
STEERING SYSTEM
13
12
7
1 Housing cover 9
2 Pump housing 8
6
4 Radial seal
18 2
5 Circlip (inner)
6 Seal ring
7 Housing cover
8 Supporting ring
9 Seal ring 17 19
10 Gear wheel
10
11 Gear wheel
14
12 Spring washer
20
13 Allen screw
14 Woodruff key 6
8 20
15 Spring washer 9
16 Hexagon nut 1
17 Protection cap 4 11
18 Plug 5
19 Bearing bush 19
20 Bearing bush 15
16
FIGURE 1.
4. Remove the seal rings (Fig. 1/9), supporting 5. Pull the gear wheels (Fig. 1/10 and 11) out of
rings (Fig. 1/8) and seal rings (Fig. 1/6) from the the bearing bushes.
housing (Fig. 1/2).
NOTE: For installation, check the condition of

NOTE: For installation, fit new seal rings the tooth profiles and running faces and
(Fig. 1/9 and 1 16) into the grooves of the exchange gear wheels if necessary.
engine housing. Fit supporting rings
(Fig. 1/8) onto the inserted seal rings
(Fig. 1/6) with the smooth side facing
upwards.
6/96 10-5
Section 10
STEERING SYSTEM
6. Check the condition of the running face of the 5. To exchange the control valve, unscrew the bolts
bearing bushes (Fig. 1/19 and 20) and exchange the (Fig. 2/1). Remove the connecting block (Fig. 2/2).
latter if necessary.
7. Remove the circlip (Fig. 1/5) from the groove

in the cover (Fig. 1/1 ). Press out the radial seal (Fig.
1/4).
NOTE: For installation, grease a new radial seal

and press it in with the sealing lip facing
outwards.
EXCHANGING THE CONTROL VALVE.
1. Raise up the engine hood.
NOTE: For Installation, Check the hydraulic oil

FIGURE 2.
level and top up.
2. Detach the electrical plug (Fig. 1/1 ). REMOVING AND INSTALLING THE STEERING
UNIT.
3. Unscrew the hydraulic hoses (Fig. 1/2, 3 and
4) from the connections and immediately plug the 1. Disconnect the battery.
connections and hydraulic oil hoses.
2. Detach the front cover plate.
4. Unscrew both mounting screws (Fig. 1/5) and
remove the control valve. 3. Unscrew the bolts (Fig. 1) from the instrument
panel. Remove the instrument panel and swing it
down.
FIGURE 1.
10-6 6/96
Section 10
STEERING SYSTEM
5. Unscrew four bolts (Fig. 3) for the steering

unit.
FIGURE 1.
4. Mark the hydraulic oil hoses and detach them FIGURE 3.

from the connections (Fig. 2) on the steering unit.
Immediately plug the steering unit connections and
the hydraulic oil hoses. 6. Remove the steering unit from the steering
column.

of it so as to prevent pollution. NOTE: For installation, the grooved toothing
(Fig. 4) must engage in the steering unit.
FIGURE 2. FIGURE 4.
6/96 10-7
Section 10
STEERING SYSTEM
7. To exchange, remove the banjo fittings

(Fig. 5/6).
5
6
5 6
6 1 Hose
4 3
2 Hose
6 1
3 Hose
4 Hose
2 5 Socket
6 Banjo fitting
FIGURE 5.
8. To remove the steering column, remove the 10. Remove the steering column, from below.
cap (Fig. 6/1) from the steering wheel.
9. Unscrew the mounting nut (Fig. 6/2) from the NOTE: For installation, the brackets (Fig. 7), on
steering wheel and pull off the latter. the steering column, must fit in the
recesses.
11. Check the steering column and drum shell;

exchange the complete steering column, if
necessary.
FIGURE 6.
FIGURE 7.
10-8 6/96
Section 10
STEERING SYSTEM
DISMANTLING THE STEERING CONTROL UNIT. DISMANTLING THE DOUBLE SHOCK VALVES.
Special Tools: 1. Unscrew the plugs (Fig. 1/34), for the double
Assembly tool for drive shaft - No. 079 942 01 shock valves, using a 6 mm Allen key.
Assembly tool for dust seal ring - No. 079 942 03
Assembly tool for O-ring/kin ring No. 079 942 02 2. Remove the two sealing washers (Fig. 3/4).
1. Remove the steering unit (See this section). 3. Measure the screw-in depth, on the two (2)
set screws (Fig. 3/3. Note the setting dimension
2. Unscrew the bolts in the cover (Fig. 1/26). (Fig. 2).
3. Remove the cover, from the side. 4. Unscrew the set screws, using a 6 mm Allen
Key.
4. Lift the gear set (Fig. 1/22), possibly with
spacer ring, from the unit. Remove the two (2)
O-rings (Fig. 1/25). NOTE: Shake out the two (2) springs (Fig. 3/1)
and two (2) balls (Fig. 3/2) into your hand.
5. Remove the drive shaft (Fig. 1/18). The valve seats con NOT be removed,
since they are fixed in the housing.
6. Remove the distributor plate (Fig. 1/21). Figure 3 shows the double shock valved
completely dismantled.
7. Unscrew the threaded bush, from over the
check valve.
8. Remove the O-ring (Fig. 1/20).
9. Remove the check valve ball, the pins

(Fig. 1/1 ) and the balls (Fig. 1/35) of the refill valve.
10. Hold the pin (Fig. 1/15) horizontally in the

outer and inner sliders. The pin is visible through the
open end of the inner slider (Fig. 1/5). Press the
inner slider inwards. Then remove the outer slider
(Fig. 1/6), ring (Fig. 1/14), sliding discs (Fig. 1/12)
and needle cage (Fig. 1/13) from the housing.
11. Remove the ring, sliding discs and needle

cage from the inner/outer sliders. The outer (thin)
sliding disc may “stick” in the housing. Check
whether it has been removed.
12. Press out the pin; to do so, use the dowel pin
bolt with dowel pin (Fig. 1/29) from the cover.
13. Carefully press the inner slider out of the

outer slider.
14. Press the neutral adjustment springs

(Fig. 1/16) out of the slot in the inner slider.
15. Remove the dust sealing ring and O-ring/kin

ring.
6/96 10-9
Section 10
STEERING SYSTEM
1 Pin 34
2 Dust sealing ring 33
3 Set of seals for bearing
4 Housing 18
5 Slider, inner 4
6 Slider,outer 19
35
7 Ball
8 Threaded Bush 1 20
9 O-ring 7 9
10 Kin ring 8 10
11 Bearing 21
12 Sliding disc 12
13 Needle cage
14 Ring 11 13
15 Pin 23
12
16 Set of springs 3 22 25
17 Spring 5
18 Shaft 14 24
19 Spacer
20 O-ring
21 Distributor plate
22 Gear set 6
23 Rotor
25
24 Housing
25 O-ring 28
27 Cover
26
28 Dowel pin 15
29 Dowel pin bolt
16 17 27
30 Allen screw 27
31 Type plate 29 30
32 Self-tapping screw
33 Pressure relief valve
34 Double shock valve 31
35 Ball 32
FIGURE 1.
10-10 6/96
Section 10
STEERING SYSTEM
FIGURE 2. FIGURE 4.
FIGURE 3. FIGURE 5.
DISMANTLING THE PRESSURE RELIEF VALVE. 4. Pressure relief valve completely dismantled
(Fig, 5).
1. Unscrew the plug using an 8 mm Allen key.
Remove the seal ring (Fig. 5/1 ) (Fig. 4).
2. Unscrew the set screw (Fig. 5/2) using an DISMANTLING THE PRESSURE RELIEF VALVE
8 mm Allen key. (CARTRIDGE).
3. Shake out spring (Fig. 5/3) and piston 1. Unscrew the pressure relief valve (Fig. 1/33)
(Fig. 5/4). The valve seat cannot be removed since it using an 8 mm Allen key. Remove the sealing ring.
is fixed in the housing. The valve must be exchanged if it is defective.
2. Carefully clean all parts in Shellsol K, or

similar.
3. Use new seals and washers. Carefully check

all parts for damage and wear.
6/96 10-11
Section 10
STEERING SYSTEM
ASSEMBLING THE STEERING UNIT. 3. Align the set of springs.
NOTE: Assembly pattern and color code for 4. Insert the inner slider (Fig. 1/5) into the outer
neutral adjustment springs for steering slider (Fig. 1/6).
units (Fig. 6).
Standard springs (grey) 5. Press the spring ends together and press the
2 x straight, grey plate springs, neutral adjustment springs into position in the outer
4 x curved, grey plate springs. slider.
Before assembly, all parts must be
lubricated with hydraulic oil. 6. Align and center the springs.
7. Guide the ring down over the outer slider.
NOTE: The ring must be able to turn freely of the

springs.
8. Slide the pin (Fig. 1/15) into the slider

assembly.
9. Fit the sliding disc (Fig. 1/12) and needle cage

(Fig. 1/13).
10. Assembly pattern for standard bearings

Outer sliding disc (Fig. 8/1 ) or (Fig. 1/12) Needle
FIGURE 6.
cage (Fig. 8/2) or (Fig. 1/13) Inner sliding disc (Fig.
8/3) or (Fig. 1,,’12). inner slider (Fig. 8/4), or
(Fig. 1/5) Outer slider (Fig. 8/5), or (Fig. 1/6).
1. Fit the two flat neutral adjustment springs
(Fig. 7/2) into the slot. 11. The chamfer of the inner sliding disc must
face the inner slider.
2. Fit the curved springs (Fig. 7/1 ) between the
flat springs and slide them into place (see assembly
pattern Fig. 6).
FIGURE 8.
FIGURE 7.
10-12 6/96
Section 10
STEERING SYSTEM
ASSEMBLING THE O-RING/KIN RING. 4. Fit the distributor plate so that the duct bores
are aligned with the corresponding bores in the
1. Turn the steering unit around so that the bore housing.
is horizontal. Insert the outer part of special tool No.
079 942 02 into the bore for the slider assembly. 5. Insert the drive shaft into the bore so that the
slot is parallel with the connecting flange.
2. Lubricate the O-ring (Fig. 1/9) and kin ring
(Fig. 1/10) with hydraulic oil and place on special 6. Slide assembly fork No. 079 942 01 below
tool No. 079 942 02. the toothing of the drive shaft.
3. Hold the outer part of special tool 7. Oil the two O-rings with mineral oil (viscosity:
No. 079 942 02 into the bottom of the steering unit 500 cSt at 20˚C) and fit them into the two grooves of
housing and insert the inner part of special tool No. the gear ring. Fit the gear wheel and gear ring onto
079 942 02 completely into the base. the drive shaft.
4. Press and turn the O-ring/kin ring until they

are in position in the housing. CAUTION: Fit the gear wheel (rotor) and drive
shaft so that the gear tooth base of
5. Pull the inner and outer parts of special tool the rotor is fitted in relation to the
No. 079 942 02 out of the bore in the steering unit so groove of the shaft (Fig. 9). Turn the
that the guide of the inner part remains. gear ring so that the seven
continuous bores for the bolts align
6. Insert the inner and outer sliders into the bore with the seven bores In the housing.
using gentle turning movements.
NOTE: Fit the slider assembly so that the pin is

held horizontally.
7. The guide of special tool No. 079 942 02,

which is still in the housing, is pressed out by the
slider assembly. The O-ring and kin ring are in their
positions.
8. Turn the steering unit around, again, so that

the bore is vertical. Fit the ball of the check valve into
the bore.
9. Screw the threaded bush slightly into the bore FIGURE 9.

of the check valve. The upper part of the bush must
be just below the surface of the housing.
8. Fit the spacer ring (if present).
9. Fit the cover.

ASSEMBLING THE TWO REFILL VALVES.
1. Place a ball into each of the bores.
2. Fit a pin into each of these bores.
3. Lubricate the O-ring with mineral oil (viscosity:

500 cSt at 20˚ C) and insert the O-ring into the
groove.
6/96 10-13
Section 10
STEERING SYSTEM
10. Fit a washer to the dowel pin bolt (Fig. 1/29) 3. Screw in the two set screws (Fig. 3/3) using a
and screw the bolt into the bore (Fig. 10). 6 mm Allen key and set to the dimension noted
when the screws were removed. See this section -
11. Fit washers to the six other bolts and screw “Dismantling the double shock valves”.
these in. Torque all seven bolts to 30.0 + 6.0 Nm,
tightening crosswise. 4. Screw the plug (Fig. 1/34) with sealing
washers (Fig. 3/4) into the two shock valves and
torque to 3 +/- 0 daNm using a 6 mm Allen key.
5. Fit the dust sealing ring (Fig. 1/2) with the

open side facing upwards.
6. Drive the dust sealing ring into the housing

using special tool No. 079 942 03 and a plastic
hammer.
7. If necessary, press plastic plugs into the

connection openings. Do not use a hammer.
8. To set the pressure for the pressure relief valve,

fit the steering unit and connect the hydraulic
oil hoses.
FIGURE 10.
9. For pressure setting procedures, refer to
“Checking and setting the steering pressure”, in this
ASSEMBLING THE PRESSURE RELIEF VALVE. section.
1. Insert the piston (Fig. 5/4)
2. Fit the spring (Fig. 5/3). REMOVING AND INSTALLING THE STEERING
CYLINDER.
3. Screw in the set screw (Fig. 5/2) using an
8 mm Allen key. Set the pressure at the test stand, 1. Turn the steering to the right-hand stop.
or at the machine.
4. Screw the plug with seal ring (Fig. 5/1) into the DANGER: Do NOT stand in the roller’s
housing using an 8 mm Allen key. articulation area when the engine is
running. The clearance in this area
closes when the machine is turned to
NOTE: Torque 5 +/- 1 daNm.
the right, or the left.
2. Disconnect the hydraulic oil hoses from the

ASSEMBLING THE DOUBLE SHOCK VALVES.
steering cylinder connections and plug the
connections (Fig. 1/21 and 22).
1. Place a ball (Fig. 3/2) into each of the bores.
2. Fit a spring (Fig. 3/1 ) and a valve disc onto

each of the two balls.
of It so as to prevent pollution.
10-14 6/96
Section 10
STEERING SYSTEM
NOTE: For installation, check the hydraulic oil 4. Completely remove the steering cylinder.’
level and top up if necessary. To bleed
the steering cylinder, let the engine idle 5. If necessary, detach the connection fittings from
and turn the steering several times to the the steering cylinder (Fig. 1/19).
left-hand and right-hand stops.
NOTE: For installation, check the seal rings (if

3. Pull the cotter pin out of the steering cylinder present) and use new ones if necessary.
bearing gudgeon (Fig. 1/7 and 17) and drive out the
gudgeon. Remove the washers (Fig. 1/8 and 14).
6. Check the rod end bearing (Fig. 1/1) in the
cylinder bearings (Fig. 1/4 and 1/13) and install
NOTE: For installation, fit washers on both sides with new, if necessary.
of the self-aligning bearings. Grease the
parts.
1 Rod end bearing 21 Hose

2 Hexagon nut 22 Hose 14
3 Washer 23 Steering cylinder
4 Cylinder bearing
9
5 Washer 13
6 Cotter pin
18
7 Gudgeon
8 Washer
9 Rod and bearing 11 17
10 Hexagon bolt 12 14
11 Hexagon nut
12 Washer 12 23
2 10
13 Cylinder bearing
14 Washer 3 18 15
15 Washer 16
16 Cotter pin 7
17 Gudgeon 19
18 Screw plug 4
19 Socket 8 19 20
20 Angular fitting 1
22
5 20
6 21
8
FIGURE 1.
6/96 10-15
Section 10
STEERING SYSTEM
REPAIRING THE STEERING CYLINDER. ASSEMBLY.
DISMANTLING. 1. Insert new parts: guide rings (Fig. 1/8), seal

(Fig. 1/7), guide ring (Fig. 1/6), scraper (Fig. 1/5),
1. Unscrew the cylinder cover (Fig. 1/4) with a loop ring (Fig. 1/9) and seal ring (Fig. 1/1) into the
grooved nut wrench. guiding bush (Fig. 1/4) in the same position as
before removal.
2. Pull the piston rod out of the cylinder tube.
2. Fit the loop ring (Fig. 1/12) into the piston.
3. Unscrew the nut (Fig. 1/13) from the piston
rod (Fig. 1/2). 3. FIT THE SEAL (Fig. 1/11).
4. Pull the piston (Fig. 1/10) and cylinder tube 4. Oil the parts with clean hydraulic oil.
(Fig. 1/3) from the piston rod.
5. Note, or mark, the position of the individual

seal
6. Check the parts for wear and exchange if

necessary.
1 Seal ring 11Seal

2 Piston rod 12 Loop ring 9
3 Cylinder tube 13 Nut 1
4 Guiding bush 4
5 Scraper 8
6 Guide ring 7
6
7 Seal 5
8 Guide ring
9 Loop ring 2
10 Piston
3
13
11
10
12
FIGURE 1.
10-16 6/96
Section 10
STEERING SYSTEM
CHECKING AND SETTING THE STEERING 6. Unscrew the plug and turn the set screw
PRESSURE. accordingly (Fig. 2).
1. Connect a 600 bar pressure gauge to the

steering pressure test connection (Fig. 1 ).
FIGURE 1.
FIGURE 1.
NOTE: Turning the screw in, increases the
pressure. Turning the screw out, lowers
the pressure.
2. Start the diesel engine.
3. Turn the steering to the final stop. 7. Screw the plug back in and fit the cover plate.
DANGER: Do NOT stand in the roller’s NOTE: If the pressure cannot be set, perform
articulation area when the engine is troubleshooting in accordance with the
running. The clearance in this area troubleshooting chart.
closes when the machine is turned to
the right, or the left.
8. Check the steering, charging and vibration
pump, see Section 11 - DRUM AND
VIBRATION.
NOTE: Nominal value: 90 -106 bar.

Measurement evaluation: If the nominal
value is not reached, perform the
following setting.
5. Detach the cover plate.
6/96 10-17
Section 10
STEERING SYSTEM
TROUBLE ANALYSIS FOR THE STEERING SYSTEM
NO response when steering No flow from pump. Check for pump output. Repair,
wheel is turned. or replace, pump or other parts
of the pump as needed.
Remove unit. Repair or replace

Control unit has damage. as needed.
Remove cylinder. Repair or

Steering cylinder has replace as needed.
damage.
Slow or hard steering. Low system oil level. Add oil as needed. Find and
correct cause of low oil level.
Hose[s] in system in a Remove, clean or replace

stopped condition. hose[s].
Dirt in system. Check suction strainer. Clean or

replace as needed. Clean
COMPLETE hydraulic system,
IF needed [see section 8].
Steering control unit sleeve Remove unit, remove replace

and spool worn. spool and sleeve.
Steering control unit Remove unit, remove and

metering gear worn. replace metering gear.
Charge/steering/vibration See charge/steering/vibration

pump damaged. pump in this section.
Manual steering check ball Remove unit, remove and

off its seat. replace check ball. Inspect seat.
Steering wheel does NOT Steering control unit has Remove unit, remove and
center. broken centering springs. replace centering springs.
Steering wheel rotation is Steering control unit has Remove unit, remove and
continuous. broken centering springs. replace centering springs.
Steering control unit has burr Remove unit. Remove, repair or

on sleeve and/or spool. replace spool and/or sleeve as
needed.
10-18 6/96
Section 10
STEERING SYSTEM
Wrong steering response to Steering supply hoses NOT Check for CORRECT
steering wheel command. correctly connected to unit connection locations and
and/or cylinders. change as needed.
Steering control unit metering Remove unit, align metering

star to shaft slot NOT aligned star to slot in shaft in
correctly. CORRECT position.
NO pressure OR flow from Relief valve has internal Remove steering control unit.
valve. damage. Repair, or replace, with NEW
[see THIS section].
System pressure low. Relief valve not set to correct Remove steering control unit.
specifications. Repair, or replace, [see THIS
section].
System pressure high. See above information. See above information.
System pressure NOT Relief valve has damaged Remove steering control unit.
steady - varies. parts. Repair, or replace, [see THIS
section].
STEERING CYLINDER
NO motion from steering NO oil being supplied to Check the system for damaged
cylinder. steering cylinder. pump, or relief valve, steering
control unit, hose[s]. Check oil
level. Repair as needed. See
THIS “Trouble Analysis”.
Cylinder has internal damage. Remove cylinder, repair, or

replace, as needed.
Slow motion from steering LOW oil supply to cylinder. Check as above.
cylinder.
6/96 10-19
Section 10
STEERING SYSTEM
STEERING CYLINDER
Action of cylinders is jerky. Air in system. Check oil level in reservoir.

Add oil as needed. Find and
correct cause for low oil level.
Check for loose hose to fitting
connections. Tighten as
needed.
Excessive lost motion at Damaged relief valve in Remove and replace relief
cylinder. steering control unit. valve, or unit, as needed.
Bent or deformed cylinder Remove cylinder, repair or

piston or rod. replace as needed.
Bushings at steering cylinder Remove and replace bushings

to machine worn. as needed.
Loose cylinder anchor pin, Inspect and tighten nut the

retainer pin and/or anchor CORRECT specification as
capscrew. needed.
Cylinder yoke worn/broken at Remove cylinder, repair or

rod and/or anchor end. replace as needed.
CHARGE/STEERING/
VIBRATION PUMP
NO flow from pump. Low oil level in hydraulic oil Add oil as needed. Find and
reservoir. correct cause of low oil level.
Pump flex drive plate has See Section 8 “Pump Drive

damage. Plate Trouble Analysis”.
Gear pump has internal Remove pump and repair or

damage. replace as needed.
LOW flow from pump. Low oil level in hydraulic oil Add oil as needed. Find and
Restricted inlet suction hose. Drain hydraulic oil reservoir.

Remove, clean, or replace,
hose.
10-20 6/96
Section 10
STEERING SYSTEM
CHARGE/STEERING/
VIBRATION PUMP
LOW flow from pump Air being drawn into hydraulic Check connections. Tighten
[continued]. system. as needed.
Pump has internal leakage. Remove pump. Disassemble,

repair, or replace, as needed.
Pump makes noise. Pump NOT being supplied Check oil level and add oil as
enough oil, due to low oil level. needed. Find and correct
cause of low oil level.
Restricted inlet suction hose. Remove, clean, or replace,

hose.
Pump has internal damage. Remove, repair, or replace,

pump as needed.
6/96 10-21
Section 10
STEERING SYSTEM
NOTES
10-22 6/96
Section 11
DRUM AND VIBRATION SYSTEM
TABLE OF CONTENTS
PAGE
COMPONENTS OF THE SYSTEM ......................................................................................................... 11-2
DRUM AND VIBRATION ......................................................................................................................... 11-2
BASIC OPERATION ................................................................................................................................ 11-3
REMOVING AND INSTALLING THE DRUM .......................................................................................... 11-4
EXCHANGING THE RUBBER BUFFERS .............................................................................................. 11-6
LEFT HAND RUBBER BUFFERS ....................................................................................................... 11-6
RIGHT HAND RUBBER BUFFERS ..................................................................................................... 11-6
REPAIRING THE DRUM ......................................................................................................................... 11-7
EXCHANGING THE VIBRATION MOTOR ............................................................................................. 11-9
GENERAL NOTES FOR REPAIRS .................................................................................................... 11-11
REPAIRING THE VIBRATION MOTOR ............................................................................................. 11-12
VIBRATION CIRCUIT FLUSHING ......................................................................................................... 11-14
INSTALLING THE FLUSHING SYSTEM ............................................................................................ 11-15
FLUSHING THE LINES FOR THE VIBRATION CIRCUIT ................................................................. 11-16
FLUSHING THE VIBRATION MOTOR ............................................................................................... 11-16
FUNCTIONAL CHECK ....................................................................................................................... 11-16
MAINTENANCE OF THE FLUSHING FILTER ................................................................................... 11-17
CHECKING THE VIBRATOR SHAFT SPEED ...................................................................................... 11-17
CHECKING THE CHARGING/STEERING/VIBRATION PUMP PRESSURE ....................................... 11-17
CHECKING THE VIBRATION PUMP HIGH PRESSURE ..................................................................... 11-18
CHECKING THE VIBRATION VALVE .................................................................................................. 11-18
TROUBLE ANALYSIS FOR THE DRUM AND VIBRATION SYSTEMS .............................................. 11-19
6/96 11-1
Section 11
GENERAL INFORMATION. COMPONENTS OF THE SYSTEMS.
THIS section describes the major COMPONENTS DRUM AND VIBRATION [See Figures 1 and 2].
and the basic OPERATION of the drum and
vibration systems used on the Model BW124D, The single front mounted drum and the vibration
BW124PD and BW124PDB Rollers. system it contains, has the following major
components:
PROCEDURES for removal, disassembly, inspec-
tion, assembly and installation, of these compo- 1. Drum weldment, smooth [BW124D] or footed
nents are also given, or indicated where to be [BW124PD and BW124PDB] - complete.
found, in THIS section.
2. Left and right rubber buffers.
TROUBLE ANALYSIS, if it applies, is given at the
END of THIS section.
FIGURE 1. VIBRATION SYSTEM - HYDRAULIC SCHEMATIC.
11-2 6/96
Section 11
3. Charge/steering/vibrator gear pump assembly. The hydraulic charge/steering/vibrator pump is

driven by the engine. The pump charges the trans-
4. Vibrator gear motor. mission pumps with oil and supplies the steering and
vibratory systems with oil flow.
5. Electrical solenoid moved spool in “control
valve”. The oil is directed from the pump to the vibration
system control valve.
6. Vibration control valve.
Putting the vibration system “start/stop” travel control
mounted push button switch in the “START” position,
7. System control switch will electrically energize the vibration system sole-
[See Section 7 - ELECTRICAL]. noid, found on the vibration system control valve
[see Section 7 - ELECTRICAL].
8. Hydraulic oil reservoir [SAME supply as for ALL
hydraulic systems]. The electrical solenoid moves the spool valve to the
open [FLOW] position.
9. Drum drive motor assembly [See Section 8 -
TRANSMISSION SYSTEM]. Oil from the hydraulic pump is now permitted to flow
to the hydraulic gear motor, which drives the
vibration mechanism.
BASIC OPERATION [See Figure 1]. The flow of oil turns the internal gears of the motor
and the output shaft at the end of the motor. The
The drum carries the front machine weight. It also hydraulic gear motor output shaft is used to turn the
serves to transmit the vibratory forces generated by mechanical weight found in the vibration mecha-
the vibration mechanism, inside the drum, to the nism.
work surface being compacted.
The hydraulic oil returning from the hydraulic gear
The same vibratory forces are kept from being motor flows back to the hydraulic oil reservoir.
transmitted into the frame sides through the use of
the left and right rubber buffers.
NOTE: The vibration system “ON” pressure relief
The drum assembly is mounted between the two [2] valve, found on the vibratory system
side frames and uses a total of eight [8 ] rubber control valve is adjustable. Check and
buffers, the drum drive motor mount console and the adjust, if needed, using the procedures
bearing housing on the right side and four [4] rubber found in THIS section. The “ON” relief
buffers and two stand off consoles, on the left side. valve will function if the pressure in the
system reaches a pressure MORE than
The drum weight is carried by the outer bearing at the MAXIMUM pressure it is set to permit
the outer end of the vibration mechanism and the DURING system start-up, and/or during
idler assembly and the drum drive motor. operation.
The vibration system supplies the vibratory forces
the machine uses for vibratory compaction of the When the vibration system is in the “STOP”, or
work surface through the use of BOTH hydraulic and “OFF”, condition, NO electrical current is directed to
mechanical methods. the vibration system electrical solenoid, found on the
“control valve”, and the spool valve remains in the
closed [NO flow] position.
Oil flow from the charge/steering/vibrator systems

pump will be directed back to the hydraulic oil
reservoir.
6/96 11-3
Section 11
REMOVING AND INSTALLING THE DRUM. NOTE: For installation, the same number of
intermediate plates must be fitted as
CAUTION: Remove the COMPLETE drum were removed; screw an M12x40 bolt into
assembly ONLY after making sure a the centre threaded bore in the console.
COMPLETE inspection and evaluation
indicates it is necessary. Press down the console until the
intermediate plate can be inserted
(Fig. 2).
NOTE: Installation Weight: 500 kg. Unscrew the bolt again. If the drum has
been exchanged, determine the
thickness of the intermediate plates
1. Attach lifting tackle to the front of the front again; to do so, screw the right hand side
frame and lift the front frame up until the rubber of the engine console to the front frame.
buffers are relieved (Fig. 1 ). Weight approx. 150 kg. Measure the distance between the front
frame and the console on the left hand
2. Unscrew the mounting screws of the bridge side (Fig. 3).
(Fig. 1/2) for the hydraulic oil hoses on the left and The distance measured corresponds to
right. the thickness of the intermediate plates.
Thicknesses of 1 mm and 2 mm are
3. Remove the mounting screws (Fig. 1/1 ) from available.
the front frame. Always round the thickness upwards; if,
for example, the distance measured is 1.5
4. Carefully lower the front frame onto the mm, insert an intermediate plate of 2 mm.
ground and remove the intermediate plates.
DANGER: Keep away from below the front frame

when It is being lowered.
FIGURE 2.
FIGURE 1.
FIGURE 3.
11-4 6/96
Section 11
5. Remove the mounting screws (Fig. 4/2) from 7. Unscrew the cap nuts (Fig. 6) of the
the vibration motor cover (Fig. 4/1); remove the hydraulic oil hoses from the connections on the
motor cover with attached vibration motor from the drum motor and immediately plug the
bearing cover and place it to one side. connections and hydraulic oil hoses.
CAUTION: Collect the hydraulic oil and

dispose of it so as to prevent
pollution.
NOTE: For installation, check the condition

of the O-rings in the hydraulic oil hose
connections and insert new ones if
necessary.
FIGURE 4.
6. Pull the coupling sleeve (Fig. 5) from the

coupling pinion.
NOTE: For installation, check the toothing of the

coupling sleeve for wear and use a new
sleeve, if necessary.
FIGURE 6.
8. Attach lifting tackle to the right hand and left

hand sides of the drum (Fig. 7) and lift it out of the
front frame.
NOTE: Weight approx. 500 kg.
DANGER: Do NOT stand under the drum when it

FIGURE 5. Is being lifted. When the drum has
been lowered, secure it to prevent It
rolling away.
6/96 11-5
Section 11
3. Unscrew the rubber buffers from the bearing

cover using the mounting jig (Fig. 2).
NOTE: For installation, torque the rubber buffers

to 165 Nm.
FIGURE 7.
EXCHANGING THE RUBBER BUFFERS.
Tools: Mounting jig No. 007 130 02.

FIGURE 2.
LEFT HAND RUBBER BUFFERS.

RIGHT HAND RUBBER BUFFERS.
1. Lower the front frame (see “Removing The
Drum “ in this section). 4. Remove the drum motor, see SECTION 8 -
TRANSMISSION.
2. Remove the mounting screws (Fig. 1/2) of the
console (Fig. 1/1) from the rubber bluffers and 5. Unscrew the rubber buffers from the drum
remove the console. using the mounting jig (Fig. 3).
NOTE: For installation, torque the rubber buffers

to 165 Nm.
FIGURE 1.
FIGURE 3.
11-6 6/96
Section 11
REPAIRING THE DRUM. NOTE: For installation, with the toothing facing
upwards, drive the coupling half
Tools: Puller No. 007 130 04. (Fig. 1/21) onto the vibrator shaft until the
final stop.
1. Remove the drum, see THIS section. Measure the vibrator shaft clearance; to
do so, measure and note from the top
2. Stand the drum vertically, so that the left-hand edge of the bearing housing (Fig. 1/5) to
side (vibration motor) is at the top. the top edge of the coupling half,
dimension ‘“a’” e.g. 19.7 mm.
3. Unscrew the mounting screws (Fig. 1/16) of Screw an eye bolt into the vibrator shaft
the bearing supporting ring (Fig. 1/19) and remove and pull the vibrator shaft upwards until
them. the final stop.
Remeasure and note the distance from
4. Pull the coupling sleeve (Fig. 1/22) from the the top edge of the bearing housing
coupling. (Fig. 1/5) to the top edge of the coupling
half, dimension “b” e.g. 18.2 mm. Deduct
dimension “b”’ from “a”.
NOTE: For installation, check the toothing of the 19.7 mm
coupling sleeve for wear and fit a new - 18.2 mm
sleeve if necessary. 1.5 mm = vibrator shaft clearance.
The clearance must be 0.6 - 1.8 mm.
5. Pull the bearing cover (Fig. 1/15) from the

bearing housing.
6. Remove the ball bearing (Fig. 1/13) and Nilos

ring (Fig. 1/14) from the bearing cover.
NOTE: For installation, fit the Nilos ring with the

convex side facing downwards. Drive in a
new ball bearing, as far as it will go, and
fill by up to 1/3 with lithium-soaped high
pressure grease.
7. Remove the spacer ring (Fig. 1/18).
NOTE: For installation, fit the spacer ring with

the flat side facing downwards.
8. Attach the puller to the inner coupling half

(Fig. 1/21 ) and pull the latter from the vibrator shaft.
6/96 11-7
Section 11
1 Cylinder roller bearing

2 Allen screw
3 Washer 17 6 23
4 Circlip (inner) 1
4 11
5 Bearing housing 24
8
6 Threaded pin 9
7 Drum 12
8 Nilos ring 10
9 Supporting disc
10 Fitting key
11 Spacer ring
7
12 Vibrator shaft
13 Grooved ball bearing 9 8
11 4
14 Nilos ring 15 3 2
15 Bearing cover 15
16 Allen screw 14
13 18
17 Washer 19
18 Spacer ring 21
20
19 Ring
20 Allen screw 25
21 Coupling 16 22
22 Coupling sleeve
23 Bearing housing
24 Allen screw
25 Motor cover
FIGURE 1.
9. Unscrew the mounting screws (Fig. 1/2) from 12. Pull the roller bearing (Fig. 1/1) out of the
the bearing housing. bearing housing.
10. Use pulling screws to press the bearing

housing (Fig. 1/5) off the drum and lift it out. NOTE: For installation, drive in a new roller
bearing until the final stop and fill by up
to 1/3 with lithium-soaped high-pressure
11. Remove the circlip (Fig. 1/4) from the groove grease.
in the bearing housing.
NOTE: For installation, the whole of the circlip

must lie in the groove.
11-8 6/96
Section 11
13. Screw an eye bolt into the vibrator shaft NOTE: For installation, before screwing in the
(Fig. 1/12) and pull the latter out of the drum. threaded pins, coat the threads with
Hylomar.
NOTE: For installation, carefully insert the

vibrator shaft into the lower roller 21. Screw the pulling screws into the bearing
bearing. housing and thereby press out the roller bearing.
14. Remove the fitting key (Fig. 1/10) from the NOTE: For installation, fit a new roller bearing,
groove. drive it in until the final stop and fill by up
to 1/3 with lithium soaped high pressure
15. Pull off the inner race of the bearing on both grease.
sides of the vibrator shaft (Fig. 1/12) and remove the
spacers, Nilos rings and supporting discs.
EXCHANGING THE VIBRATION MOTOR.

NOTE: For installation, perform the following
operations on both sides of the vibrator 1. Unscrew the mounting screws (Fig. 1/3) from
shaft in the same way. Slide the the bridge (Fig. 1/1) for the hydraulic oil hoses
supporting disc (Fig. 1/9) onto the shaft. (Fig. 1/2) and remove the bridge.
Slide on the Nilos ring (Fig. 1/8) so that
the angled collar faces outwards.
Slide the spacer ring onto the shaft.
Heat the inner race of the bearing up to
around 80 ˚C and, with the collar first,
slide it on until the final stop.
16. Lay the drum horizontally and secure it from

rolling away.
17. Unscrew the mounting screws (Fig. 1/24)

from the bearing housing (Fig. 1/23).
18. Use pulling screws to press the bearing

housing off the drum and remove it. FIGURE 1.

2. Unscrew the mounting screws (Fig. 2/2) from
in the bearing housing.
the motor cover (Fig. 2/1 ).
3. Pull off the motor cover with attached vibration

NOTE: For installation, the whole of the circlip
motor.
must lie in the groove.
20. Unscrew the threaded pins (Fig. 1/6) from

the bearing housing.
6/96 11-9
Section 11
FIGURE 2. FIGURE 4.
4. Check the toothing (Fig. 3) of the coupling 6 To exchange the vibration motor, unscrew the
sleeve for wear and exchange the sleeve if nut (Fig. 5/1 ) in front of the coupling pinion (Fig. 5/2)
necessary. and pull off the latter.
FIGURE 3. FIGURE 5.
5. Unscrew the cap nuts (Fig. 4) of the hydraulic 7. Unscrew the mounting screws (Fig. 6) from
oil hoses from the connection sockets. the motor cover and remove the latter.

11-10 6/96
Section 11
FIGURE 6. FIGURE 1.
8. Unscrew the mounting screws (Fig. 7/1 ) from 2. Renew all seals and gaskets (Fig. 2).
the angular flange sockets (Fig. 7/2) and remove the
latter.
NOTE: For installation, fit a new O-ring

(Fig. 7/3) into the groove of the respective
angular flange socket.
FIGURE 2.
FIGURE 7.
GENERAL NOTES FOR REPAIRS.
CAUTION: Observe the following notes when

repairing hydraulic components.
1. Close all openings on hydraulic components

(Fig. 1).
6/96 11-11
Section 11
3. Examine all sealing and sliding surfaces for 2. Mark both covers (Fig. 1/3 and 7) relative to
signs of wear (Fig. 3). the motor housing and unscrew the mounting screws
(Fig. 1/14).
NOTE: For Installation, Align the cover on the

drive side to the centering plate and
tighten both mounting screws.
3. Remove both covers.
4. Remove the seal rings (Fig. 1/10), supporting

rings (Fig. 1/8) and seal rings (Fig. 1/6) from the
housing (Fig. 1/2).
NOTE: For Installation, Fit new seal rings

FIGURE 3.
(Fig. 1/10) into the grooves of the motor
housing.
Insert new seal rings (Fig. 1/6) into the
4. Fill hydraulic components with hydraulic oil grooves of the motor housing.
before commissioning (Fig. 4). Fit supporting rings (Fig. 1/8) onto the
inserted seal rings (Fig. 1/6) with the
smooth surface facing upwards.
5. Pull the gear wheels (Fig. 1/11 and 12) out of

the bearing bushes.
NOTE: For Installation, Check the condition of

the tooth profiles and running faces and
exchange the gear wheels if necessary.
HYDRAULIC 0IL
6. Check the condition of the running face of the
bearing bushes (Fig. 1/19) and exchange the
bearing bushes if necessary.
FIGURE 4.
of the cover (Fig, 1/3). Press out the radial seal
REPAIRING THE VIBRATION MOTOR. (Fig. 1/4).
Special Tools: Centering plate.

NOTE: For installation, grease a new radial seal
1. Remove the vibration motor, see THIS and press it in with the sealing lip facing
section. outwards.
If needed, exchange/repair the charge/
steering/vibration pump assembly, see
Section 10 - STEERING.
11-12 6/96
Section 11
7
1
14
1 Protection cap 13
2 Pump housing 2
3 Housing cover 18
4 Radial seal
5 Circlip (inner)
6 Seal ring 10
7 Housing cover 8
8 Supporting ring 6
9 Pin
10 Seal ring
11 Gear wheel 19 18
12 Gear wheel 12
13 Spring washer 15
14 Allen screw
15 Woodruff key 19
16 Spring washer
17 Hexagon nut 9
18 Protection cap
19 Bearing bush 19 3
11 4
9
5
16
6 17
19 8
10
FIGURE 1.
6/96 11-13
Section 11
VIBRATION CIRCUIT FLUSHING (see Fig. 1). Before flushing:
CAUTION: Always flush the open circuit after 1. Exchange the hydraulic oil filter.
changing a unit. Otherwise particles
remaining In the circuit will quickly 2. Clean the hydraulic oil tank.
lead to further unit failure.
With strong oil contamination (scurf):

1. Open and clean the remaining units. Pump the contents of the tank through a
61J filter into the oil bag, or a container.
2. Exchange the high pressure hoses. Also fit the filter unit when filling.
CAUTION: Collect the hydraulic oil and dispose CAUTION: Change oil if there is strong
of It so as to prevent pollution. contamination if oil is discolored if oil
1 Steering unit
1
2 Vibration pump
3 Reducer 16S/15L
4 Flushing hose
5 Reducer 25S/16S
6 Reducer 25S/15L
7 Filter
8 Connection piece 15L
2 9 Vibration motor
10 Vibration control valve
8
4
4
9
8
10
FIGURE 1.
11-14 6/96
Section 11
Filter installation (see Fig. 1):
1. Filter input “IN” with flushing hose at vibration

pump output.
2. Filter output “OUT” with hose to the vibration

valve.

tank cover (Fig. 1/3) and pour the contents of the FIGURE 2.
hydraulic oil tank, with filter unit, into a clean
container, or oil bag.
4. Unscrew the hose (Fig. 3/1 ) from the vibration
valve.
CAUTION: Before installing the flushing filter,

check that the hoses and
connections are clean, and clean
them if necessary.
FIGURE 3.
5. Connect the hose (Fig. 3/1 ) with reducer to

filter input “IN”.
6. Connect the flushing hose with reducer to the

valve and the other end with reducer to filter output
“OUT” (Fig. 4).
FIGURE 1.
3. Unscrew the high pressure hoses from the

vibration motor (Fig. 2). Connect high pressure
hoses to junction socket and plug the connections.
6/96 11-15
Section 11
FIGURE 4. FIGURE 5..
FLUSHING THE LINES FOR THE VIBRATION 5. Switch on the vibration and flush for 15
CIRCUIT. minutes. During flushing, switch the vibration on ‘and
off at intervals of 30 seconds.
1. Start the diesel engine and run it at maximum
speed. 6. Shut down the diesel engine.
2. Switch on the vibration and flush for 15 7. Refit the vibration motor.
minutes. During flushing, switch the vibration on, and
off, at intervals of 30 seconds.
FUNCTIONAL CHECK.
3. Shut down the diesel engine.
1. Check the hydraulic oil level in the tank and
top up if necessary using the filter unit.
FLUSHING THE VIBRATION MOTOR.
2. Move the machine so that the drum is resting
on a flexible base (used tires).
1. Reconnect the high pressure hoses and
leakage lines to the vibration motor.
3. Switch on the vibration with the diesel engine
running and check the vibration pressures and
frequency.
4. Check all hydraulic connections for leaks
(visual inspection).
2. Unscrew the mounting screws (Fig. 5/’2) from
the motor cover (Fig. 5/1 ).
3. Pull the vibration motor out of the coupling.
4. Start the diesel engine and run it at maximum

speed.
11-16 6/96
Section 11
MAINTENANCE OF THE FLUSHING FILTER 2. Start the diesel engine and set the throttle
UNIT. lever to max. speed.
1. Exchange the flushing filter element if the red 3. Measure the speed; when doing so, rest the
control pin of the contamination indicator is pressed meter on your thumb (Fig. 2).
out.
4. Switch on the vibration.
NOTE: Also possible with very cold oil.

NOTE: Nominal value: min. 2280 vpm (38 Hz).
2. Clean the hoses and connections and keep value is not reached, troubleshooting
the flushing filter system in a protected place to must be performed in accordance with
prevent it being contaminated. the troubleshooting chart.
3. Exchange the filter cartridge of the filter unit if

the red control pin of the contamination indicator is
pressed out.
CHECKING THE VIBRATOR SHAFT SPEED.
Tools: Vibration reed frequency meter.
CAUTION: Perform measurement at operating

temperature of (40˚ C).
1. Drive the machine so that the drum rests on a FIGURE 2.

flexible base (rubber tires) (Fig. 1 ).
CHECKING THE CHARGING/STEERING AND

VIBRATION PUMP PRESSURE.
Tools: 600 bar pressure gauge, test hose
CAUTION: Perform measurement at operating

temperature (40˚ C).
1. Connect the 600 bar pressure gauge (Fig. 1)

to the steering pressure test connection.
2. Move the throttle lever to stop position.
FIGURE 1. 3. Crank the diesel engine using the starter only

(press engine shut-off); move the steering to the final
stop.
DANGER: Do not stand In the machlne’s

articulation area. Clearance closes.
6/96 11-17
Section 11
4. Read off the pressure gauge.
CHECKING THE VIBRATION VALVE.
NOTE: Nominal value: 90 - 100 bar. Tools: 600 bar pressure gauge, test hose.
value is not reached, troubleshooting
must be performed using the CAUTION: Perform measurement at operating
troubleshooting chart. temperature (40˚ C).
1. Unscrew the high pressure hose (Fig. 1 ) from

the vibration motor and seal with steel plugs.
FIGURE 1.
FIGURE 1.
CHECKING THE VIBRATION PUMP HIGH 2. Connect the 600 bar pressure gauge (Fig. 2).
PRESSURE.
3. Crank the diesel engine using the starter only
Tools: 600 bar pressure gauge, test hose and switch on the vibration.
CAUTION: Perform measurement at operating 4. Read off the value on the pressure gauge
temperature (40˚ C). (Fig. 2).
1. Move the drum onto rubber tires. NOTE: Nominal value: approx. 200 bar.
2. Connect the 600 bar pressure gauge (Fig. 1). value is not reached, troubleshooting
must be performed in accordance with
3. Run the diesel engine at max. speed. the troubleshooting chart.
4. Switch on the vibration and read off the value

on the pressure gauge.
NOTE: Nominal value: Starting pressure approx.

180 bar. Operating pressure approx. 60
bar (depends on ground below drum).
value is not reached, troubleshooting
must be performed using the
troubleshooting chart.
FIGURE 2.
11-18 6/96
Section 11
TROUBLE ANALYSIS FOR THE DRUM AND VIBRATION SYSTEMS.
DRUM AND VIBRATION
NO drum vibration when “START/STOP” push button Remove and replace switch.
system is in “on” condition. switch damaged.
Electrical circuit has damage. Inspect and check circuit.

Repair as needed [see
Section 7].
Low oil level in hydraulic oil Add oil as needed. Find and
Charge/steering/vibration Check operation. Repair or

pump NOT being driven. replace as needed [see
Section 10 ].
Charge/steering/vibration Check operation. Remove,

pump has internal damage. repair, or replace, as needed
[see Section 10].
Low or no charge oil flow to or Check charge oil flow and

through “vibration valve”. pressure [see THIS section].
Check operation of electrical
solenoid for vibration spool
movement [see Section 7].
No oil flow from vibration valve Check for oil flow. Remove,
to vibrator motor. and replace valve as needed.
Oil supply hose[s] are in Check hose[s] for stoppage.

stopped condition. Remove and clean or replace
as needed.
Vibrator motor has internal Remove, repair, or replace,

damage. motor as needed.
Drive coupling, connecting Remove and replace. Find,

vibrator motor to driven and correct, cause of
vibration mechanism, broken breakage or damage.
or has damage.
Vibration mechanism has Remove, repair, or replace,

internal damage. and install as needed.
Low oil level in hydraulic oil Add oil as needed. Find and
reservoir. correct cause for low oil level.
6/96 11-19
Section 11
DRUM AND VIBRATION
Drum vibration NOT to Vibration control valve has Remove, repair or replace
specification. internal damage. control valve as needed.
Low oil flow from control valve Check oil flow. Remove,
to gear motor. repair, or replace, valve as
needed.
Oil supply hose[s] are in a Check hose[s] for stoppage.

partially stopped condition. Remove and clean, or
replace, as needed.
Vibration gear motor has Remove, repair, or replace,

internal damage. motor as needed.
Vibration mechanism or Remove, repair, or replace,

bearings have damage. and install as needed.
Vibration from drum Rubber buffers have damage. Replace buffers, as needed.
transmitting into machine
frame.
Excessive drum movement Rubber buffers have damage. Replace buffers, as needed.
between the frame sides.
GEAR PUMP
NO flow from pump. Low oil level in hydraulic oil Add oil as needed. Find, and
reservoir. correct, cause of low oil level.
Pump drive gear has damage. Remove pump and repair, or

replace, as needed.
Gear pump has internal Remove pump and repair, or

damage. replace, as needed.
LOW flow from pump. Low oil level in hydraulic oil Add oil as needed. Find, and
reservoir. correct, cause of low oil level.
Restricted inlet suction hose. Drain hydraulic oil reservoir.

Remove, clean, or replace,
hose.
11-20 6/96
Section 11
GEAR PUMP
LOW flow from pump Air being drawn into hydraulic Check all hose to fitting
[continued]. system. connections. Tighten as
needed.
Pump has internal leakage.
Remove pump. Disassemble,
repair, or replace, as needed.
Pump makes noise. Pump NOT being supplied Check oil level and add oil as
enough oil, due to low oil level. needed. Find and correct
cause of low oil level.
Restricted inlet suction hose. Remove, clean, or replace,

hose.
Pump has internal damage. Remove, repair, or replace,

pump as needed.
GEAR MOTOR
NO output shaft rotation NO flow from gear pump. See “Gear Pump Trouble
from gear motor. Analysis” in THIS Section.
No flow from vibration control Check flow path. Remove,

valve to vibrator motor. disassemble, repair, or
replace, control valve as
needed.
Oil supply hose[s] are in a Check hose[s] for stoppage.

stopped condition Remove and clean, or
replace, as needed.
Vibrator motor has internal Remove, repair, or replace, as

damage. needed.
LOW output shaft rotation LOW oil flow from the vibration See “Gear Pump Trouble
speed from gear motor. pump. analysis” in THIS Section.
LOW oil flow from vibration Check flow path. Remove,

control valve to vibrator motor. disassemble, repair or replace
control valve as needed.
6/96 11-21
Section 11
GEAR MOTOR
LOW output shaft rotation Oil supply hose[s] are in a Check hose[s] for stoppage.
speed from gear motor partially stopped condition. Remove and clean or replace
[continued]. as needed.
Vibrator motor has internal Remove, repair, or replace, as

damage. needed.
Vibrator “high pressure” Relief valve cartridge Remove and replace relief
relief valve can NOT be assembly damaged. valve cartridge. Check and
adjusted and/or will NOT adjust relief pressure of valve
keep relief pressure, as set. as needed.
System pressure NOT Vibrator relief valve NOT Check and adjust high
Correct at system “start” adjusted to correct pressure. pressure relief setting as
and/or system “run”. needed.
SCRAPERS
Drum NOT being cleaned Scraper support and/or Replace mounting capscrews
correctly by front and/or scraper loose due to loss of as needed. Adjust scraper to
rear scraper. mounting capscrews, or not drum face as required and
adjusted correctly. tighten mounting capscrews to
correct torques [see Section
4].
Scrapers hit drum face in Scrapers are damaged, or are Inspect scrapers for damage.
one area as it rotates. NOT adjusted correctly. Remove, repair or replace as
needed. Adjust scraper to
drum face as required and
tighten mounting capscrews to
correct torques [see Section
4].
11-22 6/96
Section 12
CONTROL SYSTEMS
TABLE OF CONTENTS
PAGE
GENERAL DESCRIPTION - GOVERNOR CONTROL ........................................................................... 12-2
SYSTEM COMPONENTS ..................................................................................................................... 12-2
OPERATION ......................................................................................................................................... 12-2
GOVERNOR CONTROL CABLE ASSEMBLY REMOVAL AND REPLACEMENT............................. 12-4
GOVERNOR CONTROL CABLE TRAVEL ADJUSTMENT ................................................................ 12-4
GENERAL DESCRIPTION - TRAVEL CONTROL ................................................................................. 12-5
SYSTEM COMPONENTS ..................................................................................................................... 12-5
OPERATION ......................................................................................................................................... 12-5
TRAVEL CONTROL CABLE ASSEMBLY REMOVAL AND REPLACEMENT.................................... 12-5
TRAVEL CONTROL CABLE MOVEMENT ADJUSTMENT ................................................................ 12-7
TROUBLE ANALYSIS FOR THE CONTROL SYSTEMS ....................................................................... 12-9
6/96 12-1
Section 12
CONTROL SYSTEMS
GENERAL INFORMATION. OPERATION [See Fig. 1].
THIS section contains information about the gover- The engine governor control lever is found to the
nor control [engine throttle speed] and travel right hand side of the operator's seat. The lever
[transmission system] control [F-N-R] used on the mechanically moves the governor control cable wire,
Model BW124D, BW124PD and BW124PDB inside the control cable outer casing.
Rollers.
The control cable wire is fastened to the movement
THIS section also includes procedures for the arm of the lever assembly by the ball anchor. The
removal and replacement of the control cables and outer casing of the control cable assembly is held in
the adjustments which can be required after such an adjusted position by the hex nut on the cable and
replacements. is tightened against the throttle housing.
Trouble analysis for the systems is found at the rear The other end of the governor control cable is
of THIS section. hooked, through the extension spring, to the actua-
tion arm of the engine governor mechanism.
The outer casing of the control cable assembly, at

GENERAL DESCRIPTION - GOVERNOR this end, is also held in an adjusted position by two
CONTROL [See Fig. 1]. [2] lock nuts on the cable, which tighten against the
ball joint in the throttle bracket, on the engine.
The governor control system adjusts the engine
speed from “LOW” to “HIGH” idle. It acts as a Movement of the governor control lever moves the
mechanical linkage between the engine governor governor control cable wire inside of the outer
control lever and the engine governor. The governor governor control cable casing.
acts to control the speed of the engine.
The control cable wire moves the extension spring,
which moves the governor actuation arm. The arm
moves the internal components of the governor. At
SYSTEM COMPONENTS [See Fig. 1]. high idle, the governor keeps the engine at the
“HIGH” idle speed, selected by the operator, until a
The following MAJOR components are used in the load is placed upon the engine.
governor control system:
When load is placed upon the engine, the governor
a. Governor control lever and mounting hardware. will permit the engine speed to drop a maximum -
manufacturer determined percent “full” load condi-
b. Governor control cable assembly, including tion. When engine load is decreased, the governor
extension spring, jam nuts and hardware. will then permit the engine speed to increase back to
the high idle speed, again.
c. Engine governor control cable mounting bracket.
When the engine is being slowed to the “LOW” idle
d. Miscellaneous tie straps, plates and hardware. speed the control cable inside the outer governor
control cable assembly casing is moved and stops
pull on the extension spring.
The lack of pull allows the governor actuation arm

and internal governor components to return to the
“LOW” idle speed position, again, through internal
governor spring tension.
12-2 6/96
Section 12
CONTROL SYSTEMS
GOVERNOR CONTROL
CABLE ASSEMBLY
SAFETY NUT
DISC PLUG
HOUSING HEX NUT
WIRE
SPRING WASHER
HEX BOLT
TAPPET HEX NUT
LEVER ARM
EYE BOLT
ROCKER ARM
SPRING
(REF.)
HEX NUT SHAFT
BOOT
BRACKET TIE
HEX NUT (2 PLCS.)
HEX NUT WASHER (2 PLCS.)
BUSHING
HEX BOLT (2 PLCS.)
CABLE ASSEMBLY
FIGURE 1. ENGINE GOVERNOR CONTROL SYSTEM .
6/96 12-3
Section 12
CONTROL SYSTEMS
GOVERNOR CONTROL CABLE ASSEMBLY GOVERNOR CONTROL CABLE TRAVEL

REMOVAL AND REPLACEMENT [See FIG. 1]. ADJUSTMENT [See Fig. 1].
Use the following procedures to remove and replace Use the following procedures to adjust the amount of
the governor control cable assembly with new: the governor control cable wire travel between the
control lever and the engine governor.
a. STOP the engine. Go to the engine governor
area. Unhook and remove the extension spring from a. STOP the engine. Check to be sure the control
the governor control eyebolt on the governor actua- cable assembly casing is fully anchored at the
tion arm. Loosen the two [2] lock nuts that hold the governor control LEVER end by the lock nut being
control cable casing against the ball joint at the tightened against the housing.
throttle bracket. Move the control cable wire and
casing assembly away from the governor actuation b. Go to the engine governor area. Hook the
arm and throttle bracket. extension spring into the governor control eyebolt on
the governor actuation arm, so that the spring is
b. Go to the throttle control lever area. Loosen the NOT bound and swivels freely. Put the governor
cable to throttle control housing hex nut. control lever in the LOW idle position.
c. Remove the nut, and disc, from the bolt which c. Loosen both hex nuts, on the throttle cable, that
fastens the tappet into the throttle control housing. holds the cable housing in the adjusted position
against the ball joint in the throttle bracket. Turn the
d. Move the tappet outward and clear of the hex nuts inward, or outward and adjust the cable, so
housing. Lift the control wire ball from its seat in the that the extension spring does NOT have any pull
tappet. Move the control cable wire and casing (tension) on it with the hook end of the extension
assembly away from the lever arm and mounting spring hooked in the hole in the control eyebolt, on
bracket. the engine governor throttle lever arm.
e. Loosen all cable clamps and tie straps that hold d. Tighten both hex nuts, on the throttle cable,
the cable and casing to the machine frame and/or against the ball joint in the throttle bracket. Note that
other cables or hoses. Carefully remove the COM- the engine governor control lever is contacting the
PLETE governor control cable and casing LOW idle stop screw.
assembly from the machine.
f. Remove the extension spring and all jam and CAUTION: Be SURE the governor control
lock nuts from the control cable assembly, just taken lever does NOT move while
from the machine. doing step “c and d”.
g. Install the extension spring, all jam and lock nuts

onto the NEW control cable assembly. Carefully e. Put the governor control lever in the HIGH idle
install the NEW governor control cable and casing position. Note that the engine governor control lever
assembly into the machine in the SAME position at contacts the HIGH idle stop screw.
which the original cable assembly was in when
removed. Replace ALL cable ties with NEW and f. Start the engine and check the engine governor
install and tighten all cable clamps, if used. control system for CORRECT operation from “LOW”
to “HIGH” engine idle speed and back to “LOW”
h. Finish installation and adjust the governor engine idle speed by moving the governor control
control cable travel using the procedures given in lever.
THIS section, as needed.
WARNING: Keep the HANDS and CLOTHING

CLEAR of the engine at ALL times.
12-4 6/96
Section 12
CONTROL SYSTEMS
GENERAL DESCRIPTION - TRAVEL CONTROL Movement of the travel control [F-N-R] lever moves
[See Fig. 1]. the control cable wire inside of the outer cable
casing.
The transmission control system permits the selec-
tion, and control, of direction [F-N-R] and speed, up The control cable wire moves the second transmis-
to maximum, of machine travel. It acts as a mechani- sion pump actuation arm from the center [NEU-
cal linkage between the travel control lever and the TRAL] position to the forward, or reverse, travel
transmission pumps. position. Further control lever movement, in forward
or reverse, increases machine travel speed up to
maximum.
SYSTEM COMPONENTS [See Fig. 1]. The first transmission pump actuation arm is moved
exactly the SAME amount, from the center [NEU-
The following MAJOR components are used in the TRAL] position to the forward, or reverse, travel
travel control system: position by a linkage assembly, having ball joints
and a threaded link rod.
a. Travel control lever, [F-N-R] assembly and
mounting hardware. This linkage arrangement connects the first and
second transmission pump actuation arms and
b. Travel control cable assembly with adjustable controls equal pump stroking, in either travel
ball joint, with lock nut on ends. direction.
c. Control cable mounting brackets.
d. Miscellaneous tie straps and related hardwares. TRAVEL CONTROL CABLE ASSEMBLY RE-
MOVAL AND REPLACEMENT [See FIG. 1].
Use the following procedures to remove and replace

OPERATION [See Fig. 1]. the travel control cable assembly with new:
The travel control lever [F-N-R] is found to the right a. STOP the engine. Go to the area of the trans-
hand side of the operator's seat. The lever mechani- mission pumps. Remove the capscrew and nut, from
cally moves the travel control cable wire, inside the through the ball joint and the second transmission
control cable outer casing. pump actuation arm. Move the ball joint away from
the arm.
The control cable wire is fastened to the movement
arm of the lever assembly by the angular joint and b. Loosen the two [2] jam nuts, on the direction
safety nut. The outer casing of the control cable control cable, at the mount bracket on the first
assembly is held in an adjusted position by the two transmission pump. Move the control cable assem-
[2] hex nuts on the cable, tightened against the ball bly away from the mount bracket.
joint at the mounting bracket.
c. Go to the travel control lever area. Lift the
The other end of the control cable is fastened to the hinged seat and access panel. Remove the tie strap
actuation arm of the second transmission pump holding the small electrical wire assembly to the
assembly by the clevis and pin. travel control cable.
The outer casing of the control cable assembly, at d. Go to the lower side of the travel control
this end, is held in an adjusted position by two [2] assembly. Loosen the cable housing to pipe joint
hex nuts on the cable, tightened against the ball joint lock nut.
in the first transmission pump mounting bracket.
6/96 12-5
Section 12
CONTROL SYSTEMS
TRAVEL CONTROL ASSEMBLY
CABLE ACTUATION
RACK
PIPE JOINT
LOCK NUT
JAM NUT
DISCS
LOCK NUT
JAM NUT
JAM NUT
CONTROL CABLE
ASSEMBLY
BALL JOINT ASSEMBLY
NUT
DISC
DISC
CAPSCREW
FIGURE 1. TRAVEL CONTROL SYSTEM.
12-6 6/96
Section 12
CONTROL SYSTEMS
e. Use the hands to turn the complete control m. Put the small electrical wire assembly in
cable assembly counterclockwise until the assembly position against the travel control cable and install a
is free to be removed from the travel control assem- new tie strap. Adjust the travel control cable, using
bly. Move the control cable assembly away from the the procedures given in THIS section, as needed.
travel control assembly and from the machine.
NOTE: Turning the control cable assembly TRAVEL CONTROL CABLE MOVEMENT
releases the threaded cable from the ADJUSTMENT [See Fig. 1].
cable actuation rack, inside the travel
control assembly. Use the following procedures to adjust the amount of
travel control cable wire movement between the
control lever and the second transmission pump
f. Measure and write down the position of the hex actuation arm.
hut found on the threaded end of the cable which
was installed into the cable actuation rack. Measure a. STOP the engine. Install the steering lock bar.
and write down the position of the ball joint assembly Lift the machine and support both the front [drum
on the threaded end of the cable which connects to end] and the rear [tire end] clear of the floor with
the second transmission pump actuation arm. solid wood blocking.
g. Remove the nut, ball joint assembly, and all lock

nuts and discs from the control cable assembly just DANGER: Block securely using SOLID wood
taken from the machine. blocking. Keep CLEAR of the machine
while lifting, blocking and lowering the
h. Install the discs, lock nuts, ball joint assembly machine.
and nut onto the NEW control cable assembly at the
SAME positions noted in step "f".
b. Go to the transmission pump area. Remove the
i. Carefully install the threaded end of the NEW capscrew and nut, from through the ball joint and the
control cable assembly into the travel control second transmission pump actuation arm.
assembly.
c. Go to the travel control lever area. Put the travel
j. Use the hands to turn the complete control cable control lever in the exact NEUTRAL position.
assembly clockwise, until the nut on the threaded
cable end is tightened against cable actuation rack, d. Go to the transmission pump area. Loosen the
inside the travel control assembly. Tighten the cable one [1] jam nut, on the cable assembly that is
housing to pipe joint lock nut securely. against the adjustable ball joint sleeve. Hold the ball
joint in position directly above the second transmis-
k. Put the control cable assembly into the mount sion pump lever arm. Turn the sleeve inward, or
bracket, on the first transmission pump assembly. outward, a small amount, to position the center of
Tighten each jam nut against the discs and notched the ball joint exactly EVEN with the center of the
bracket. through hole in the pump actuation arm.
NOTE: Put one [1] disc and one [1] jam nut on CAUTION: Be SURE the travel control
each side of the notched bracket. lever does NOT move while
doing step “d ”.
l. Put the ball joint in position at the second trans-

mission pump actuation arm. Install the capscrew e. Tighten the one [1] jam nut against the adjust-
through the ball joint and the actuation arm. Install able ball joint sleeve, while holding the sleeve. Install
nut onto the capscrew and securely tighten. the capscrew, from the top side, through the ball
joint and the actuation arm. Install nut onto the
capscrew and securely tighten.
6/96 12-7
Section 12
CONTROL SYSTEMS
f. Go to the travel control lever and note that both h. Check the transmission control system for
transmission actuation arms move to the FULL CORRECT operation from “NEUTRAL” to “FOR-
stroked position when the travel control lever is WARD” and “NEUTRAL” to “REVERSE” control
moved from “NEUTRAL” to “FULL FORWARD” and lever positions.
from “NEUTRAL” to “FULL REVERSE” positions.
i. STOP the engine. Lift the machine and remove
g. Start the engine. Keep the travel control lever in the blocking from under both the front [drum end]
the NEUTRAL position. Keep the engine throttle at and the rear [tire end] and lower the machine to the
LOW idle. Release the secondary/parking brake floor. Remove the steering lock bar.
system. Note that NO drum, or tire, rotation occurs.
DANGER: Keep CLEAR of the machine

DANGER: Keep ALL personnel CLEAR of the while lifting, removing blocking and
machine, at ALL times, during lowering the machine.
the operation check.
NOTE: If the tire drum and tires rotated during

step "g", repeat steps "b" through "g",
again, until NO movement is noted.
12-8 6/96
Section 12
CONTROL SYSTEMS
TROUBLE ANALYSIS FOR THE CONTROL SYSTEMS
THROTTLE CONTROL SYSTEM
Governor control Cable not connected at lever or Correct where loose.

Lever does NOT extension spring to engine
move governor. governor eye bolt.
Control cable seized. Remove control cable and replace

NEW. Adjust as/if needed.
Control assembly seized. Remove, free as needed, or

replace with new, and install.
Engine governor assembly Remove, repair, or replace, as

has internal damage. needed.
Governor control Control cable partially seized in Remove and free, or replace
lever moves casing. with new, as needed.
governor, but NOT
easily. Control assembly sticking Remove lever, free as needed
and install.
Engine governor has Remove and repair, or

internal damage. replace, as needed.
Engine high idle Governor control Adjust control cable

speed can NOT be cable travel NOT travel using CORRECT
reached. adjusted correctly. procedures.
Governor stop not Adjust governor stop

adjusted correctly. using CORRECT
procedures.
Engine governor has Remove and repair, or

Engine has internal, or Evaluate and repair

system damage. as needed.
Engine speed does NOT Governor control cable Remove, free, or

return to low idle, after being sticking. replace, as needed.
above low idle speed.
Governor control cable Adjust control cable
travel NOT adjusted travel using CORRECT
correctly. procedures.
Engine governor has Remove, repair, or

Engine has internal, Evaluate and repair

or system, damage. as needed.
6/96 12-9
Section 12
CONTROL SYSTEMS
TROUBLE ANALYSIS FOR THE CONTROL SYSTEMS
TRAVEL CONTROL SYSTEM
Travel control Cable not connected at hand Connect where not connected.
lever does NOT lever, or at transmission
move second transmission actuation arm.
pump actuation arm.
Control cable seized. Remove control cable and
replace with NEW. Adjust as
needed.
Control assembly seized. Remove, free as needed and

install.
Displacement control assembly Remove and replace, with

has internal damage (seized). NEW.
Travel control Control cable partially seized in Remove and free, or

lever moves second casing. replace, as needed.
transmission pump actuation
arm, but NOT easily. Control assembly sticking Remove lever, free as needed
and install.
Transmission pump has Remove and repair, or

Full forward and/or reverse Transmission control Adjust control cable

position can NOT be cable travel NOT travel using CORRECT
reached. adjusted correctly. procedures.
Transmission pump[s] Remove and replace

Displacement control damaged. control[s]. See Section 8 -
TRANSMISSION.
Transmission pump[s] has Remove and replace pump[s].

major internal damage. See Section 8 - TRANSMIS-
SION.
Transmission pump[s] does Travel control cable Remove, free, or

NOT return to neutral, sticking. replace, as needed.
after being at full forward
and/or reverse position. Travel control cable Adjust control cable
travel NOT adjusted travel using CORRECT
correctly. procedures.
Transmission pump[s] Remove and replace

displacement control damaged. control[s]. See Section 8 -
TRANSMISSION.
Transmission pump[s] has Remove and replace pump[s].

major internal damage. See Section 8 - TRANSMIS-
SION.
12-10 6/96
Section 13
OPTIONAL EQUIPMENT
TABLE OF CONTENTS
PAGE

LEVELING BLADE SYSTEM ...................................................................................................................13-2
DESCRIPTION ......................................................................................................................................... 13-2

SYSTEM ITEM DESCRIPTION AND OPERATION .................................................................................13-3
LEVELING BLADE SYSTEM HYDRAULIC PUMP.................................................................................. 13-3
LEVELING BLADE CONTROL VALVE ...................................................................................................13-3

LEVELING BLADE CYLINDER ............................................................................................................... 13-3
SYSTEM CONTROL FOOT PEDAL AND LINKAGE .............................................................................. 13-3
LEVELING BLADE CONTROL VALVE ...................................................................................................13-4

REMOVAL ............................................................................................................................................. 13-4
INSTALLATION .................................................................................................................................... 13-4
PRIORITY VALVE ................................................................................................................................... 13-5

REMOVALAND INSTALLATION ......................................................................................................... 13-5
LEVELING BLADE CYLINDER ............................................................................................................... 13-6
REMOVAL ............................................................................................................................................ 13-6

DISASSEMBLY .................................................................................................................................... 13-6
CLEANING AND INSPECTION ........................................................................................................... 13-7
ASSEMBLY .......................................................................................................................................... 13-8

INSTALLATION .....................................................................................................................................13-8
LEVELING BLADE SYSTEM RELIEF PRESSURE CHECK AND ADJUSTMENT................................. 13-8
LEVELING BLADE ASSEMBLY ........................................................................................................... 13-10

REMOVAL AND INSTALLATION ...................................................................................................... 13-10
REMOVAL ....................................................................................................................................... 13-10
INSTALLATION ............................................................................................................................... 13-10

LEVELING BLADE CONTROL FOOT PEDAL AND LINKAGE ........................................................... 13-12
LINKAGE CHECK AND ADJUSTMENT PROCEDURE .................................................................... 13-12
OPTIONAL LIGHTING SYSTEM ........................................................................................................... 13-13

CHECKS AND ADJUSTMENT ........................................................................................................... 13-14
TROUBLE ANALYSIS FOR THE LEVELING BLADE SYSTEM .......................................................... 13-15
6/96 13-1
Section 13
OPTIONAL EQUIPMENT
GENERAL INFORMATION. The leveling blade system provides a method to

move and level fill material as the machine is
THIS section contains a description and service operated in either direction of travel.
information about the leveling blade system, used on
the Model BW124PDB footed drum Roller, and The manual/hydraulic control system permits the
optional operation lighting system available for the
Model BW124D, BW124PD and BW124PDB leveling blade to be placed in one [1] of four [4]
Rollers. positions, which can be changed at any time during
machine operation.
LEVELING BLADE SYSTEM.
DESCRIPTION [Fig. 1].
The leveling blade system is standard on the Model

BW124PDB footed drum Roller.
TO FILTER
TO STEERING UNIT
21
POS. DESCRIPTION
01 TANK
10 ENGINE
18 STEERING PUMP
19 PRIORITY FLOW DIVIDER
20 BLADE VALVE
21 BLADE CYLINDER
19
M5 TO VIBRATION
PUMP
10
18
20
13 01
TITLE MAX. PRESSURE (BAR)
M5 BLADE 172
OPTIONAL
EQUIPMENT
FIGURE 1. OPTIONAL LEVELING BLADE SYSTEM - HYDRAULIC SCHEMATIC.
13-2 6/96
Section 13
OPTIONAL EQUIPMENT
The FOUR [4] leveling blade positions are: The valve is supplied oil flow the flow regulator valve
and has the control spool moved through the system
1. RAISE leveling blade. foot pedal control, and linkage.
0. HOLD leveling blade. The valve will react to the movement of the foot
pedal in any of the FOUR [4] positions. Oil flow is
2. LOWER leveling blade. directed through the control valve when the foot
pedal is placed in position 1, or 2. Oil flow is then
3. FLOAT and LOCK leveling blade. directed to the leveling blade cylinder. The leveling
blade cylinder rod then is moved by the flow of oil
The leveling blade system contains the following supplied through, and from, the control valve to the
MAJOR items which are used within the system: position selected by the operator moved foot pedal.
1. One [1] FLOW REGULATOR VALVE assembly. When NO leveling blade system oil flow needs are
present, [position 0 and 3] oil flow supplied to the
2. One [1] LEVELING BLADE CONTROL VALVE control valve is directed from the control valve to the
assembly. steering control unit and back to the hydraulic oil
reservoir.
3. One [1] LEVELING BLADE CYLINDER.
4. One [1] LEVELING BLADE assembly [contains

blade weldment WITH bolt on blade edges]. LEVELING BLADE CYLINDER.
5. One [1] system CONTROL FOOT PEDAL The leveling blade cylinder is of the double acting
assembly [includes ALL brackets, rods, joints and type.
related hardware].
When required, the cylinder is supplied oil flow from
6. Miscellaneous ADDITIONAL ITEMS [hoses, the “A” or “B” outlet ports of the leveling blade
fittings, frame brackets and related hardware]. control valve.
Oil returning from the cylinder is directed back to the

leveling blade control valve. It then flows through the
SYSTEM ITEM DESCRIPTION AND OPERATION valve, to the steering control unit and back to the
[See Fig. 1]. hydraulic oil reservoir.
LEVELING BLADE SYSTEM HYDRAULIC PUMP.
The LEVELING BLADE system uses oil flow pro- SYSTEM CONTROL FOOT PEDAL AND
duced by the charging/steering/vibration pump LINKAGE.
assembly. System oil is routed from the pump
assembly to, and then through, the flow regulator The system control foot pedal, and linkage, contains
valve. the foot pedal, threaded rod, fork joint, link connec-
tor, mounting brackets, and miscellaneous hard-
The machine steering system has "priority" for use ware.
of oil flow at any time both the steering and leveling
blade systems are being used at the SAME time. The assembly serves as a mechanical link between
the foot pedal and the spool of the leveling blade
control valve. Movement of the foot pedal is me-
LEVELING BLADE CONTROL VALVE. chanically relayed to the control valve spool by the
assembly. When the assembly is correctly adjusted,
The LEVELING BLADE CONTROL VALVE is a the movement of the spool is to the CORRECT
single spool, four [4] way, four [4] position valve with position, so that the leveling blade will also be in the
one [1] externally adjusted relief valve. CORRECT position, and match the foot pedal
position selected by the operator.
6/96 13-3
Section 13
OPTIONAL EQUIPMENT
LEVELING BLADE CONTROL VALVE. INSTALLATION [See Fig.1].
REMOVAL [See Fig. 1]. Use the following procedures to install the leveling
blade control valve:
Use the following procedures to remove the leveling
blade control valve for replacement: 1. Put the NEW leveling blade control valve in
position inside the riser. Install the hex bolts. Install
the washers and castle nuts onto the bolts and
WARNING: Be SURE the blade rests on the tighten the nuts securely.
ground.
Do NOT service the blade system or 2. Remove the cap from each fitting in the valve.
components with the blade raised Remove the plug from each hose. Put each hose
from the ground. onto the correct control valve fitting as indicated by
the identification tags put on the hoses and fittings
during removal. Tighten the hose fittings securely
1. Lower the blade to the ground. Stop the engine. onto the control valve fittings.
Remove the access cover from the leveling blade
control valve mounting area, inside the control panel 3. Align the holes in the link connector and valve
riser. Wash the leveling blade control valve area, spool. Install the cross pin through the holes in the
where the valve is mounted, and ALL hose connec- link connector and valve spool. Put the cotter pin
tion fittings with steam, and dry using compressed through the cross pin and bend.
air.
4. Check the hydraulic oil level of the hydraulic oil
2. Remove cotter key from the cross pin connect- reservoir. ADD oil IF needed [See Section 4 -
ing the link connector to control valve spool. Remove MAINTENANCE].
the connector from the spool end.
5. Follow ALL “pre-start” procedures given in
3. Put an identification tag on EACH hose and Section 8 - TRANSMISSION SYSTEM.
fitting. Remove All hoses from the leveling blade
control valve. Put plugs in ALL hoses and put caps 6. Check, and if needed, adjust the leveling blade
on ALL fittings. system relief pressure and/or valve actuation
linkage, using the procedures given in THIS section.
4. Hold the valve in position. Loosen and remove
all castle nuts and washers from the hex bolts that 7. Start the engine and check the system for
fasten the valve to the riser. Carefully move the CORRECT operation.
valve away from the riser and out of the machine.

CAUTION: Do NOT permit the valve to fall while ANY system problem is noted and
being removed. repair.
BLADE CONTROL VALVE HOSE
NOTE: At this time, NO internal valve parts are

serviced. Remove and replace the valve HEX BOLT
(2 PLCS) CASTLE NUT
with NEW. (2 PLCS)
HOSE
WASHER
(2 PLCS)
HOSE
HOSE
HOSE
FIGURE 1.
13-4 6/96
Section 13
OPTIONAL EQUIPMENT
PRIORITY VALVE. 6. Put the priority valve and bracket assembly in

position on the floor plate . Align the notched bracket
REMOVAL AND INSTALLATION [See Fig. 1]. slots with the through holes in the floor plate. Install
the hex bolts from the top side. Install the washers
Use the following procedures to remove and install and castle nuts onto the bolts and tighten the nuts
the priority valve: securely.
7. Remove the cap from each fitting in the valve.

WARNING: Be SURE the blade rests on the Remove the plug from each hose. Put each hose
ground. onto the correct control valve fitting as indicated by
Do NOT service the blade system or the identification tags put on the hoses and fittings
components with the blade raised during removal. Tighten the hose fittings securely
from the ground. onto the control valve fittings.
8. Install the access cover onto the control panel

1. Lower the blade to the ground. Stop the engine. riser. Install the retaining capscrews and tighten
Remove the access cover from the priority valve securely.
mounting area, inside the control panel riser. Wash
the priority valve area, where the valve is mounted, 9. Check the hydraulic oil level of the hydraulic oil
and ALL hose connection fittings with steam, and air reservoir. ADD oil IF needed [See Section 4 -
dry. MAINTENANCE].
2. Put an identification tag on EACH hose and 10. Follow ALL “pre-start” procedures given in
fitting. Remove both hoses from the priority valve. Section 8 - TRANSMISSION SYSTEM.
Put plugs in both hoses and put caps on both
fittings. 12. Start the engine and check the steering and
blade systems for CORRECT operation.
3. Hold the valve in position. Loosen and remove
the castle nuts and washers from the hex bolts that
fasten the valve mounting bracket to the floor plate . DANGER: Keep Clear of the rollers articulation
Carefully move the valve and bracket away from the area during the steering check.
floor plate and out of the machine. Clearance in this area closes when
the machine is turned to the right, or
the left.
CAUTION: Do NOT permit the valve to fall while
being removed.
ANY system problem is noted and
4. Hold the bracket in a vise. Loosen and remove repair.
the castle nuts and washers from the hex bolts that
fasten the valve to the mounting bracket. Move the HEX BOLT
WASHER
HEX NUT
WASHER
valve away from the bracket. FLOW DIVIDER VALVE
HOSE HOSE
NOTE: NO internal valve parts are serviced.

Remove and replace the valve with NEW. FLOOR PLATE BRACKET
5. Hold the bracket in a vise. Put the NEW valve HEX NUT
in position against the mounting bracket. Align the

HEX BOLT
through holes in the valve and bracket. Install the
hex bolts through the bracket and valve, from the
outer side. Install the washers and the castle nuts FIGURE 1.
onto the hex bolts and tighten securely.
6/96 13-5
Section 13
OPTIONAL EQUIPMENT
LEVELING BLADE CYLINDER.
REMOVAL [See Fig.1].

PIN
Use the following procedures to remove the UPPER CYLINDER
MOUNT ARM
blade cylinder for repair, or replacement. SPACER
SPACER
HOSE
1. Put the leveling blade "DOWN" onto the ground. CYLINDER WASHER
Stop the engine. Wash the leveling blade cylinder, COTTER PIN
hoses and the area where it connects with CLEAN
HOSE
diesel fuel and dry using compressed air. PIN
SPACER
LOWER CYLINDER
MOUNT ARM
WARNING: Be SURE the blade rests on the SPACER
ground.
Do NOT service the blade system, or
WASHER COTTER PIN
components, with the blade raised
from the ground.
2. Put an identification tag on EACH hose and

cylinder fitting. Loosen and remove the cylinder oil
supply and return hose fitting at EACH cylinder
fitting. Put a plug in EACH hose fitting end and a cap FIGURE 1.
on EACH cylinder fitting.
DISASSEMBLY [See Figure 1] .
3. Go to the upper cylinder mount arm. Remove
one [1] cotter pin from the cylinder retaining pin. 1. Wash the cylinder with All purpose degreaser,
Remove the cylinder retaining pin, spacers and part number 178297, and allow to air dry.
washer from the cylinder and mount arm.
2. Put the cylinder in a vise, with the shell area
4. Go to the cylinder lower cylinder mount arm. held securely by the jaws. Put the cylinder rod in the
Remove one [1] cotter pin from the cylinder retaining extended position.
pin. Remove the cylinder retaining pin, spacers and
washer from the cylinder and the lower cylinder CAUTION: Do NOT crush the shell area of the
mount arm. cylinder.
5. CAREFULLY remove the leveling blade cylinder

from the machine. 3. Remove the two [2] capscrews that fasten the
steel rod end cap to the packing gland assembly.
Remove the end cap from the cylinder shell and
from against the packing gland assembly. Move the
WARNING: HOLD the cylinder SECURELY. Do end cap downward on the cylinder rod.
NOT permit the cylinder to fall from
the machine. 4. Push the packing gland assembly inward. Use a
plier, or a screw driver to carefully remove the
packing gland retaining wire from the groove in the
cylinder shell.
6. Inspect the spherical bushing in the upper and
lower cylinder mount arms. If worn or damaged,
remove the bushing[s] and replace with new. WARNING: Safety glasses must be worn during
wire removal.
5. Carefully move the packing gland assembly

outward from inside the cylinder shell and slide it
downward on the cylinder rod.
13-6 6/96
Section 13
OPTIONAL EQUIPMENT
CLEANING AND INSPECTION [See Figure 1] .

1. Wash all cylinder parts with All purpose
degreaser, part number 178297, and allow to air dry.
2. Inspect each part for wear or damage. Replace
worn or damaged parts with new.
3. Inspect the gland assembly and the piston
assembly for wear or damage. Replace either, or
both, items if worn or damaged.
5. Inspect the inside of the cylinder shell for wear,
nicks, burrs, scratches, rust or other damage.
Replace e the shell if worn or damaged.
6. Inspect the cylinder rod for wear or damage to

the chrome surface. Replace the rod if worn or
damaged, bent or if has a nicked, rusted, scratched
or pitted chrome surface.
NOTE: Slight damage can be removed with fine

sandpaper, or emery cloth.
FIGURE 1. CAUTION: Do NOT sand all chrome plating from

the outside of the rod. If there is any
doubt about chrome plating having
6. Pull on the cylinder rod and carefully remove the been removed from the rod, check by
piston/rod assembly from the cylinder shell bore. applying copper sulfate to the .
The rod will discolor where chrome
7. Put the cylinder rod end clevis in a vise and has been removed. If this condition is
tighten the vise to hold the clevis securely.
noted, replace the cylinder rod or
8. Remove the large locknut on the piston. complete cylinder assembly.
Wash the cylinder rod after the above
9. Remove the piston from the cylinder rod. damage repair has been done, and air
Remove both piston seals from the piston. Remove dry the rod.
the one [1] static seal from the groove in the cylinder
rod.
10. Move the packing gland assembly up the
cylinder rod and off of the rod.
11. Remove the cylinder rod wiper from the inner
bore of the gland assembly. Remove the rod sealing
o-ring and back up ring from the inner bore of the
gland assembly. Remove the gland to shell sealing
o-ring and back up ring from the groove in the outer
diameter of the gland assembly.
6/96 13-7
Section 13
OPTIONAL EQUIPMENT
ASSEMBLY [See Figure 1]. 9. Move the cylinder rod end cap upward on the
cylinder rod and into position on the cylinder shell.
CAUTION: ALL cylinder parts MUST be very Align the two [2] holes in the end cap with the tapped
clean. The assembly area MUST be holes in the gland assembly. Install the two [2] end
clean. Dirt , of any type, can cause cap retaining capscrews into the tapped holes and
damage to the cylinder and/or other tighten securely.
hydraulic system components and
repeat failure can occur. 10. Fill the cylinder with NEW approved and
filtered hydraulic oil. Close the ports on the blade
cylinder with plugs. Install the cylinder back onto the
1. Put CLEAN hydraulic oil on ALL cylinder parts. machine.
Put the cylinder rod in a vise, with the clevis end
through mounting holes between the vise jaws.
Tighten the vise to securely hold the rod. Put tape
over the threaded area on the rod.
INSTALLATION.
2. Install the new rod wiper, rod seal, back up ring
and o-ring into the inner bore of the gland assembly. Reverse the removal procedures to install the
Install the NEW back up ring and o-ring into the leveling blade cylinder [See CYLINDER REMOVAL
groove at the outside diameter of the gland assem- procedures and Fig. 1].
bly. If removed, install the rod end cap over the end
of the cylinder rod and move downward. Put the
gland assembly over the end of the cylinder rod end
and carefully slide the assembly towards the end of NOTE: Check the hydraulic oil level after
the rod. installing the leveling blade cylinder,
top up if necessary. To bleed the leveling
blade cylinder run the engine at idling
3. Install a new cylinder rod static o-ring seal into speed and fully raise and lower the
the cylinder rod groove. leveling blade.
4. Carefully install the new piston seals onto the
piston. Install the piston onto the cylinder rod. Check the operation of the leveling blade system
after cylinder installation.
5. Remove the tape from the threaded area on the
rod. Install the locknut onto the threaded rod. Tighten
the locknut to a torque of 250 - 300 ft. lbs. [350 - 420 DANGER: Keep ALL personnel CLEAR OF the
N.m]. leveling blade. Clearance CLOSES
between the blade and ground when
6. Carefully compress the piston seals, with the the leveling blade is raised and
fingers, while sliding the piston/rod assembly into the then lowered. Serious INJURY, or
cylinder shell bore. DEATH, can occur if caught between
the blade and ground.
7. Carefully compress the o-ring and back up ring,
on the outside diameter of the gland assembly, with
the fingers. Keep the rings compressed and carefully
move the gland assembly into the cylinder shell. LEVELING BLADE SYSTEM RELIEF PRESSURE -
CHECK AND ADJUSTMENT [See Fig. 1].
8. Push the gland assembly fully into the shell, so
that the gland retaining wire groove, in the cylinder
shell, is seen. Use a plier, or screw driver, to care- Use the following procedures to check and, if
fully install the gland retaining wire fully into the needed, adjust the leveling blade system relief
groove. pressure:
1. STOP the engine. Find the steering/leveling

WARNING: Eye protection MUST be worn during
wire installation. blade systems pressure check port fitting at the top
of the steering pump. Wipe the check port area with
a CLEAN cloth.
2. Loosen and remove the cap from the pressure

check fitting. Install a 5,000 psi. [345 bar] pressure
gauge, on a hose, onto the pressure check port
fitting and tighten securely.
13-8 6/96
Section 13
OPTIONAL EQUIPMENT
3. Check the hydraulic oil level in the hydraulic oil 6. Keep the engine in the STOPPED condition.
reservoir. ADD oil IF needed [See Section 4 - Wipe the relief valve cartridge assembly and control
MAINTENANCE]. valve housing area using a CLEAN lint FREE cloth.
4. Put the secondary/parking brake system in the 7. Loosen the pressure adjusting screw locknut a
“ON” [APPLIED] condition. Start the engine. Put the SMALL amount.
engine throttle in the HIGH idle position. Move the
leveling blade foot pedal to the LOWER position and 8. Adjust the system relief pressure by turning the
make the leveling blade reach, and then put pres- pressure adjusting screw a SMALL amount.
sure on, the ground. NOTE the HIGHEST pressure
indicated on the pressure gauge. Put the engine
throttle in the LOW idle position and run the engine CAUTION: Turn the adjusting screw ONLY a
for a period of 3-5 minutes. STOP the engine. SMALL amount inward or outward.
Turning the adjusting screw CLOCK-
WISE will INCREASE the system relief
WARNING: Keep CLEAR of the leveling blade pressure. Turning the adjusting screw
assembly during the pressure check COUNTER CLOCKWISE will DECR-
procedure. The blade MUST be EASE the system relief pressure.
lowered onto the ground.
9. Hold the pressure adjusting screw in position

CAUTION: The leveling blade system RELIEF and tighten the locknut.
pressure MUST be 1,850 +/- 50 psi.
[124 +/- 35 bar] to be CORRECT. ANY
pressure ABOVE , or BELOW, this CAUTION: Do NOT move the pressure adjusting
pressure MUST be changed by screw.
external adjustment of the relief valve
assembly, found on the bottom of the
leveling blade control valve. 10. Check the system relief pressure AGAIN using
the procedures given in step “4” and ALL “NOTES”,
“CAUTIONS” and “WARNINGS”. If the pressure is
NOTE: IF the pressures indicated were correct, CORRECT, do step “5” at THIS TIME.
NO system relief pressure adjustment
is required. DO step “5”, given below, at
THIS time. If the pressure indicated was NOTE: If the relief pressure is still NOT correct,
NOT correct do NOT do step “5” at THIS REPEAT the steps “7” through “10”
time. See the “CAUTION” following step UNTIL the relief pressure is CORRECT,
“5”. then do step “5”.
5. Loosen and remove the hose and pressure

gauge from the pressure check port fitting. Install
and tighten the cap onto the pressure check port BLADE VALVE
fitting.
CAUTION: IF the relief pressure] was NOT PRESSURE

ADJUSTING
SCREW
correct, ADJUST the leveling blade
system RELIEF pressure using the LOCKNUT
following ADDITIONAL procedures:

ALLEN WRENCH
FIGURE 1.
6/96 13-9
Section 13
OPTIONAL EQUIPMENT
LEVELING BLADE ASSEMBLY. NOTE: IF only the bushing[s] are being

replaced, lower the leveling blade arms
REMOVAL AND INSTALLATION. down. Remove the bushing[s] from the
blade arm bore[s]. Replace the
USE the following procedures to remove and install bushing[s] with NEW.
the COMPLETE leveling blade assembly. The
procedure also includes steps to remove and
replace the bushing found on EACH side of 6. If complete leveling blade assembly removal is
the frame at the point where the leveling blade arms required, carefully lift the assembly a small amount
fasten to the frame. and move it away from the frame and machine.
WARNING: Keep CLEAR of the leveling blade

REMOVAL [See Fig. 1]. assembly while being lifted and
moved.
1. Put the leveling blade assembly in the DOWN
position and onto the ground. STOP the engine.
NOTE: Inspect the two [2] shoe weldments,
which are fastened to the underside of
WARNING: Be SURE the blade rests on the the leveling blade, for excessive wear or
ground. damage. Replace as needed. Inspect the
Do NOT service the blade system, or bolt on reversible blade cutting edges for
components, with the blade raised wear or damage. Reverse, or replace, as
from the ground. needed at THIS time.
2. Wash the COMPLETE leveling blade assembly

and mounting area with steam, and air dry.
INSTALLATION [See Fig. 1].
3. Go to the cylinder rod end. Remove the rod end
from the mounting ear [see this section]. 1. Use a CLEAN cloth to remove ANY oil or grease
from the bushing bore in the leveling blade arm.
4. Fasten a chain, having a capacity more than CAREFULLY lift the leveling blade assembly and
1,000 lbs. [454 kg], to EACH leveling blade arm at a move it into position, so that the pin bore in each
point near the frame to arm area. Fasten a hoist, leveling blade arms bushing is in alignment with the
having a capacity more than 1,000 lbs. [454 kg], to mounting bracket bores, on EACH side of the frame.
the chains and apply ONLY enough lifting pressure
to keep the chains tight.
WARNING: Keep CLEAR of the leveling blade
5. Loosen and remove the center retaining cap- assembly while being lifted and
screw and large washer found at the outer side of moved into position.
EACH blade mounting bracket. Loosen and remove
the two [2] clamping capscrews found at EACH end
of the flat ridge steel. Remove the blade arm mount-
ing pin. Repeat the procedure on the OPPOSITE 2. Keep the leveling blade arms in position, so that
side of the machine. the bushing bore is aligned with the mounting
bracket bores. Put multipurpose grease on each
mounting pin. Carefully install the mounting pin
WARNING: Keep the hands clear of the pin bore through the outer side of the mounting bracket,
to arm and mounting bracket area through the bushing bore, in the leveling blade arm,
during pin removal. A pinch area can and into the other side bore in the mounting bracket.
exist if the blade arms move.
13-10 6/96
Section 13
OPTIONAL EQUIPMENT
3. Put the pin in position from the outer side of the 7. Start the engine and check for correct operation
mounting bracket. Put Loctite #242 on the threaded of the leveling blade assembly.
area of the two [2] capscrews that fasten pin into to
the bracket. Install and securely tighten the
capscrews . WARNING: Keep CLEAR of the leveling blade
during the check of operation.
4. Go to the opposite of the machine and repeat
step "3".
5. Put the leveling blade cylinder rod end. Connect

the cylinder rod end to the mounting ear [see this
section]
PIN
HEX BOLT
HEX BOLT
BUSHING
DETACHED BLADE ARM
FIGURE 1.
6/96 13-11
Section 13
OPTIONAL EQUIPMENT
LEVELING BLADE CONTROL FOOT PEDAL AND CAUTION: Do NOT adjust the fork joint outward
LINKAGE. to the point that LESS than 1/2 inch
[12.7 mm] of the rod threads remain in
LINKAGE CHECK AND ADJUSTMENT the fork joint to meet the condition
PROCEDURE [See Fig. 1]. described in step “e” above.
CAUTION: Check the leveling blade system NOTE: If LESS than 1/2 inch [12.7 mm] of
control linkage adjustment AFTER the threaded rod end would remain in the
control foot pedal, threaded rod or adjustable fork joint, GO to the CONTROL
other linkage items have been VALVE end of the threaded bar. Remove
removed, replaced and installed the cotter pin from the cross pin to
again. valve spool cross pin. Loosen the hex nut
from against the link connector.
Turn the joint outward, so that the
Use the following procedures to check and, if available link center hole to control valve
needed, adjust the threaded rod linkage between the spool center hole length is INCREASED.
control foot pedal and the leveling blade system Install the cross pin through the
control valve: link connector and valve spool bores. Put
the cotter pin through cross pin and
1. Lower the leveling blade onto the ground. STOP bend. Tighten the hex nut against the fork
the engine. joint. Repeat step “e” from above.
WARNING: Be SURE the blade rests on the CAUTION: Do NOT adjust the link outward
ground. to the point that LESS than 1/2 inch
Do NOT service the blade system, or [12.7 mm] of the threaded rod threads
components, with the blade raised remains in the link connector.
from the ground.
f. Install the cross pin, and washer, through the link

2. Go to the underside area below the foot pedal connector and pedal lever from the inner side. Install
arm. Loosen the hex nut, which keeps the fork joint the cotter pin through the cross pin and bend.
in the “adjusted” position.
g. Start the engine. Check the operation of the
3. Put the foot pedal control in the EXACT center leveling blade system in EACH position.
of the “LOWER” [#2] position.
d. Go to the leveling blade control valve and make WARNING: Keep CLEAR of the leveling blade,
SURE the control valve spool, and control linkage cylinder and leveling blade arms
threaded rod are in the “BLADE DOWN” position. during the check of system
operation.
e. Go to the underside area below the foot pedal,
again. Remove the cross pin and washer from the
fork joint to pedal lever. Turn the fork joint inward, or CAUTION: The leveling blade MUST go to the
outward, and adjust the position of the joint, so that SAME position at which the control
the through hole in the fork joint is in the EXACT foot pedal is positioned for EACH of
same position as the through hole in the pedal lever. the FOUR [4] leveling blade
When the adjustment is correct, tighten the hex nut positions.
against the adjustable fork joint.
13-12 6/96
Section 13
OPTIONAL EQUIPMENT
CONTROL VALVE
CROSS PIN
LINK CONNECTOR
NUT
FORK JOINT COTTER PIN
WASHER
CROSS PIN THREADED ROD
COTTER PIN
WASHER
PEDAL LEVER
FIGURE 1.
OPERATION LIGHTING SYSTEM. When the control switch is put in the “ON” position
current will flow through the switch to the dash
The operation lighting system is used to enable gauge and instrument illumination light harness, the
machine operation under dark conditions. front light harness and the rear light harness.
The lighting system is available as a factory installed Current then flows through the harnesses to and
option, or can be added to the machine by the through the lights to ground.
nearest Distributor.
The system contains light assembly supply wiring NOTE: Also see Section 7 - ELECTRICAL
harnesses, 10 amp fuse, securing clamps and ties SYSTEM - for additional system
one [1] front headlight light assembly and one tail information.
light assembly.
When the ignition key switch is in the “ON” position,

system electrical current is supplied from the con-
nection terminal F06 of the circuit bridge to the
system control switch.
6/96 13-13
Section 13
OPTIONAL EQUIPMENT
CHECKS AND ADJUSTMENT. Check the operation of the system EACH time the
machine is started to be sure the system is without
The front head light assembly is able to be adjusted faults, which can cause the system to NOT operate
to aim the beam of light as desired. Loosen the correctly when needed. Replace any component that
retaining nut on the mounting bracket to light assem- has damage, as needed.
bly through bolt. Adjust the light assembly as desired
and tighten the nut on the through bolt to
secure the light in the desired adjusted position. CAUTION: Replace a damaged component with
the same type or sized item. NEVER
use a wire having a smaller gauge
than the wire being replaced. Use
ONLY EQUAL, or LARGER, size wire.
FIGURE 1.
13-14 6/96
Section 13
OPTIONAL EQUIPMENT
TROUBLE ANALYSIS FOR THE LEVELING BLADE SYSTEM
BLADE CONTROL VALVE
No leveling blade action Control linkage connection Replace missing connect-

when control foot pedal at foot pedal, or at ion part and correctly
placed in ANY of the valve, NOT installed adjust control linkage
four [4] positions.
NO oil flow being Check for oil flow from

supplied to system from steering pump
steering pump
Leveling blade system Check relief pressure

relief pressure set too and adjust as needed
LOW for system to
operate
Leveling blade system Remove and replace

relief valve has damage relief valve with NEW.
[will NOT permit system Check system relief
to develop ANY pressure and adjust if
pressure] needed
Leveling blade control Remove and replace valve

valve has internal
damage
Oil supply and/or return Check hose[s]. Clean, or

hoses from and back to replace, as needed
control valve plugged or
damaged [NO oil
reaches and/or returns
from leveling blade
cylinder]
6/96 13-15
Section 13
OPTIONAL EQUIPMENT
BLADE CONTROL VALVE
NOT all four [4] Leveling blade control Check linkage and
leveling blade actions foot pedal to control adjust as needed
operate when control valve linkage NOT
foot pedal is placed in adjusted correctly
the correct position.
Control valve spool Remove and replace
NOT moving to correct valve with NEW
location to port oil
flow correctly
Leveling blade arms Find and remove

being restricted in obstruction. Check
their movement by an leveling blade action
obstruction
Leveling blade system Check pressure. Adjust

relief pressure set too relief pressure to
LOW [functions needing CORRECT specification
high pressure NOT
working]
BLADE CYLINDER
NO motion from leveling No oil being supplied to Check system for oil
blade cylinder. blade cylinder flow from blade system pump
to control valve and/or control
valve and the cylinder. Correct
cause of NO oil supply
as needed
Cylinder has Remove, disassemble,

internal damage clean, inspect and repair as
needed. Install cylinder
Slow motion from the Low oil supply to the cylinder Check as indicated above
leveling blade cylinder.
13-16 6/96
Section 13
OPTIONAL EQUIPMENT
BLADE CYLINDER
Action of cylinders is jerky. Air in system Check oil level in reservoir.

Add oil as needed. Find and
correct cause for low oil level.
Check for loose hose to
fitting connections. Tighten
as needed
Excessive lost motion at Bent or deformed cylinder Remove cylinder, repair or

cylinder. piston or rod replace as needed
Bushing[s] at blade cylinder Remove and replace

to blade mount or anchor bushing[s] as needed
worn
6/96 13-17
Section 13
OPTIONAL EQUIPMENT
NOTES
13-18 6/96
Section 14
SPECIAL TOOLS
TABLE OF CONTENTS
PAGE
SPECIAL EQUIPMENT AND TOOLS ..................................................................................................... 14-2
6/96 14-1
Section 14
SPECIAL TOOLS
GENERAL INFORMATION. 3. Mounting jig for exchanging the rubber buffers

(Fig. 3):
The following "Special Tool List" includes the equip- Part no.: 007 130 02
ment, or tool, description and part number assigned
to the equipment, or tool.
SPECIAL EQUIPMENT AND TOOLS.
1. Vibration read frequency meter (Fig. 1):

Part no.: 300 120 80
FIGURE 3.
4. Centering jig for vibration motor cover (Fig. 4):

Part no.: 007 130 05
FIGURE 1.
2. Filling and filtering unit with oil bag (Fig. 2:

Part no.: 007 610 01
FIGURE 4.
5. Puller for coupling half on vibrator shaft (Fig. 5:

Part no.: 007 130 04
FIGURE 2.
14-2 6/96
Section 14
SPECIAL TOOLS
FIGURE 5. FIGURE 7.
6. Pin wrench for screwing tension nut on and off 8. Centering plate for drive shaft (Fig. 8):
the articulated joint (Fig. 6): Part no.: 079 942 01
Part no.: 007 122 01
FIGURE 8.
FIGURE 6.
7. Centering plate for cover on steering, charging

and vibration pump (Fig. 7):
Part no.: 007 130 06
6/96 14-3
Section 14
SPECIAL TOOLS
9. Mounting tool for dust sealing ring (Fig. 9):

Part no.: 079 942 03
FIGURE 11.
13. Hydraulic test case (Fig.12):

FIGURE 9. Part no.: 007 610 03
10. Mounting tool for O-ring/kin ring (Fig. 10):

Part no.: 079 942 02
FIGURE 12.
14. Test hose, 1m long (fig. 13):

FIGURE 10. Part no.: 079 930 02
11. Flushing filter - travel circuit (Fig. 11):

Part no.: 007 000 01
12. Filter element:

Part no.: 079 930 01
14-4 6/96
Section 14
SPECIAL TOOLS
15. Flushing hose, 16S connection (Fig. 14): 17. Flushing hose, 15L connection (Fig. 16):
Part no.: 055 513 72 Part no.: 055 510 09
16. Reducing socket, 25S/16S (Fig. 15):

Part no.: 055 423 27
6/96 14-5
Section 14
SPECIAL TOOLS
18. Electrical test kit (Fig. 17):

Part no.: 057 505 70
19. Junction socket, 16S (Fig. 18): 21. Flushing filter, vibration circuit (Fig. 20):
Part no.: 055 459 43 Part no.: 079 930 29
22. Filter element

Part no.: 079 930 14
23. Double end union, R 3/4" - 15L

Part no.: 055 40 89
FIGURE 18.
20. Junction socket, 15L (Fig. 19):

Part no.: 055 459 32
FIGURE 20.
14-6 6/96
Section 14
SPECIAL TOOLS
24. Threaded bar, M 16, with eye (Fig. 21):

Part no.: 007 122 21
FIGURE 21.
6/96 14-7
Section 14
SPECIAL TOOLS
NOTES
14-8 6/96

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BW 124D, BW124PD,

Instructions for repair

ALWAYS support the machine with sound blocking.

ALWAYS keep tools in a good and clean condition.

SECTION 1 - INTRODUCTION .................................................................................................................. 1-1.

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

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

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

SECTION 5 - FRAME, HITCH AND FALLING OBJECT/

SECTION 6 - ENGINE ................................................................................................................................ 6-1.

SECTION 7 - ELECTRICAL SYSTEM ....................................................................................................... 7-1.

SECTION 8 - TRANSMISSION SYSTEM .................................................................................................. 8-1.

SECTION 9 - BRAKE SYSTEM ................................................................................................................. 9-1.

SECTION 10 - STEERING SYSTEM ....................................................................................................... 10-1.

SECTION 11 - VIBRATION SYSTEM ...................................................................................................... 11-1.

SECTION 12 - CONTROL SYSTEMS ..................................................................................................... 12-1.

SECTION 13 - OPTIONAL EQUIPMENT ................................................................................................ 13-1.

SECTION 14 - SPECIAL TOOLS ............................................................................................................ 14-1.

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

OPERATING INSTRUCTIONS ....................................................................................................................... 1-2

MAINTENANCE PROCEDURES ................................................................................................................... 1-4

REPAIR PROCEDURES ................................................................................................................................ 1-4

NAME PLATE / SERIAL NUMBER PLATE ................................................................................................... 1-4

SERIAL NUMBER .......................................................................................................................................... 1-4

FIGURE 1-1. BOMAG MODEL BW124D SINGLE SMOOTH DRUM ROLLER.

FIGURE 1-2. BOMAG MODEL BW124PD SINGLE PAD DRUM ROLLER.

The maintenance schedules and procedures are

CAUTION: Follow ALL the maintenance sched-

Major machine component repair procedures are

CAUTION: For correct machine component repair

NAME PLATE/SERIAL NUMBER PLATE [See Fig-

The combination name plate/serial number plate is

If the plate is lost, or damaged, it must be replaced

SERIAL NUMBER [See Figures 1-4, 1-5 and Table

The serial number indicates the design series, manu-

BW124D KEWANEE SERIAL NUMBER YEAR SHIPPED

TABLE 1-1. MACHINE SERIAL NUMBER DESIGNATIONS.

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

TABLE 2-1. FRAME AND HITCH SPECIFICATIONS ............................................................................ 2-2.

TABLE 2-2. ENGINE SPECIFICATIONS ................................................................................................ 2-2.

TABLE 2-3. ELECTRICAL SPECIFICATIONS ....................................................................................... 2-5.

TABLE 2-4. TRANSMISSION SYSTEM SPECIFICATIONS .................................................................. 2-6.

TABLE 2-5. BRAKE SYSTEM SPECIFICATIONS ................................................................................. 2-8.

TABLE 2-7. DRUM, VIBRATION, AND SCRAPER SPECIFICATIONS ............................................... 2-10.

TABLE 2-8. TIRE SPECIFICATIONS ................................................................................................... 2-12.

TABLE 2-9. CONTROL AND INDICATOR SPECIFICATIONS ............................................................ 2-13.

TABLE 2-10. OPTIONAL EQUIPMENT SPECIFICATIONS................................................................. 2-14.

TABLE 2-11. DIMENSION SPECIFICATIONS ..................................................................................... 2-15.

TABLE 2-12. MACHINE WEIGHT SPECIFICATIONS ......................................................................... 2-17.

TABLE 2-13. PERFORMANCE SPECIFICATIONS ............................................................................. 2-18.

TABLE 2-14. MACHINE SYSTEM CAPACITY SPECIFICATIONS...................................................... 2-18.

TABLE 2-15. COMPONENT WEIGHTS................................................................................................ 2-19.

TABLE 2-16. TORQUE SPECIFICATIONS FOR STANDARD

TABLE 2-17. TORQUE SPECIFICATIONS FOR STANDARD

TABLE 2-18. LUBRICATION OILS, HYDRAULIC OILS AND

TABLE 2-19. ADHESIVE THREAD LOCKING SPECIFICATIONS...................................................... 2-23.

Machine dimensions, weights, and performance specifications are

TABLE 2-1. FRAME AND HITCH SPECIFICATIONS.

ITEM DESIGN DATA