operations, service, and parts manual · thank you for purchasing the lb performance ptc-15b...

Operations, Service, and Parts Manual

Manual No. 1013224-01

LB Performance PTC-15B Pneumatic Roller

This manual applies to Serial Number 136732

and above.

TM

TM

ii

TM

Safety

Information and Specifications

Component Location

Operation

Maintenance

Schematics

Illustrated Parts List (IPL)

1

2

3

4

5

6

7

TM Thumb Index

Safety


Component Location

Operation

Maintenance

Schematics

Illustrated Parts List (IPL)

1

2

3

4

5

6

7

TM

TM

LB Performance PTC-15B Pneumatic Rolleriv

DISCLAIMER AND COPYRIGHT

Disclaimer:All information, illustrations and specifications in this manual are based on the latest information available at the time of publishing. The illustrations used in this manual are intended as representative reference views only. Moreover, because of our continuous product improvement policy, we may modify information, illustrations and/or specifications to explain and/or exemplify a product, service or maintenance improvement. We reserve the right to make any change at any time without notice. VT LeeBoy, Inc., VT LeeBoy, LeeBoy, and Rosco are all the same entity and are used interchangeably.

©2016 VT LeeBoy, Inc.LeeBoy reserves all copyright and other rights in this manual and the manual’s content. No part of this manual may be reproduced or used in any way without the written permission of LeeBoy, except as necessary to operate LeeBoy equipment.

California Proposition 65 WARNINGDiesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Battery posts, terminals and other related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and other reproductive harm. Wash hands after handling.

TM

TM

TABLE OF CONTENTS

LB Performance PTC-15B Pneumatic Roller v

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Machine Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Hot Material Precautions . . . . . . . . . . . . . . . . . . . . . . . 1-7

Hydraulic Systems Precautions . . . . . . . . . . . . . . . . . . . 1-7

Refueling Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Battery Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . 1-8

Parking Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Storage Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . 1-9

Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Safety Decals Care . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Decal Installation (Sticker Type) . . . . . . . . . . . . . . . . . . . 1-11

Decal Installation (Top Protected) . . . . . . . . . . . . . . . . . . 1-11

Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Limited Warranty Policy . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Specification Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Standard Inch Fasteners . . . . . . . . . . . . . . . . . . . . . . . 2-6

Metric Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Determining Proper Torque . . . . . . . . . . . . . . . . . . . . . 2-8

TM


Introduction

vi

Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Operator’s Control Console . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Parking Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Receiving the Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Preliminary Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Operator Platform Adjustment . . . . . . . . . . . . . . . . . . . . 4-5

Beacon Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Break-In Procedures. . . . . . . . . . . . . . . . . . . . . . . . . 4-5

PV480® POWERVIEW Display . . . . . . . . . . . . . . . . . . . . . . . 4-6

Soft Keys (Buttons) . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Status Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

System Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

User Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Pre-Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Engine Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Engine Warm-Up . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Cold Weather Engine Warm-Up . . . . . . . . . . . . . . . . . . . 4-14

Directional Control . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Speed Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Parking The Machine . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Water Spray System . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Tire Scrapers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Coco Mats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Ballast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Principles of Compaction . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Rolling Techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Rolling Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

TM


Introduction

vii

Rolling Thick Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Rolling Thin Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Compaction Of Base Materials . . . . . . . . . . . . . . . . . . . . 4-20

Parking the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Towing And Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Emergency Towing . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Machine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Preparing Machine for Maintenance . . . . . . . . . . . . . . . . . 5-4

Neutral Start System . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Every 10 Hours or Daily Routine Maintenance . . . . . . . . . . . . 5-5

50-Hour or Weekly Routine Maintenance . . . . . . . . . . . . . . 5-5

100-Hour or Monthly Routine Maintenance . . . . . . . . . . . . . . 5-5

250-Hour or Quarterly Routine Maintenance . . . . . . . . . . . . . 5-5

500-Hour or Semi-Annual Routine Maintenance . . . . . . . . . . . 5-6

1000-Hour or Annual Routine Maintenance . . . . . . . . . . . . . 5-6

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Checking the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Changing the Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . 5-6

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Changing Engine Fuel Filter . . . . . . . . . . . . . . . . . . . . . 5-7

Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . 5-8

Cleaning And Checking Fuel Filler Cap . . . . . . . . . . . . . . . . 5-8

Air Cleaner System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Radiator and Coolant System. . . . . . . . . . . . . . . . . . . . . . . . 5-9

Draining and Flushing Coolant System . . . . . . . . . . . . . . . . 5-9

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Hydraulic Oil Requirements . . . . . . . . . . . . . . . . . . . . . 5-12

Hydraulic System Checks . . . . . . . . . . . . . . . . . . . . . . 5-12

Checking Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . 5-12

TM


Introduction

viii

Introduction

Checking And Cleaning Hydraulic Reservoir Filler Cap . . . . . . . . 5-13

Changing Hydraulic Filters . . . . . . . . . . . . . . . . . . . . . . 5-13

Draining, Flushing, And Filling Hydraulic Oil Reservoir . . . . . . . . 5-13

Pumps And Motors. . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Adjusting Priority Relief Valve . . . . . . . . . . . . . . . . . . . . 5-14

Water Spray System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Adjusting Spray Pattern . . . . . . . . . . . . . . . . . . . . . . . 5-14

Cleaning Water Spray Nozzles . . . . . . . . . . . . . . . . . . . . 5-15

Water Pump Replacement . . . . . . . . . . . . . . . . . . . . . . 5-16

Scrapers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Coco Mats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Tires and Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Changing The Tires . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Axles And Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Roll Over Protective Structure (ROPS) . . . . . . . . . . . . . . . . . . . 5-17

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Preparing For Long Term Storage . . . . . . . . . . . . . . . . . . 5-18

Periodic Maintenance During Storage . . . . . . . . . . . . . . . . 5-18

Removing The Machine From Storage . . . . . . . . . . . . . . . . 5-18

Weldment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19


Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

PV480 Diagnostic Trouble Code (DTC) Chart. . . . . . . . . . . . . . . . 5-31

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Electrical Schematic (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . 6-3


Main Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Joystick Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Joystick Interface harness . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Work Lights and Turn Signal harness . . . . . . . . . . . . . . . . . . . . 6-13

Engine Harness (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Engine Harness (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Engine Remote Panel Assembly . . . . . . . . . . . . . . . . . . . . . . 6-19

Fuse Block Harness (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

Fuse Block Harness (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . 6-23

Instrument Panel Assembly (1 of 2) . . . . . . . . . . . . . . . . . . . . . 6-25

TM


Introduction

ix


Back-Up Alarm Harness . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

Water Pump Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

Ground Jumper Harness . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

Hydraulic Schematic (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . 6-35


Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Yoke Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Wheel Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Scraper Blade Group . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

Coco Mat Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Covers and Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Water System (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

Water System (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

Cummins Engine (1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28



Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

Electrical Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

Control Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

Relay Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42

Hydraulic Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44

Miscellaneous Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46

11-Wheel Assembly Option (1 of 2) . . . . . . . . . . . . . . . . . . . . . 7-48


Traction Control Option . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52

Heat Shield Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54

Alphabetical Parts Index (API) . . . . . . . . . . . . . . . . . . . . . . . 7-56

TM


Introduction

x

NOTES

TM


Introduction

xi

INTRODUCTION

Thank you for purchasing the LB Performance PTC-15B Pneumatic Roller. We wish you many years of safe and efficient operation of your roller.

READ THIS MANUAL PRIOR TO OPERATING the machine. It is an important part of the roller and should be kept with the machine at all times in the dedicated storage container provided. Even though you may be familiar with similar equipment, you MUST read and understand this manual before operating this machine to avoid injury and help prevent damage to the machine. If this manual becomes lost or damaged, contact your authorized LB Performance dealer immediately to order a replacement (see Contact Information in Section 2).

This manual is intended as a guide for the safe and efficient use of the roller, including procedures for proper operation and maintenance. This manual contains information that was available at the time of printing and is subject to change without notice.

Use this manual with all supplemental books, engine and transmission manuals, and parts books. Related service bulletins should be reviewed to provide information regarding some of the recent changes.

If any questions arise concerning this publication or others, contact your authorized LB Performance dealer for the latest available information.

NOTE: This manual is accompanied by an engine instruction manual provided by the engine’s manufacturer. Please follow the operation and maintenance instructions as specified in both this manual, engine manual and any other manuals provided with your product.

TM


Introduction

xii

NOTES

TM

TM

Page

Section 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Machine Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Hot Material Precautions . . . . . . . . . . . . . . . . . . . . . . . 1-7

Hydraulic Systems Precautions . . . . . . . . . . . . . . . . . . . 1-7

Refueling Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Battery Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . 1-8

Parking Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Storage Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . 1-9

Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Safety Decals Care . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Decal Installation (Sticker Type) . . . . . . . . . . . . . . . . . . . 1-11

Decal Installation (Top Protected) . . . . . . . . . . . . . . . . . . 1-11

LB Performance PTC-15B Pneumatic Roller 1-1

SAFETY

Section 1

TM

NOTES

Safety

LB Performance PTC-15B Pneumatic Roller1-2

TM

This manual provides important information to familiarize you with safe operating and maintenance procedures. Even though you may be familiar with similar equipment, you MUST read and understand this manual before operating the roller and follow its instructions when operating the machine.

Safety is everyone’s business and our top concern. Knowing the guidelines covered in this section will help ensure your safety, the safety of those around you, as well as proper roller operation.

Keep safety labels in good condition. If safety labels become missing or damaged, replace them with new matching labels. Replacement safety labels are available from your authorized LB Performance dealer (see Safety Labels on Page 1-10).

You can find more information about occupational health and safety in the paving industry on the internet. A few resources are listed below:

www.osha.gov

cdc.gov

www.asphaltpavement.org

www.safety.fhwa.dot.gov/

LOOK FOR THESE SYMBOLS THROUGHOUT THIS MANUAL. THESE ITEMS ARE EXTREMELY

IMPORTANT FOR THE SAFETY OF YOU AND YOUR COWORKERS. READ AND UNDERSTAND

THOROUGHLY. HEED THE WARNINGS AND FOLLOW THE INSTRUCTIONS.

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Indicates a situation which can cause damage to the equipment, personal property and/or the environment, or cause the machine to operate improperly.

NOTE: Indicates a procedure, practice or condition that should be followed in order for the machine or component to function in the manner intended.

1

Safety


TM

11

SAFETY PRECAUTIONS

The safety messages that follow have CAUTION level hazards.

Pre-Operation Hazard

Read and understand this Operation Manual before operating or servicing the engine to

ensure that safe operating practices and maintenance procedures are followed.

• Never permit anyone to service or operate the machine without proper training.

• Safety signs and labels are additional reminders for safe operating and maintenance techniques.

• Contact your authorized LB Performance dealer for additional training.

• Make sure you are aware of all laws and regulations that are in effect for the location in which the roller is operated.

• Make sure you have all necessary licenses to operate the roller.

The safety messages that follow have DANGER level hazards.

Power Lines Hazard

If your machine comes into contact with electric power lines, observe the following:

• Stay in the operators seat.

• Warn other workers to stay away and do not touch any control or any part of the machine.

• If contact can be broken, drive the machine away from the danger zone.

• If contact cannot be broken, stay in the operators seat until told that power is off.

• Failure to observe these directions could result in electrocution or death.

Electrocution Hazard

Disconnect the battery before welding anywhere on the machine.

Suffocation Hazard

Carbon monoxide poisoning is a serious condition that occurs as a result of improper ventilation.

• Never operate the internal combustion engine on this machine in an enclosed area with poor ventilation. Ensure proper ventillation to reduce risk of carbon monoxide poisoning or death.

Exhaust Hazard

All internal combustion engines create carbon monoxide gas during operation and special precautions are required to avoid carbon monoxide poisoning:

• Never block windows, vents or other means of ventilation.

• Always ensure that all connections are tightened to specifications after repair is made to the exhaust system.

The safety messages that follow have WARNING level hazards.

Crush Hazard

Keep bystanders away from work area before and during operation.

Modification Hazard

Never modify the machine without the written consent of LB Performance. Any modification can affect the safe operation of the roller and may cause personal injury or death.

Safety


TM

Exposure Hazard

Operators must be aware of their work environment and the equipment needed to work safely.

• Always wear personal protective equipment, including appropriate clothing, gloves, work shoes, and protection for eyes and ears as required by the task at hand.

Explosion Hazard

While the engine is running or the battery is charging, hydrogen gas is being produced and can be easily ignited. Keep the area around the battery well-ventilated and keep sparks, open flame, and any other form of ignition out of the area.

• Always disconnect the negative (-) battery cable before servicing the machine.

• Do not start the engine by shorting the starter circuit or any other starting method not stated in this manual. Only use the starting procedure as described in this manual to start the engine.

• Never charge a frozen battery. Always slowly warm the battery to room temperature before charging.

Fire and Explosion Hazard

• Diesel fuel is flammable and explosive under certain conditions.

• Never use a shop rag to catch fuel.

• Wipe up all spills immediately.

• Never refuel with the engine running.

• Store any containers containing fuel in a well-ventilated area, away from any combustibles or sources of ignition.

Fire Hazard

When operating machinery there is a risk for fire. Always have appropriate safety equipment available.

• Keep a charged fire extinguisher within reach when working in an environment where a fire may occur.

• Have all fire extinguishers checked periodically for proper operation and/or readiness.

• Always read and follow safety-related precautions found on containers of hazardous substances like parts cleaners, primers, sealants and sealant removers.

• Undersized wiring systems can cause electrical fires.

Entanglement/Sever Hazard

Verify there are no people, obstacles or other equipment near the machine before starting the engine. Sound the horn as a warning before starting the engine.

If the engine must be serviced while it is operating, remove all jewelry and tie back long hair before operating or servicing the machine.

• Keep hands, other body parts, and clothing away from moving/rotating parts.

• Always stop the engine before beginning service. Before maintenance, remove negative battery cable from battery post to ensure vehicle is not operated during maintenance.

• Verify that all guards and covers are properly attached before starting the engine. Do not start the engine if any guards or covers are not properly installed on the roller.

• If you must run the engine during maintenance procedures, make sure you have a helper to keep bystanders clear of the roller and make observations of moving parts as requested by the operator.

Alcohol and Drug Hazard

Never operate the machine while under the influence of alcohol, drugs, or when ill.

1

Safety


TM

11

Piercing Hazard

High-pressure hydraulic fluid or fuel can penetrate your skin and result in serious injury. Avoid skin contact with high-pressure hydraulic fluid or diesel fuel spray caused by a hydraulic or fuel system leak such as a

broken hydraulic hose or fuel injection line.

• If you are exposed to high-pressure hydraulic fluid or fuel spray, obtain prompt medical treatment.

• Never check for a hydraulic fluid or fuel leak with your hands. Always use a piece of wood or cardboard. Contact your authorized LB Performance dealer to repair the damaged parts.

Flying Object Hazard

Always wear eye protection when cleaning the machine with compressed air or high-pressure water.

Dust, flying debris, compressed air, pressurized water or steam may cause eye injury.

Coolant Hazard

Coolant must be handled properly to ensure operator safety.

• Wear eye protection and rubber gloves when handling engine coolant.

• If contact with the eyes occurs, flush eyes with clean water for 15 minutes.

• If contact with skin occurs, wash immediately with soap and clean water.

Burn Hazard

Some of the machine’s surfaces become very hot during operation and shortly after shutdown.

• Keep hands and other body parts away from hot machine surfaces.

• Handle hot components with heat-resistant gloves.

The safety messages that follow have CAUTION level hazards.

Poor Lighting Hazard

The work area must be well lit to ensure safe and proper operation.

• Ensure that the work area is adequately illuminated.

• Always install wire cages on portable safety lights.

Tool Hazard

Always use tools appropriate for the task at hand and use the correct size tool for loosening or tightening LB Performance machine parts.

Safety


TM

The safety messages that follow have NOTICE level hazards.

Any part that is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit must be replaced.

Always tighten components to the specified torque. Loose parts can cause damage to the machine or cause it to operate improperly.

Only use replacement parts approved by LB Performance. Other replacement parts may affect warranty coverage.

Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil, diesel fuel, and engine coolant. Consult the local authorities or reclamation facility.

Dispose of hazardous materials in accordance with all applicable laws and regulations. Never dispose of hazardous materials by dumping them into a sewer, on the ground, or into groundwater or waterways.

Clean all accumulated dirt and debris away from the body of the roller and its components before you inspect the roller or perform preventive maintenance procedures or repairs. Operating a roller with accumulated dirt and debris will cause premature wear of roller components. Accumulated dirt and debris also hinders effective roller inspection.

Retrieve any tools or parts that may have dropped inside of the roller to avoid improper roller operation.

If any alert indicator illuminates during roller operation, stop the engine immediately. Determine the cause and repair the problem before continuing to operate the roller.

MACHINE PRECAUTIONS

Hot Material Precautions• Wear protective gear for face, hands, feet, and body

when operating the roller.

• Allow machine to cool before repairing or maintaining working components.

• DO NOT remove radiator cap, drain plugs, service grease fittings, or pressure taps while engine is hot. Add coolant to the radiator and perform other services only when the engine is stopped and fully cooled.

Hydraulic Systems Precautions• Ensure all components are in good working condition.

Replace any worn, cut, abraded, flattened or crimped hoses and metal lines.

• DO NOT attempt makeshift repairs using tape, clamps or cements. The hydraulic system operates under extremely high pressure and such repairs could cause serious injury.

• Wear proper hand and eye protection when checking for a high pressure leak. Use a piece of wood or cardboard as a back stop to isolate and identify leaks.

Hydraulic oil under pressure can cause serious personal injury. Check for oil leaks with a piece of cardboard. DO NOT expose hands to possible high-pressure oil. Turn off engine before attempting to tighten oil lines and fittings.

• Escaping pressurized hydraulic fluid has force sufficient to penetrate the skin, which could cause serious personal injury. Ensure all pressure is relieved before disconnecting line, hoses or valves.

• If injury from concentrated high pressure steam or hydraulic fluid occurs, seek medical attention immediately. Injuries resulting from hydraulic fluid penetrating the skin’s surface can result in serious infections or toxic reactions.

1

Safety


TM

11

Refueling Precautions• Do NOT overfill the fuel tank as overflow creates a fire

hazard when spilled on hot components.

• DO NOT smoke when refueling and never refuel when the engine is running. Fuel is highly flammable and should be handled with care. Death or serious injury can occur due to explosion and/or fire.

• DO NOT fill fuel tank to capacity. Allow room for expansion to reduce the risk of fuel expanding and spilling from the tank.

• Tighten fuel cap securely. Should fuel cap be lost, replace it with an original manufacturer’s approved cap. Pressurization of the tank may result from use of non-approved cap.

• Prevent fires by keeping the machine clean of accumulated debris, grease, and spilled fuel.

• Use ultra-low sulfur diesel fuel (ULSD) only.

Battery Precautions• Keep all sparks and flames away from batteries, as

gas given off by electrolytes is explosive.

• Acid propelled by an explosion can cause blindness if it comes in contact with eyes. Always wear safety glasses when working near batteries.

• If you come in contact with battery electrolyte solution, wash off immediately. Chemicals can cause burns.

• Always disconnect the battery ground cable before working on the electrical system to avoid injury from spark or short circuit. Electrical shock and burns can occur.

• To avoid electrolyte loss, DO NOT tip batteries more than 45 degrees.

Starting and Stopping Precautions• Check all around the machine to make sure there are

no people in its path machine before starting. DO NOT start until area is clear. Death or serious injury can occur to bystanders from being crushed under a moving machine.

• Check brakes, steering and other control devices before starting.

DO NOT operate the engine in an enclosed area without proper ventillation. Exhaust gasses are odorless and deadly.

Parking Precautions• Park roller on level ground whenever possible, set

steering levers in neutral and lock. Apply the parking brake (if this optional comonent is installed). Park the machine with wheels securely blocked on grades.

• Before leaving operator’s station:

1. Place the truck in neutral and engage the parking brake.

2. Turn off all accessories.

3. Shut off engine.

• Remove ignition key when leaving roller parked or unattended.

Safety


TM

Operating Precautions• Always comply with local regulations regarding

moving equipment on public roads and highways.

• Know and use the hand signals required for a particular job. Know who has the responsibility for signaling.

• Make sure that all lights and reflectors comply with state and local regulations. Make sure that they are clean, in good working order, and can be seen clearly by all traffic.

• DO NOT ride on attachments.

• Check all gauges and warning instruments for proper operation. If malfunctions are found, shut down the machine and report the problem for resolution. If the failure causes loss of steering control, loss of brake control, or loss of engine power, stop roller motion as quickly as possible.

• Drive the machine with care. Make sure speed is compatible with conditions. Use caution on rough ground, slopes, and while turning.

• Be alert for hazards and obstructions such as ditches, trees, cliffs, overhead power lines, and areas where there is danger of a slide.

• Be aware of and understand the job site traffic flow patterns.

• Obey flagmen, road signs, and signals.

• Watch for bystanders. Never allow anyone to be under the machine during operation. Never allow anyone to reach into the machine during use.

• Operator must understand which circumstances require using signals when working in traffic zones. Use tail lights, slow moving vehicle signs, and warning beacon as needed when traveling on public roads.

Storage Precautions• Store machine in an area away from human activity.

• Do not permit children to play on or around the stored machine. Serious injury or death can occur from improper/unauthorized use of the machine.

• Make sure the unit is stored on a surface that is firm, level, and free of debris.

• Store the machine inside a building or cover securely with a weatherproof tarpaulin.

Maintenance Precautions• DO NOT attempt repairs unless trained to do so.

Refer to manuals and experienced repair personnel for help.

• Before working on the machine, securely block the machine and any components that may fall. Block any working components to prevent unexpected movement while repairs are being made.

• Always wear safety glasses and other required safety equipment when servicing or making repairs.

• Disconnect battery before working on the electrical system.

• Avoid lubrication or mechanical adjustments while the roller is in motion or while engine is operating.

• If lubrication or mechanical adjustment is necessary, use extreme caution.

• Never make repairs on pressurized components such as fluid lines, the fuel system, or mechanical items until the pressure has been relieved.

• When servicing or replacing hardened pins, use a brass drift or other suitable material between the hammer and pin.

• Keep brake and steering systems in good operating condition.

1

Safety


TM

11

SAFETY DECALS

LocationIf the machine has been repainted, it is extremely important that all decals referring to CAUTION, WARNING and DANGER be replaced in their proper locations. The illustration on this page will aid you in determining the proper locations. A description is provided below for each safety label.

For additional instructions, contact your dealer.

NOTE: It is the responsibility of the owner and operator to make sure that all safety labels are readable and located on the machine as designated by LB Performance .

Figure 1-1. Safety Decal Locations

Safety


TM

Safety Decals Care1. Keep safety decals and signs clean and legible at all

times.

2. Become familiar with the content and the position of each safety decal. Decals include important information.

3. Replace decals and signs that are missing or become impossible to read.

4. When replacing parts that display a safety decal, ensure that the new part is fitted with a decal as well.

5. Obtain replacement safety decals or signs from your authorized LB Performance dealer.

Decal Installation (Sticker Type)1. Be sure that the installation area is clean and dry.

Use hot, soapy water to clean the surface where the decal will be applied.

2. Thoroughly dry the surface.

3. Measure and fit decal before removing the paper backing.

4. For decals with no top protection paper, remove the smallest split-backed paper.

5. Align decal over the specified area and carefully press exposed portion into place.

6. Slowly remove the remaining backing and carefully smooth the remaining portion of the decal into place.

7. Small air pockets can be pierced with a pin and smoothed using a piece of the decal backing.

Decal Installation (Top Protected) 1. If the decal has a protective top paper, use hot

soapy water on the surface where the decal will be applied. Leave wet.

2. Determine the proper location, remove protective back paper and soak decal in clean soapy water before application. This will help to alleviate air bubbles in the applied decal.

3. Smooth decal into place with a squeegee and check for air bubbles.

4. Small air pockets can be pierced with a pin and smoothed out using a piece of the decal backing.

5. When decal is completely smoothed, carefully remove top paper.

1

Safety


TM

11

NOTES

Safety


TM

Page

Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Limited Warranty Policy . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Specification Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Standard Inch Fasteners . . . . . . . . . . . . . . . . . . . . . . . 2-6

Metric Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Determining Proper Torque . . . . . . . . . . . . . . . . . . . . . 2-8


INFORMATION AND SPECIFICATIONS

Section 2

TM

LIMITED WARRANTY POLICY

Warranty

1. Subject to the limitations, exclusions, and claims procedures set forth herein, LB Performance warrants [to the first retail purchaser] that this product will be free from substantial] defects in materials and workmanship during the warranty period.

2. If a defect in material or workmanship is found, your authorized LB Performance Dealer is to be notified during the warranty period. LB Performance and its authorized Dealer will repair or replace any part or component of the unit or part that fails to conform to the warranty during the warranty period.

3. The warranty period will begin on the initial start-up, training and delivery of the unit by the Dealer to the customer, and will expire after twelve (12) months following the delivery of the machine to the first retail purchaser.

4. Manufacturers’ Warranties: Engines are warranted by their manufacturers and may have warranty coverage that differs from that of LB Performance. LB Performance does not warrant any engine.

5. Replacement parts furnished by LB Performance are covered for the remainder of the warranty period applicable to the unit or component in which such parts are installed.

6. LB Performance has the right to repair any component or part before replacing it with a new one.

7. All new replacement parts purchased by a LB Performance Dealer will carry a six-month warranty.

8. This Limited Warranty is governed by the laws of the State of North Carolina.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESSED, STATUTORY AND IMPLIED WARRANTIES APPLICABLE TO UNITS, ENGINES, OR PARTS INCLUDING WITHOUT LIMITATION, ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR USE

OR PURPOSE OR AGAINST INFRINGEMENT.

Items Not Covered

LB Performance is not responsible for the following:

1. All used units or used parts of any kind.

2. Repairs due to normal wear and tear or brought about by abuse or lack of maintenance of the machine.

3. Attachments not manufactured or installed by LB Performance.

4. Liability for incidental or consequential damages of any type including, but not limited to, lost profits or expenses of acquiring replacement equipment.

5. Miscellaneous charges.

Limitations

LB Performance has no obligation for:

1. Any defects caused by misuse, misapplication, negligence, accident or failure to maintain or use in accordance with the most current operating instructions.

2. Unauthorized alterations.

3. Defects or failures caused by any replacement parts or attachments not manufactured by or approved by LB Performance.

4. Failure to conduct normal maintenance and operating service including, without limitation, providing lubricants, coolant, fuel, tune-ups, inspections or adjustments.

5. Unreasonable delay, as established by LB Performance, in making the applicable units or parts available upon notification of a service notice ordered by same.

6. Warranty Responsibility: The warranty responsibility on all engines rests with the manufacturer of the engine.

7. Warranty and Parts Support: LB Performance may have support agreements with some engine manufacturers for warranty and parts support. However, LB Performance does not warrant the engine.

8. This Limited Warranty sets forth your sole remedy in connection with the sale or use of the LB Performance product covered by this Limited Warranty.

9. This Limited Warranty extends only to the first retail purchaser, and is not transferable.

10. In the event any portion of this Limited Warranty shall be determined to be invalid under any applicable law, such provision shall be deemed null and void and the remainder of the Limited Warranty shall continue in full force and effect.

Other Limitations IN NO EVENT, WHETHER AS A RESULT OF BREACH OF CONTRACT OR WARRANTY OR ALLEGED NEGLIGENCE OR LIABILITY WITHOUT FAULT, SHALL LB PERFORMANCE BE LIABLE FOR SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING, WITHOUT LIMITATION, LOSS OF PROFIT OR REVENUE, COST OF CAPITAL, COST OF SUBSTITUTED EQUIPMENT, FACILITIES OR SERVICES, DOWNTIME COSTS, LABOR COSTS OR CLAIMS OF CUSTOMERS, PURCHASERS OR LESSEES FOR SUCH DAMAGES. IN NO EVENT WILL WARRANTY COMPENSATION, OR OTHER DAMAGES AVAILABLE FROM LB PERFORMANCE, EXCEED THE PURCHASE PRICE OF THE PRODUCT.



TM

CONTACT INFORMATIONFor information regarding parts and repairs about your LB Performance product, contact your authorized LB Performance dealer. If your dealer is unable to resolve the problem, contact LB Performance directly.

Record dealer information in the space provided. For additional information about LeeBoy, please visit: www.lbperformancepaving.com.

Sales Representative:

Dealership Name:

Dealership Address:

Dealership Phone:

Record of OwnershipPlease complete the following information for use if you need to contact LB Performance for service, parts or literature.

Machine Model Number:

Product Serial Number:

Date of Purchase:

NameplateThe nameplate contains the model and serial numbers used to identify the machine and its components for parts or service information. Refer to the Engine Operator’s Manual for the location of the engine nameplate.

Figure 2-1. Nameplate Location

2



TM

22

SPECIFICATION CHARTSThe specifications provided in this section include screed weights, dimensions, performance, and torque values for both metric and standard inch fastener.

Replace original equipment only with components approved by LB Performance.

Table 2-1. Machine Dimensions

ITEM SPECIFICATION

Overall Weight (Static) 13,325 lbs. (6,044 kg)

Overall Weight (Loaded) 30,500 lbs. (13.835 kg)

Overall Length 14 ft 00 in (4.27 m)

Overall Height (With ROPS) 9 ft 2 in (2.80 m)

Overall Height (Without ROPS) 7 ft 6 in (2.29 m)

Overall Width 5 ft 8 in (1.73 m)

Rolling Width (9 Wheel) 5 ft 8 in (1.73 m)

Rolling Width (11 Wheel) 6 ft 11 in (1.83 m)

Wheelbase 8’4” (2.54 m)

Turning Radius (Inside - 9 Wheel) 8 ft 8 in (2.64 m)

Turning Radius (inside - 11 Wheel) 8 ft 5 in (2.44 m)

Ground Clearance 11 in (28 cm)

Frame Articulation + / - 39°

Frame Oscillation + / - 10°

tire Articulation + / - 4°



TM

Table 2-2. Engine Specifications

ITEM SPECIFICATION

Manufacturer and Model Cummins QSF2.8 T4

Engine Type Vertical 4-Cycle Liquid-Cooled Charged Air Diesel

Performance 74 HP (55kW) @ 2500 RPM

Torque 221 lb/ft (300 N-m) @ 1600 RPM

Combustion System Direct Injection (IDI)

Intake System Turbocharged Charged Air Cooled and EGR

Bore, Stroke and Displacement 3.7 in (94 mm); 3.94 in (100 mm); 171 cu in (2.8 L)

Table 2-3. Electrical Specifications

ITEM SPECIFICATION

Batteries One - 12 Vdc Maintenance Free

Cold Cranking Amps (CCA) 950 CCA

System Voltage 12 Vdc, 120 amp

Table 2-4. Hydraulic System

ITEM SPECIFICATION

Main Pump 4.56 cu in (75 cc); 5511 PSI; (Relief)

Steering Pump 1.16 cu in (19 cc); 7 GPM (Flow Divider)

Hydraulic Filters Remote Pressure; 200 Mesh; 15 GPM

Oil Cooler Radiator/Oil Cooler, Engine Fan Cooling

Ground Speed 0 - 14.5 mph (0 - 23.3 kph)

Table 2-5. Fuel and Lubricants

ITEM SPECIFICATION

Engine Oil 9.6 qt (9.08 L) with filter; 15W-40

Hydraulic Oil 14 gal (53 L); 5W20 AWAT OIL

Coolant 15.25 qt (14..43 L); Ethylene/Glycol or Propylene Glycol

Fuel 35 gal (132.49 L); Ultra low sulfur Diesel

Grease Shell Avania EP Grease or Equivalent

Water 150 gal (567.81 L)

Table 2-6. Machine-Specific Specifications

ITEM SPECIFICATION

Calculated Maximum Gradeability 20.5%

Tires7.5 x 15 Bias, 14 Ply, Smooth. (5 front & 4 rear) See tire pressure chart in Section 4.

2



TM

22

TORQUE SPECIFICATIONSThe following tables list torque values for standard hardware. This is a guide for average application involving typical stresses and machined surfaces. Values are based upon physical limitations of clean, plated and lubricated hardware. Under more extreme

conditions, individual torque value should be followed. Conversion formulas are provided below:

Conversion Formula

ft-lb to N•m [ft-lb]*1.3558 = [N•m)

ft-lb to in-lb [ft-lb]*12 = [in-lb]

N•m to in-lb [N•m]*8.8508 = [in-lb]

Standard Inch FastenersTable 2-7. Torque Specifications For Standard Inch Fasteners

SIZE THREAD

CAPSCREWS: SAE GRADE 5 CAPSCREWS: SAE GRADE 8

TORQUE (ft lb) TORQUE N•m TORQUE (ft lb) TORQUE N•m

Dry Lubed Dry Lubed Dry Lubed Dry Lubed

1/4 20 UNC 8 6 11 8 12 9 16 12

28 UNF 10 7 14 9 14 10 19 14

5/16 18 UNC 17 13 23 18 25 18 34 24

24 UNF 19 15 26 20 27 20 37 27

3/8 16 UNC 31 23 42 31 44 33 60 45

24 UNF 35 26 47 35 49 37 66 50

7/16 14 UNC 49 37 66 50 70 52 95 71

20 UNF 55 41 75 56 78 58 106 79

1/2 13 UNC 75 57 102 77 106 80 144 108

20 UNF 85 64 115 87 120 90 163 122

9/16 12 UNC 109 82 148 111 154 115 209 156

18 UNF 121 91 164 123 171 128 232 174

5/8 11 UNC 150 113 203 153 212 159 287 216

18 UNF 170 127 230 172 240 180 325 244

3/4 10 UNC 267 200 362 271 376 282 510 382

16 UNF 297 223 403 302 420 315 569 427

7/8 9 UNC 429 322 582 437 606 455 822 617

14 UNF 474 355 643 481 669 502 907 681

1 8 UNC 644 483 873 655 909 681 1232 923

14 UNF 722 542 979 735 1020 765 1383 1037

1-1/4 7 UNC 1121 840 1520 1139 1817 1363 2464 1848

12 UNF 1241 930 1683 1261 2012 1509 2728 2046

1-1/2 6 UNC 1950 1462 2644 1982 3162 2371 4287 3215

12 UNF 2194 1645 2975 2230 3557 2668 4823 3617



TM

Metric Fasteners

Table 2-8. Torque Specifications for Metric Fasteners

NOMINAL SIZE AND PITCH

CLASS 8.8 [GRADE 5 EQUIVALENT] CLASS 10.9 [GRADE 8 EQUIVALENT]

TORQUE (ft lb) TORQUE N•m TORQUE (ft lb) TORQUE N•m

Dry Lubed Dry Lubed Dry Lubed Dry Lubed

M4 x 0.7 2 2 3 2 3 2 4 3

M5 x 0.8 5 3 7 4 7 5 9 7

M6 x 1 8 6 11 8 11 8 15 11

M8 x 1.25 19 14 26 19 27 20 37 27

M10 x 1.5 37 28 50 38 53 40 72 54

M12 x 1.75 65 49 88 66 93 70 126 95

M14 x 2 104 78 141 106 148 111 201 150

M16 x 2 161 121 218 164 230 173 312 235

M18 x 2.5 222 167 301 226 318 239 431 324

M20 x 2.5 314 236 426 320 449 337 609 457

M22 x 2.5 428 321 580 435 613 460 831 624

M24 x 3 543 407 736 552 777 582 1053 789

M27 x 3 796 597 1079 809 1139 854 1544 1158

M30 x 3.5 1079 809 1463 1097 1544 1158 2093 1570

Hydraulic Fittings

Tightening Flare-Type Tube Fittings

1. Check the flare and flare seat for defects that might cause leakage.

2. Align tube with fitting before tightening.

3. Lubricate connection.

4. Hand tighten swivel nut until snug.

5. To prevent twisting the tube(s), use two wrenches. Place one wrench on the connector body and tighten the swivel nut with the second to the torque shown in Table 2-9.

NOTE: The torque values shown are based upon lubricated connections.

Table 2-9. Torque Specifications for Steel Flare Type Tube Fittings

TUBE SIZE OUTER

DIAMETER

NUT SIZE ACROSS

FLATSTORQUE VALUE

(IN) (IN) (LB FT) (N•m)

3/16 7/16 8 11

1/4 9/16 12 16

5/16 5/8 16 22

3/8 11/16 23 31

1/2 7/8 38 52

5/8 1 54 73

3/4 1 1/4 75 102

7/8 1 3/8 83 113

2



TM

22

Determining Proper TorqueThe only reliable method of creating a consistently leak-free and long-lasting connection is to ensure the coupling is brought to the proper torque. Using a torque wrench with crowfoot is the best method, but the flats method can be used if a torque wrench is not available.

The most straightforward method of determining the correct torque setting is to multiply the desired torque by the length of the wrench from the center of the handle to the center of the drive (L); divided by the length of the wrench from the center of the handle to the crowfoot center (LA) as shown below:

LAL

Figure 2-2. Torque Wrench - Crowfoot

The minimum torque values are adequate for sealing most applications. Maximum torque values should never be exceeded.

There are several methods of determining the correct setting on the torque wrench when using a crowfoot. All of the methods involve making the setting proportional to the effective change in length of the wrench multiplied by the desired final torque. The equations and illustration below describe proper measurements. (Use LEGEND below).

Equations

• Torque setting if the crowfoot is placed in line with respect to the wrench:

TS = TD * L / LA

OR

TS = TD * L / (L+E)

• Torque setting if the crowfoot is placed at 90° with respect to the wrench

TS = TD * L / LH

OR

TS = TD * L / √(L2 + E2)

• To estimate the crowfoot size (E)

E = Drive Size * 0.5 + Distance between Drive and Open End + Wrench Size * 0.5774

L

E

LA

LH

Figure 2-3. Measurements Needed

LEGENDL = Distance from center of torque wrench handle to the center of socket drive

E = Distance from center of socket drive to the center of crowfoot

LA = Distance from center of torque wrench handle to the center of crowfoot

LH = Distance from center of torque wrench handle to the center of crowfoot, when mounted at 90°

TD = Desired torque at the fitting

TS = Torque setting indicated on wrench



TM

Coupling Installation

Use the following steps for proper coupling installation:

1. Determine the correct torque value for your coupling.

NOTE: Only use the torque values specified from the manufacturer. DO NOT use SAE torque recommendations.

2. Ensure the seal face and threads are clean and in good condition. O-Rings should be lubricated with light oil, but threads should be completely dry unless making pipe thread connections (interference seal).

NOTE: Attach the male end of the hose onto the equipment first since it may be necessary to rotate the entire hose assembly to tighten the male threads. Then route the hose into position while avoiding twisting the hose.

3. Tighten the connection (by hand), bringing the seal face into contact and rotating the nut until it stops.

4. Mark a line across the coupling nut and backup hex for the flats method verification of coupling torque.

5. Apply a wrench to the backup hex to prevent the coupling and hose from moving while tightening the nut with a torque wrench.

Failure to retain the backup hex during installation will also result in additional clamp load force that could cause damage to the seal face.

NOTE: The coupling nut must be in motion for an accurate torque reading. If the nut is stopped before final torque value is achieved, it must be loosened and retightened until the torque is attained while the nut is in motion.

If a torque wrench cannot fit into the coupling area or if it is unavailable, the flats method may be used to ensure that the coupling is properly tightened, as shown in the following figure:

Example 2 Flats difference

Mark Line on Nut

Figure 2-4. Flats Method Tightening

NOTE: The mark placed on the nut and backup hex after tightening by hand should rotate during final tightening according to the table below. (Figure 2-12) The nut and backup hex can then be marked to indicate if the coupling loosens over time.

Table 2-10. Flats Method Values for Selected Terminations

FLATS METHOD VALUES

Termination Type

Dash Size Flats

JIC -4 1.5 - 1.75

JIC -6 1.0 - 1.5

JIC -8 1.5 - 1.75

JIC -10 1.0 - 1.5

JIC -12 1.0 - 1.5

JIC -16 .75 - 1.0

JIC -20 .75 - 1.0

JIC -24 .75 - 1.0

JIC -32 .75 - 1.0

JIS -4 .5 - 1.5

1. Seal faces must be in contact with the fitting fully tightened by hand before marking flats.

2. The flats method is most accurate for the first assembly cycle. For multiple disassembly and assembly cycles, torque values are more reliable.

3. Tightening two (2) flats or more may damage seal faces.

2



TM

22

Table 2-11. Torque Specifications For US Style Coupling Terminations

JIC, SAE 45°, ORFS, O-RING BOSS, GATES ADAPTERLESS AND MEGASEAL

DASH SIZE

JIC 37°, SAE 45° & Mega-Seal

(Steel)

JIC 37°, SAE 45° & Mega-Seal

(Brass)

Flat Face O-Ring Seal (Steel)

SAE O-Ring Boss (Steel) & Gates

Adapterless ≤ 4000 PSI

SAE O-Ring Boss (Steel) & Gates

Adapterless > 4000 PSI

Min Max Min Max Min Max Min Max Min Max

-3 8 10

-4 10 11 5 6 10 12 14 16 14 16

-5 13 15 7 9 18 20

-6 17 19 12 15 18 20 24 26 24 26

-8 34 38 20 24 32 40 37 44 50 60

-10 50 56 34 40 46 56 50 60 72 80

-12 70 78 53 60 65 80 75 83 125 135

-14 65 80 160 180

-16 94 104 74 82 92 105 111 125 200 220

-20 124 138 75 83 125 140 133 152 210 280

-24 156 173 79 87 150 180 156 184 270 360

-32 219 243 158 175

Table 2-12. Torque Specifications for DIN 24, DIN 60, and Inverted Cone Style Coupling Terminations

DIN 24, DIN 60, AND INVERTED CONE

Size (mm) Torque (lb ft)

Light Series

Tube OD

Heavy Series

Tube ODMin Max

6 7 15

8 15 26

10 8 18 30

12 10 22 33

14 12 26 37

15 14 30 52

16 30 52

18 20 44 74

22 25 59 89

28 30 74 111

38 74 162

35 133 184

42 148 221

Table 2-13. Torque Specifications for 4-Bolt Flange Connections

4-BOLT FLANGES

Dash Size Bolt Size (in) Torque (lb ft)

-8 0.31 17

-12 0.38 26

-16 0.44 43

-20 0.50 65

-24 0.63 130

-32 0.75 220

1. Align faces and tighten bolts (by hand) before applying final torque in a pattern. The seal faces must be parallel with an even bolt tension to seal properly.

2. Torque values apply to bolts that are plated or coated in light engine oil.

3. Before assembly, lubricate O-Ring with light oil (SAE 10W or 20W).



TM

Table 2-15. Torque Specifications for BSP 30° Inverted Cone and JIS Coupling Terminations

Table 2-14. Torque Specifications for NPTF Dry Seal Pipe Threads

NPTF

Dash Size Max Torque (ft-lb)

-2 20

-4 25

-6 35

-8 45

-12 55

-16 65

-20 80

-24 95

-32 120

1. The torque values obtained from tightening pipe threads can vary considerably depending upon thread condition. Adequate sealing can occur at values much lower than the maximum values listed above. Only enough torque to achieve adequate sealing should be used.

2. When using a male tapered pipe thread with a female straight or parallel pipe thread, maximum values are 50% of those listed in the table above.

3. If thread sealant is used, maximum values shown should be decreased by 25%.

BSP 30° INVERTED CONE AND JIS

Dash SizeTorque (ft-lb)

Min Max

-2 7 9

-4 11 18

-6 19 28

-8 30 36

-10 37 44

-12 50 60

-16 79 95

-20 127 152

-24 167 190

-32 262 314

2



TM

22

NOTES



TM

Page

Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Operator’s Control Console . . . . . . . . . . . . . . . . . . . . . . . . 3-4


COMPONENT LOCATION

Section 3

TM

NOTES

Component Location


TM

COMPONENTS OVERVIEWThis section describes the major components for the LB Performance PTC-15B. Become familiar with these components before operating the machine.

The PTC-15B pneumatic roller is a heavy duty asphalt compactor. A single operator can control all compacting functions from the safety and comfort of the operator seat.

EngineThe PTC-15B is equipped with a Cummins 74 HP diesel engine, which is mounted near the rear of the compactor.

A fuel lift pump mounted to the left side of the engine draws diesel fuel from the fuel tank, which is mounted on the engine compartment.

The air cleaner is mounted under the top of the hood, which removes fine particles such as dust, sand, chaff and lint from the air.

The fuel filter removes contaminants from diesel fuel before it flows into the injection pump where it is injected into the engine combustion chamber.

The radiator mounted in front of the engine cools the engine. As coolant flows through the radiator, airflow from the engine-driven fan removes heat.

Refer to the Engine Operator’s Manual accompanying your compactor for additional engine information.

Hydraulic SystemThe hydraulic system provides power and control for all drive and steering functions. The main hydraulic pump produces power to move the rear drive motors. Electric solenoid valves with switches in the control panel control 2 speed and breaks for the rear hydraulic motors. The front pump powers the steering orbital and steering cylinders through a 7 GPM flow divider valve.

The system consists of:

• Two (2) hydraulic pumps with a minimum 10 GPM (gallons per minute) [49.2 LPM (liters per minute)].

• Two (2) solenoid valves.

• Two (2) hydraulic cylinders.

• Two (2) hydraulic motors.

• Electronic controls at operators platform.

3

Component Location


TM

33

OPERATOR’S CONTROL CONSOLE

Figure 3-1. Operator’s Control Panel

Component Location


TM

Table 3-1. Operator’s Control Panel

ITEM NO.

CONTROL NAME FUNCTION

1Direction Control Joystick

Controls Direction and speed of the machines travel. The lever has a built-in neutral lock. Lift the lever to disengage neutral lock.

2 Water Sprayer Switch Controls the water spray nodules.

3 Emergency Stop ButtonThis button breaks power to the ignition switch. Push button to lock, twist button to unlock.

4 Parking Brake SwitchFlip switch up to engage parking brake. Flip switch down to the OFF position to turn off parking brake.

5 12 VDC Outlet This outlet is a standard 12-volt automotive DC outlet.

6 Beacon Light Switch This toggle switch turns the beacon light on top of the canopy OFF and ON.

7 Head Light Switch This toggle switch turns the front lights OFF and ON.

8Wait to Start Light

Light illuminates when engine is preparing for ignition. Do not turn over engine while light is on.

9 Steering Wheel and Horn

This wheel controls the hydraulic cylinders to pivot the machine left and right. The center of the steering wheel contains a horn.

10 Work Light Switch This toggle switch turns the rear lights OFF and ON.

11 Traction Control Switch (11 Wheel Option)

This toggle switch turns differential traction OFF and ON.

12 Ignition Switch

Controls starting, running and shutting down machine. To start machine, insert key and turn key clockwise to the START position.

To shut down machine, turn key counterclockwise to the OFF position and remove key.

132 Speed Switch

This toggle switch toggles the 2 speed solenoid to change the displacement of the rear hydraulic motors.

14 PV480 Display This interactive display controls and displays several functions on the machine.

3

Component Location


TM

33

NOTES

Component Location


TM

Page

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1


Parking Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Receiving the Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Preliminary Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Beacon Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

PV480® POWERVIEW Display . . . . . . . . . . . . . . . . . . . . . . . 4-6

Soft Keys (Buttons) . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Status Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

System Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

User Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Pre-Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Engine Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Engine Warm-Up . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Cold Weather Engine Warm-Up . . . . . . . . . . . . . . . . . . . 4-14

Directional Control . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Speed Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Water Spray System . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Coco Mats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Principles of Compaction . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17


OPERATION

Section 4

TM

Rolling Techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Rolling Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Rolling Thick Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Rolling Thin Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Parking the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20


Operation TM

GENERAL INFORMATION This section provides the Operating instructions for the LB Performance PTC-15B Pneumatic Roller. It is important to read, understand and follow all precautions, operating instructions, and warnings in this manual before starting and operating the machine.

Failure to observe the operating precautions and warning instructions provided in this manual can cause serious injury or death. Only authorized personnel who are trained in machine operation, mechanical characteristics and safe operation in varying terrain should operate the Model PTC-15B Pneumatic Roller.

The machine should be kept in good mechanical condition at all times.

DO NOT operate a machine needing repair. Be sure to place an information tag on the instrument panel clearly stating “DO NOT OPERATE” and remove key on a machine needing repair. Repair all damage promptly as even minor damage can result in major system failures.

DO NOT start or operate the Model PTC-15B Pneumatic Roller before reading, understanding, and following all information given in this section and shown on the machine. The operator must read and understand the function of all controls, indicators and gauges before starting the engine. Serious injury or death can result if these procedures are not followed.

Operation Hazard! Never leave machine operator station unattended with machine in gear and/or in motion. Operator station is defined as the platform area within arms reach of active control steering box. Operator must remain in operator’s station at all times when machine is in gear and/or in motion. Before leaving machine operator station, operator must return joystick to the neutral position.

4

Operation


TM

444444

Parking Safety• ALWAYS park the roller on solid, level ground. If this

is not possible, park the roller at a right angle to the slope.

• ALWAYS engage emergency brake when parking or leaving the machine unattended.

• USE proper flags, barriers and warning devices, especially when parking in areas of traffic.

Maintenance Safety • NEVER work on the roller while the engine is running.

• NEVER fill the fuel tank while the engine is running.

• DO NOT change the engine governor settings.

• ALWAYS replace damaged or lost decals.

• DISCONNECT battery cables when working on the electrical system or welding.

• If the battery needs a charge, be sure the battery charger is OFF when making connections.

• BE SURE the correct battery polarity is observed [negative (-) to negative (-) and positive (+) to positive (+)], when connecting a battery charger or jumper cable.

• DO NOT use hands to find hydraulic leaks. High pressure fluid can penetrate the skin, causing severe injury.

• DO NOT service or repair the machine in a raised position unless supported by approved jacks and jack stands.

RECEIVING THE ROLLERThe LB Performance PTC-15B Pneumatic Roller is thoroughly inspected at the factory before shipping. However, road hazards or other incidents may occur during transport that result in damage. Inspect the machine as outlined below and perform necessary repairs before placing the machine in service:

1. Check the engine oil level as shown in the Engine Operator’s Manual.

2. Check the fuel tank, cooling system, engine oil, and hydraulic reservoir for proper levels and contaminants. If contaminants are suspected, flush and fill the system.

3. Check inside of the water tank for contaminants or objects that could be harmful to the water system. Ensure water flows freely from sprayer.

4. Check for fuel, oil, water and hydraulic leaks.

5. Check all hydraulic functions. Any repairs and adjustments should be performed by a qualified mechanic or consult your authorized LB Performance dealer.

6. Check the drive motors to ensure it stops while the machine is in neutral.

7. Check for missing parts. If parts are missing or motor roller is damaged, consult your authorized LB Performance dealer.

8. Check the Emergency Brake to ensure it is operating properly.

9. Check the seat belt.

Operation


TM

PRELIMINARY PROCEDURES

Operator Platform AdjustmentThe operator platform can be adjusted forward/backward or left/right in relation to the steering column. In addition, the operator can adjust the seat’s suspension for a firm or soft ride. For the operator’s added comfort and safety, the seat can swivel to the left or right. The adjustment levers are located directly under the operator platform. (Figure 4-1)

1234

Figure 4-1. Operator Platform Adjustment

NOTE: The machine operator must be seated to make proper adjustments.

Do not adjust the operator platform while the Roller is in motion. Adjustments must be made while the Roller is at rest and with the Direction Control lever in the neutral detented position.

To adjust the platform forward/backward:

1. While seated, push the adjustment lever #1 to the left.

2. Using body weight, slide the platform forward or backward to the desired position.

3. Release the adjustment lever. Insure that the lever has engaged the locking mechanism.

To swivel the platform:

1. While seated, pull the adjustment lever #3 out.

2. Using body weight, turn the platform to a full 90° left or right position.


To adjust the platform left/right:

1. While seated, step down hard on the adjustment lever #4 to release the locking pin.

2. Using body weight, slide the platform completely to the left or right position.


Item #2 adjusts the suspension of the seat. Turn the wheel to the left for a firmer ride. Turn the wheel to the right for a softer ride.

Beacon LightThe beacon light switch on the control panel operates the flashing safety light on top of the canopy or optional FOPS (Fall on protection structure).. This light warns traffic of slow-moving equipment.

• To turn ON the beacon light, push two-way beacon switch UP.

• To turn OFF the beacon light, push two-way beacon switch DOWN.

Break-In ProceduresNOTE: Make every effort to become familiar with the

feel and sound of the machine.

4. Observe engine operation carefully.

5. Check the engine oil and coolant frequently.

6. Operate engine at normal loads.

7. Check indicators and gauges frequently during operation.

8. Avoid excessive engine idling.

9. Perform 10 hour or daily service.

10. Watch for fluid leaks and repair immediately.

11. Perform service intervals as indicated in Maintenance, Section 7 of this manual.

12. Check engine manufacturer’s manual for additional information on engine break-in.

4

Operation


TM

444444

PV480® POWERVIEW DISPLAYWhen you turn on the ignition key, a sequence of screens will display on the controller. First you will see a notation in the upper left corner, “Booting,” followed by Murphy logo displays, and then the main screen is displayed. The lit status icons at the top of the screen will disappear momentarily.

Main MenuThe Main Menu default screen (home). Open it from any screen by pressing the Main Menu ( ) soft key, then the Select ( ) soft key. (Figure 4-2)

Figure 4-2. Gauge Screen

1 - Engine Speed/RPM

2 - Engine Coolant Temperature

3 - Hydraulic Temperature

4 - Electrical Potential Voltage

5 - Actual Engine Torque Percentage

6 - Oil Pressure – Lamp Only

7 - Fuel Level

8 - Engine Total Hours of Operation

Scroll through the Main Menu list using the UP/DOWN soft keys to maneuver the cursor (>) to the action item:

• Gauges (Main Menu Default Screen)

• Diagnostics

• System Info

• Lamp Info

• User Settings

Set Points and Throttle Speed

Use the first button to select set points (while not in the the menu). Select desired default throttle speed using buttons. (Figure 4-2)

Use the second button to switch between DPF commands and throttle speed.

1 2 3 4 5

1000 RPM 2200 RPM1400 RPM 1600 RPM 2600 RPM

Figure 4-3. Engine Throttle Speeds Screen

1 - 1200 RPM

2 - 1400 RPM

3 - 1800 RPM

4 - 2200 RPM

5 - 2400 RPM

Operation


TM

Soft Keys (Buttons)Your Soft Key choices are associated with the throttle source. (Some throttle sources may not be present on your model.)

Table 4-1. Soft Key Buttons

Status Icon Description

Set Points — Displays the engine-requested RPM/speed quick set points.

Freeze Frame — Requests the freeze frame data from the ECU when faults are present.

Main Menu — Two full pages that list five action items to select: Gauges, Diagnostics, System Info, Lamp Info, User settings.

Down — Navigates the curser (>) downward through a list.

Up — Navigates the curser (>) upward through a list.

Select — Enters the action item next to the cursor in a list. Also used with the Main Menu soft key to get back to the Main Menu from any screen.

Deselect — Closes pop-up messages.

Plus — Increases the engine requested speed.

Minus — Decreases the engine requested speed.

Speed/Throttle — Opens the speed/throttle adjustment command and enables the Plus and Minus soft keys (+/-).

4

Operation


TM

444444

Status IconsThe Status icons are color-coded and illuminate when communicating to the operator. Pay close attention to any Status icon and color if it appears.

Table 4-2. Status Icons

Status Icon Description

Check Engine — When this lamp is illuminated, a fault exists within the control system. The engine may continue to operate, however, it is unable to perform DPF cleaning either automatically or manually.

Take action immediately to correct the fault.

Parking Break Switch — The park icon displays when the parking brake is applied.

NOTE: To perform a Parked Regeneration, the “P” and “N” lamps must be illuminated.

Transmission Neutral — The neutral icon displays when the transmission is in neutral.

NOTE: To perform a Parked Regeneration, the “P” and “N” lamps must be illuminated.

Engine Exhaust High Temperature Lamp — This lamp illuminates during the regeneration cycle to warn of high exhaust temperatures. This lamp will turn off when normal operating temperatures are reached after the regeneration cycle.

Be sure engine exhaust is away from combustible materials when this is illuminated.

Glossary of Terms and Acronyms

CAN – Controller Area Network

DM1 – Diagnostic Message 1, Active Diagnostic Trouble Codes

DM2 – Diagnostic Message 2, Previously Active Diagnostic Trouble Codes

DM3 - Diagnostic Message 3, Diagnostic Data Clear/Reset for Previously Active DTCs

DM4 – Freeze Frame Parameters

DPF – Diesel Particulate Filter

DTC – Diagnostic Trouble Code

ECU – Engine Control Unit

FMI – Failure Mode Identifier

PGN – Parameter Group Number

SPN – Suspect Parameter Number

Operation


TM

DiagnosticsScroll through the Main Menu list using the UP/DOWN soft keys and stop the cursor (>) next to the action item Diagnostics. Press the Select ( ) soft key. The screen (Figure 4-4) displays the following items:

• Active Diagnostics

• Logged Diagnostics

Figure 4-4. Diagnostics Screen

Active Diagnostics

Use the UP/DOWN soft keys and stop the cursor (>) next to the action item Active Diagnostics. Press the select ( ) soft key. The screen displays active warnings or faults from the ECU. (Figure 4-5)

Each diagnostic is shown with the appropriate Suspect Parameter Number (SPN) and Failure Mode Indicator (FMI), Text Description (if available), and the ID/Name of the device that transmitted the DM1 message.

Press the UP/DOWN soft keys to reach the next diagnostic in the list.

Figure 4-5. Active Diagnostics Screen

4

Operation


TM

444444

Logged Diagnostics

Use the UP/DOWN soft keys and stop the cursor (>) next to the action item Logged Diagnostics. (Figure 4-6)

Press the select ( ) soft key. The screen displays the controller requests DM2 (stored trouble codes, inactive), warning or faults from the ECU. Each diagnostic is shown with the appropriate information:

• Suspect Parameter Number (SPN)

• Failure Mode Indicator (FMI)

• Text Description (if available)

• ID/Name of the device that transmitted the DM1 message

NOTE: Select the Freeze Frame Button to request the freeze frame data from the ECU when faults are present.

Figure 4-6. Logged Diagnostics Screen

System InfoScroll through the Menu list using the UP/DOWN soft keys and stop the cursor (>) next to the action item System Info. (Figure 4-7) Press the select ( ) soft key. The screen displays the following items:

• Engine Model• Engine Serial Number• ECU Software ID• Fuel Rate• Time since last active Regen

Figure 4-7. System Info Screen

Press the UP/DOWN soft keys to display a screen with application and configuration information. (Figure 4-8)

Figure 4-8. Application and Configuration Information Screen

Operation


TM

User SettingsScroll through the Menu list using the UP/DOWN soft keys and stop the cursor (>) next to the action item User Settings. Press the select ( ) soft key. The screen displays the following action items:

• Colors• Brightness• Language• Units• Date• Time

Screen Color

Use the UP/DOWN soft keys and stop the cursor (>) next to the action item Colors. Set your preference for day or night vision by using the +/– soft keys. (Figures 4-9 and 4-10)

Figure 4-9. Set Night Vision Color Preferences Screen

Figure 4-10. Set Day Vision Color Preferences Screen

Screen Brightness

Use the UP/DOWN soft keys and stop the cursor (>) next to the action item Brightness. Set the brightness of the backlight by using the +/– soft keys. (Figure 4-11)

Figure 4-11. Set Brightness Of Backlight Screen

4

Operation


TM

444444

Language

Use the UP/DOWN soft keys and stop the cursor (>) next to the action item Language. Set your language preference using the +/– soft keys. (Figure 4-12)

• English

• French

• German

• Spanish

• Italian

• Japanese

Figure 4-12. Set Language Preferences Screen

Units

Use the UP/DOWN soft keys and stop the cursor (>) next to the action item Units. Set your unit preference using the +/– soft keys. (Figure 4-13)

• USA Standard

• Metric kPa

• Metric Bar

Figure 4-13. Set Unit Preferences Screen

Operation


TM

Date and Time Settings

Use the UP/DOWN soft keys and stop the cursor (>) next to the action item Date. Press the Select ( ) soft key to initiate change to the month value. Use the (+/–) soft keys to increment or decrement the number. Use the DOWN arrow to reach the day value and year value and the +/– soft keys to make changes. (Figure 4-14)

Use the UP/DOWN soft keys and stop the cursor (>) next to the action item Time. Press the Select ( ) soft key to initiate change to the hour value. Use the (+/–) soft keys to increment or decrement the number. Use the DOWN arrow to reach the minutes value and the +/– soft keys to make changes.

NOTE: A reboot is required for changes to the date setting to take effect.

Figure 4-14. Time Setting Screen

PRE-START Always check the following items before starting the machine:

• Inspect machine for any malfunctioning, broken or missing parts. Promptly repair before operating.

• Check hydraulic hoses for wear and leaks. Replace if damaged.

• Ensure all instructional and safety decals are in place and legible. These decals are very important for operator safety. Read and follow all instructions on decals.

• Check engine oil, coolant and hydraulic oil levels. Fill to the correct level if needed.

• Check for fuel level and refill if needed.

Fill the fuel tank with the engine off. NEVER fill fuel tank near an open flame or when smoking.

• Check for frayed or worn electrical wires and loose or corroded connectors.

• Check tires for air pressure, wear, cuts and damage. Inspect wheels for loose, damaged or missing hardware.

• Check levers for freedom of movement. Be sure operator’s area is free of debris.

• Check steps and supports for damage. Repair if necessary.

• Check for missing parts. If parts are missing or motor roller is damaged, consult your authorized LB Performance dealer.

• Check protective devices, ROPS (Roll-Over Protection System), canopy, shields and seat belt for wear or damage.

If protective devices are damaged, DO NOT use roller until proper repairs are made.

• Check for water leaks and inside water tank for contaminants or objects that could harm the water system.

4

Operation


TM

444444

MACHINE OPERATIONNOTE: Refer to the engine manufacturer’s operation

and maintenance manual for instructions when starting engine for the first time. Follow engine manufacturer’s recommendations for fuel and oil.

Engine Start-Up The Directional Control (FNR) lever

must be set in the NEUTRAL position before starting engine.

DO NOT operate the starter longer than 20 seconds. If the engine does not start, allow the starter to cool for two to three minutes.

1. Set throttle to full open which is toward the front of the roller.

2. Insert key into ignition switch and turn clockwise to the START position. Release key when engine starts.

3. Let engine idle for 30 seconds, then set the desired throttle speed.

4. Check indicator and gauge operation.

In the event of a “false start”, allow the engine to completely stop before re-starting. If starter is engaged while the flywheel is still rotating, the starter pinion and flywheel ring gear may clash, resulting in damage to the starter or ring gear.

Engine Warm-Up Allow engine and hydraulic oil to warm

up before activating components.

1. Start engine and let it idle for several minutes. Do not accelerate rapidly during warm-up.

2. Operate the engine at less-than-normal loads and speeds until engine reaches normal operating temperatures.

Running the engine at high RPMs will shorten its useful life.

NOTE: See engine manufacturer’s operation and maintenance manual for more information.

Cold Weather Engine Warm-Up In cold weather, keep the fuel tank

filled to reduce the chances for condensation and corrosion. Do not fill the fuel tank to capacity. Leave room for fuel expansion.

In cold weather, it is extremely important to allow the engine and hydraulic oil to warm up before activating components.

• Run engine for five minutes.

• Operate each of the hydraulic functions before moving machine.

Directional Control The PTC-15B Pneumatic Roller is designed to operate from forward to reverse with a single drive lever. It’s possible, however, to change the position of the drive lever to either side of the steering column. These positions are inter-connected and arranged in this manner for the operator’s convenience.

• Move lever from NEUTRAL (N) to FORWARD (F) position to move roller forward. Move lever backward from NEUTRAL (N) to REVERSE (R) position to move roller backwards.

• Move lever further away from NEUTRAL (N) position to increase ground speed. Move lever closer to NEUTRAL (N) position to decrease ground speed.

• With machine off and brake engaged. Unplug the 6-pin connector and pull the thumb latch to remove the joystick box and move to the opposite side. Make sure thumb latch seats and the joystick 6-pin connector is plugged in before operating the machine.

When operating on an incline, the roller may start to pull downward. Increase the throttle setting, move drive lever towards NEUTRAL, or a combination of the two, will counteract the pull.

Operate the engine at full throttle to avoid over-heating the hydrostatic drive system. Rolling speed should be controlled by the position of the direction control lever, not the throttle.

DO NOT change roller direction with fast movements of the Forward/Neutral/Reverse lever. Always move the lever from one direction through neutral to the opposite direction with slow movements to prevent damage to the system.

Operation


TM

Speed SelectorThe two-speed toggle switch allows the operator to move between high speed or low speed. To change from low to high speed, move the toggle to the desired position, and then move the Direction Control lever to neutral. After the desired speed change has been achieved, move the Direction Control lever to FORWARD or REVERSE position.

Generally, high speed is used for travel to and from a job site. Most rolling is done in low speed. However, depending on machine ballasted weight and absence of any inclines at the job site, the operator may choose to roll in high speed.

BrakingIf stopping on a grade, the distance needed to come to a stop will be longer, the steeper the grade. Familiarize yourself with the job site so you can anticipate these variables.

The hydrostatic drive system provides dynamic braking action. This braking occurs when the Direction Control lever is returned to neutral from FORWARD or REVERSE position.

The secondary park brake is integrated within the wheel motors. A switch on the instrument panel activates the park brake. In addition, the park brake is automatically activated when the engine is NOT running and/or when no hydraulic pressure is available.

During normal operation, dynamic braking is sufficient for stopping the Roller. If for any reason the Roller doesn’t stop when the Direction Control lever is returned to neutral, the operator should engage the park brake. After the Roller is brought to a safe stop, inspect and troubleshoot to determine the cause of dynamic braking failure.

If the park brake has been automatically activated due to hydraulic failure, it will be necessary to manually release the park brake. Refer to Emergency Towing later in this section for steps to complete this procedure.

In emergencies the Emergency Stop button will cut power from the ignition switch turning off the engine and bringing the machine to a stop.

Parking The Machine Operation Hazard! Never leave

machine operator station unattended with machine in gear and/or in motion. Operator station is defined as the platform area within arms reach of control steering box. Operator must remain in operator’s station at all times when machine is in gear and/or in motion. Before leaving machine operator station, operator must return Control Lever to neutral position, turn off all accessories, set parking brake switch to ON position, shut off the engine, and remove the ignition key.

Before leaving the machine, perform the following procedures:

1. Park machine on a level surface.

2. Return the Direction Control lever to the neutral detented position.

3. Set the emergency brake to prevent machine from rolling when left unattended.

4. Place ignition switch in the OFF position and remove key.

Setting The Emergency Brake

A switch at the upper right side of the instrument panel activates the park brake. In addition, the park brake is automatically activated when the engine is NOT running and/or when no hydraulic pressure is available.

4

Operation


TM

444444

Water Spray SystemThe water spray system provides water to the front and rear tires. The water cools the tires and prevents asphalt from sticking to them during operation. The pressurized water system assures an even spray across the face of the tires.

The water spray switch is located on the instrument panel. This switch allows the operator to turn the water on and off during operation. In the up position, AUTO, the flow will shut off when the Direction Control lever is moved to the neutral position. In the center OFF position, all flow is stopped. In the down ON position, the flow will continue to wet the tires as long as the toggle is in this position. To achieve the most efficient use of the spray system, use the AUTO position.

The water tank is located at the front of the Roller directly above the front ballast. The water tank fill cap is located on top of the tank on the right side. Maintain an adequate supply of water in the tank to insure consistent operation of the spray system.

When not in use or parked for an extended time the water system can be manually shut off by the disconnect valve beside the water pump and strainer.

Do not operate the water system with the disconcert valve engaged. Doing so may damage the water pump..

Do not fill water tank with any liquid other than water. Chemicals can react with heat and asphalt products and cause an explosion.

To prevent damage to the water system from freezing temperatures, disconnect the strainer from the pump so that the water drains from the water tank and pump.

NOTE: The water pump and strainer are located under the front step on the right side of the machine

Spray Pattern AdjustmentThe water spray pattern may require occasional adjustment. Check spray patterns periodically at both front and rear tires. Use the following procedure to adjust the spray pattern.

1. Use an Allen wrench to loosen the set screws on both the left and right sides of the spray bar (Figure 4-15).

2. Direct the spray pattern from the nozzles to insure complete coverage across the width of the Roller tires.

3. Tighten the set screws.

Figure 4-15. Water Spray Bar

Tire ScrapersTire scrapers remove asphalt particles and prevent buildup on the tire surfaces. Scrapers are factory adjusted to insure optimal surface tension. Check scraper springs and scraper pads for excessive wear. Replace springs and pads as required.

Scraper Adjustment

The front and rear scrapers see considerable wear during the rolling process. Periodic adjustment and/or replacement may be necessary. Inspect scraper bars, pads, and springs daily to insure reliable surface tension and even scraper surfaces.

Operation


TM

Coco MatsThe coco mats provide a more even distribution of water across the face of the tires to help prevent asphalt buildup from continued use. Check the mats periodically for wear and buildup. Replace coco mats if they show excessive wear or asphalt buildup during inspection.

BallastFilling the front and rear ballast compartments with water or sand adds weight and allows for greater compaction.

The fill plug for the front ballast is at the left front, inside the operator’s compartment. The fill plug for the rear ballast is on top of the ballast compartment, at the left rear side.

A plug for draining the ballast compartments is located at the bottom center of each compartment, just behind the frame.

If using water ballast, use a mixture of 50% water and 50% alcohol, or the equivalent, during freezing temperatures.

PRINCIPLES OF COMPACTIONCompacting an asphalt surface is an important element of paving to provide a smooth surface that will remain smooth under the pressures of all kinds of traffic. It is also important to obtain optimum air void to create a durable surface that can withstand the effects of air, water and temperature changes. (Air voids are the spaces in the hot mix not filled by either the aggregate particles or the asphalt cement.) Optimum air void should be approximately two (2) to eight (8) percent, according to the Asphalt Institute recommendations.

To accomplish a quality surface, two conditions must exist: Correct mix temperature and asphalt confinement. The Asphalt Institute recommends using asphalt that is between 185° F (85° C) and 300° F (150° C). At this temperature, asphalt will aid in forcing the aggregate into a dense mat. If the mix is too cool, a dense mat is harder to achieve.

Three forces acting on each other achieve asphalt confinement. These three forces are: the roller, the mix, and the sub grade under the mat. When these three forces act on each other with equal resistance, confinement of the asphalt is achieved and compaction is complete.

The PTC-15B is a nine-wheel pneumatic roller operated in the intermediate roller position behind a vibratory or static steel-wheel breakdown roller, and in front of a static steel-wheel finish roller. Pneumatic rollers are sometimes used, however, for initial rolling of the mix as well as occasionally for “finish” rolling. Use of this Roller for base compaction is not recommended due to its lack of traction.

Tire pressure is a key factor in the proper use of a pneumatic roller. A higher tire pressure will result in a more rounded tire surface.

High domed tires tend to slip more easily and cut into the mat surface. A flatter tire profile will displace the mix less and achieve a smoother mat surface.

Tire pressure is normally kept constant for a particular project, but the pressure selected depends on the properties of the mix being compacted and the position of the roller on the mat. (Table 4-3)

4

Operation


TM

444444

Table 4-3. Compaction Weight Table

Ballast Type & Weight

* Tire Pressure

Ply

PSI

kg/sq/cm

6 ply

60

4.22

12 ply

110

7.78

14 ply

130

9.14

Add Steel Lbs.

**

Load Per Tire

(Empty)

6.66 TON

GCP

CA

PSI

kg/sq. cm

SQ. IN.

sq. cm

52.60

3.70

29.60

191.00

71.00

5.00

22.20

143.23

81.20

5.71

19.40

125.16

1131

Front

1600 lb.

728 kg.

Water

10 TON

GCP

CA

PSI

kg/sq. cm

SQ. IN.

sq. cm

56.33

3.96

39.11

252.32

76.33

5.37

29.22

181.52

87.78

6.17

25.22

162.71

2108

Front

678

Rear

2222 lb.

1008 kg.

Dry Sand

12 TON

GCP

CA

PSI

kg/sq. cm

SQ. IN.

sq. cm

59.00

4.15

45.00

290.32

79.67

5.60

33.34

215.10

91.34

6.42

29.34

189.30

3309

Front

1560

Rear

2667 lb.

1210 kg.

Wet Sand

15.25 TON

GCP

CA

PSI

kg/sq. cm

SQ. IN.

sq. cm

62.60

4.40

54.60

352.26

85.40

6.00

40.00

258.06

97.20

6.83

35.20

227.10

7110

Front

4540

Rear

3400 lb.

1542 kg.

ROLLING TECHNIQUES Do not change Roller direction

with fast movements of the Direction Control lever. Always move the lever from one direction through neutral to the opposite direction with slow movements. This allows the hydraulic system’s dynamic ability to stop the machine at neutral, and prevents damage to the system.

Operate the engine at full throttle to avoid over-heating the hydrostatic drive system. Rolling speed should be controlled by the position of the direction control lever, not the throttle.

NOTE: If you notice the engine is lugging down dur-ing a heavy pull when the Direction Con-trol lever is in the FORWARD or REVERSE position, move the lever towards neutral to decrease speed and increase torque to the final drive.

For most paving jobs, two or more rollers are required. Rolling should be continuous until all of the laid mix is thoroughly compacted. At least three coverages should be made.

In general, the rolling operation is comprised of three phases and should begin as soon as the hot mix is laid down. The three phases of rolling are:

• Breakdown or Initial - This phase provides most of the needed compaction density.

• Intermediate - This phase seals the surface.

• Finish - This phase removes blemishes from the final surface.

Operation


TM

Rolling PatternFor best results, the rolling pattern and other factors should be determined prior to paving the site using a test strip of the same mix. These factors include:

• Travel speed and the number of passes will not be the same for all jobs.

• Different mix design, lift thickness and lay-down temperatures will require different compaction techniques.

• Various travel speeds can be applied to test the asphalt mat to determine the best combination.

Remember, the best rolling pattern is the one that provides the most uniform coverage and density.

The following general points should be used as guidelines for obtaining the pattern.

1. Keep tires warm to prevent sticking. Use a small amount of non-foaming detergent or water soluble oil on the wetting mats at the beginning of the operation to prevent sticking until the tires get warm. Once Roller wheels are warm, moisten Roller wheels with small amounts of water or asphalt release agent to prevent sticking.

DO NOT use fuel oil on roller wheels.

2. Move at a slow, uniform speed, not more that 5 mph (8 kpr).

3. Avoid sharp turns. Accelerate and decelerate smoothly on a fresh mat. DO NOT change the pattern unless the mix or lift changes.

4. DO NOT make sudden changes in one direction or line of travel. Sudden changes cause displacement of the asphalt. If displacement occurs, the area must be loosened and the original grade restored before re-rolling.

5. DO NOT allow heavy equipment (including rollers) to stand on asphalt until it has completely set.

6. Keep tire pressures at their recommended psi rating. DO NOT overinflate tires as this causes mix displacement.

7. Extend each path further into the mix than the previous path. When the width of the lane has been finished, move across the mat on cooled material and repeat.

WIDTH OF ROLLERFIRST PASS

RETURN

SECOND PASS

RETURN

THIRD PASS

RETURN

DIRECTION OF PAVING

WIDTH OF LANE

Figure 4-16. Rolling Pattern

8. Each pass of the roller should proceed in a straight direction of travel into the mix. Each return pass should be in the same path as the forward path. (Figure 4-16)

Rolling Thick Lifts1. Start rolling 12 to 15 inches (300 - 375 mm) from the

unsupported lower edge.

2. Compact the center material first so there is more stability for the roller as it moves toward the edges. The edge that has not been compacted helps with confine asphalt during the first passes.

3. After the central area of the spread is compacted, the edge may be compacted without lateral movement.

Rolling Thin Lifts1. Start on the low side with the roller wheels

extending two to four inches (51 - 102 cm) over the edge of the mat. Follow the paver as closely as possible.

2. The second pass should be in the reverse direction, staying in the same path as the first pass.

3. Continue in reverse until the machine is on previously compacted material, then move forward again as close to the paver as possible.

4. Continue Steps 2 through 3 until a full width of the lane is paved, ending in the reverse direction.

5. Move the roller over to the low side again to start a new run from the low side.

6. Overlap each pass three to four inches (75 - 100 mm).

4

Operation


TM

444444

Compaction Of Base MaterialsThe roller can be used to compact some base materials if special practices and options are used. The PTC-15B Roller has two drive motors on the rear which are parallel. If one slips, all the hydraulic flow will go to the wheel that is slipping. This allows the machine to become stuck easily when compacting base materials.

The optional Traction Control kit will lock the hydraulic drive so that power is diverted to the non-slipping tires. This greatly improves the ability of the PTC-15B Roller to compact loose materials. If a machine equipped with the traction kit is used on relatively flat terrain, on material with good traction, it can be used to compact base materials.

PARKING THE MACHINE Before leaving the operator’s seat, perform the following procedures:

1. Park machine on a level surface and set park brake.

2. Return drive lever to the neutral (center) position.

3. Idle engine for three to five minutes at 1/2 speed (RPM).

4. Turn the ignition switch key counterclockwise to the OFF position and remove the key.

A fail-safe hydraulic emergency brake, mounted underneath the steering wheel on the steering column, uses a knob to disengage the emergency brake.

Towing And Transport Do not tow the LB Performance PTC-

15B except for machine breakdown, and then only to remove it from a road. To prevent machine runaway, block roller wheels before manually releasing the park brake.

Preparing The Machine For Trailer Transport

When transporting the Roller on a trailer, use a trailer that is large and heavy enough to handle the Roller in all driving situations.

1. Clean the machine using a pressure washer. Remove all loose gravel, mud or debris from wheels and frame.

2. Remove ballast from the Roller.

3. Lock the articulation link before attempting to load the Roller on a trailer (Figure 4-17).

Figure 4-17. Articulation Link

4. Make sure the combined height of the truck, trailer and loaded Roller meet height restrictions for the local area, including bridges, overpasses, and overhead obstructions. Remove the canopy structure if the machine does not meet height restrictions.

5. Park the transfer vehicle or trailer on a level surface with transmission in park and engine off.

6. Engage the transfer vehicle’s emergency brake and use wheel chocks in both directions.

Operation


TM

Emergency TowingBe sure you understand the following procedure completely before proceeding. If the park brake has been automatically activated due to hydraulic failure, the park brake must be manually released using the steps below. Once the park brake has been manually released, the only way to re-apply it is to release the pressure at the connection outlined in step 2.

1. To manually release the park brake, you must first by-pass the system pump by following the instructions in the service manual supplied with the pump. Do not attempt to operate or run the engine with the pump by-pass activated.

2. The solenoid valve is located inside the access panel on the left side of the machine. Remove the hose attached to the solenoid valve (Figure 4-19) coming from the charge pressure (Port #3) on the right side of the valve. Attach a hydraulic hand pump (Enerpac Model P-142 or similar hand pump). The fitting is an SAE 37° JIC male (06 size) with 9/16-18 threads.

Figure 4-19. Solenoid Valve

Turn ignition switch ON and move the brake toggle switch to the OFF position.

3. Using the hand pump, apply pressure to this connection. The brake should begin to release at 140-175 psi. DO NOT EXCEED 250 psi to avoid damaging the system.

4. Release pressure on the hand pump and/or flip the brake toggle switch to the ON position to reapply the brake.

5. Proceed to tow the Roller to the roadside.

7. Use a ramp or loading dock. Make sure the ramp weight capacity will support the machine and has a low angle of rise to the trailer bed.

Be sure loading dock and trailer are the same height. Do not bounce Roller or force Roller to climb over edge. This could cause the Roller to slide off or damage the bearings.

8. Load the machine on the trailer bed by driving straight on, centered on the trailer. The Roller center-line must be over the trailer center-line.

NOTE: Roller should be positioned to insure even distribution of load between trailer axles and trailer hitch.

9. Block Roller tires to prevent Roller from moving forward or backward.

10. Idle the engine at 1/2 speed (RPM) for 3 to 5 minutes.

11. Place engine throttle at slow idle.

12. Place transmission lever in neutral.

13. Place ignition switch in the OFF position and remove the key.

14. Secure the Roller to the trailer at its tie-down points (Figure 4-18), using chains rated in excess of roller weight.

Tie Down Tie Down

Figure 4-18. Tie Down Points

15. Cover the exhaust opening with heavy gauge plastic to prevent dust and moisture from entering the engine.

NOTE: Remove the plastic cover from the exhaust before operating the machine.

4

Operation


TM

444444

NOTES

Operation


TM

Page

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Machine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Preparing Machine for Maintenance . . . . . . . . . . . . . . . . . 5-5

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Neutral Start System . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Checking the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Changing the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Changing Engine Fuel Filter . . . . . . . . . . . . . . . . . . . . . 5-7

Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . 5-7

Cleaning and Checking Fuel Filler Cap . . . . . . . . . . . . . . . . 5-7

Air Cleaner System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Replacing Engine Air Filter Elements . . . . . . . . . . . . . . . . . 5-8

Radiator and Coolant System. . . . . . . . . . . . . . . . . . . . . . . . 5-8

Checking Radiator and Coolant Level . . . . . . . . . . . . . . . . 5-8

Draining, Flushing and Filling Coolant System . . . . . . . . . . . . 5-9

Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11


MAINTENANCE

Section 5

TM

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Hydraulic Oil Requirements . . . . . . . . . . . . . . . . . . . . . 5-12

Hydraulic System Checks . . . . . . . . . . . . . . . . . . . . . . 5-12

Checking Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . 5-12

Checking and Cleaning Hydraulic Reservoir Filler Cap . . . . . . . . 5-13

Changing Hydraulic Filters . . . . . . . . . . . . . . . . . . . . . . 5-13

Draining, Flushing, and Filling Hydraulic Oil Reservoir . . . . . . . . . 5-13

Pumps and Motors . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Adjusting Priority Relief Valve . . . . . . . . . . . . . . . . . . . . 5-14

Water Spray System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Adjusting Spray Pattern . . . . . . . . . . . . . . . . . . . . . . . 5-14

Cleaning Water Spray Nozzles . . . . . . . . . . . . . . . . . . . . 5-15

Water Pump Replacement . . . . . . . . . . . . . . . . . . . . . . 5-16

Scrapers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Coco Mats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Chassis and Running Gear . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Changing the Tires . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Axles and Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Roll Over Protective Structure (ROPS) . . . . . . . . . . . . . . . . . . . 5-17

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Preparing for Long Term Storage . . . . . . . . . . . . . . . . . . 5-18

Periodic Maintenance During Storage . . . . . . . . . . . . . . . . 5-18

Removing the Machine From Storage . . . . . . . . . . . . . . . . 5-18

Weldment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19


Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

PV480 Diagnostic Trouble Code (DTC) Chart. . . . . . . . . . . . . . . . 5-31

Maintenance


TM

Engine Operator’s Manual accompanying your roller for more detailed engine service information.

When performing any routine maintenance, always include the previous routine maintenance hours in the higher hourly schedule.

Cleaning and maintenance should only be performed in a designated area where the oil and other fluids can be contained. These by-products should be discarded in accordance with environmental regulations.

MAINTENANCE SCHEDULE Before performing any maintenance procedures on the LB Performance PTC-15B Pneumatic Roller, review safety information in Section 1.

Always use the appropriate and correct sized tools to prevent injury damage to the machine.

Following the maintenance schedules and procedures will maintain the roller in top operating condition and provide years of trouble-free operation. Refer to the

Table 5-1. Periodic Maintenance Schedule

System Item

Eve

ry 1

0 H

our

s

Dai

ly

Eve

ry 5

0 H

our

s

Wee

kly

Eve

ry 1

00

Ho

urs

Mo

nthl

y

Eve

ry 2

50

Ho

urs

Mo

nthl

y

Eve

ry 5

00

H

our

s

Eve

ry 1

00

0

Ho

urs

Engine

Check oil level. X

Replace engine oil and oil filter (initial 50 hours, then every 500 hours).

X

Check primary and secondary air filters. X

Replace primary air filter. X

Replace secondary air filter. X

Check drive belts. X X

CoolingCheck coolant level. X

Replace coolant. X

FuelCheck engine fuel filter. X

Replace engine fuel filter. X

Hydraulic

Check hydraulic oil level. X

Check hydraulic return and charge filters. X

Replace hydraulic oil. X

Replace hydraulic return and charge filters. X

Clean hydraulic strainer. X

Replace hydraulic strainer. X

Lubrication

Front wheel bearing. X

Re-Pack front wheel bearings. X

Steering cylinder. X

Articulation joint. X

Re-pack rear wheel bearings (11-wheel option).

X

Water SystemCheck watering system strainer. X

Clean spraybar line and nozzles. X

5

Maintenance


TM

55

ROUTINE MAINTENANCE

Preparing Machine for MaintenancePerform the following steps before leaving the operator’s position, unless the maintenance procedure instructs otherwise.

1. Park the roller on a flat, even surface.

2. Place drive lever in NEUTRAL.

3. Apply Emergency Brake.

4. Run engine at 1/2 speed (RPM) for three to five minutes.

5. Reduce engine speed (RPM) to slow idle.

6. Place ignition switch in the OFF position.

If maintenance must be performed with the engine running, DO NOT leave machine unattended.

NOTE: When performing any routine maintenance such as 50, 100, 250, 500 and 1000 hours, always include the previous routine mainte-nance hours in the higher hourly schedule.

Neutral Start System A Neutral Start Switch has been installed to prevent operation of the engine starter when the transmission is not in neutral. To check this system:

1. Place drive lever in the FORWARD or REVERSE position.

2. Turn ignition switch key clockwise to the START position. Engine should not start in gear.

3. Repeat test with the direction lever in the opposite direction. Engine should not start in gear.

DO NOT operate machine if the starter cranks engine with the direction lever in gear. See local dealer for neutral start system troubleshooting and repair.

4. Place the direction lever in NEUTRAL and turn ignition switch key clockwise to the START position. Starter should crank engine.

Machine Lubrication Proper lubrication is necessary to maintain the LB Performance PTC-15B at top efficiency.

3 2 1

Figure 5-1. Lubrication Points

ITEM NO. LOCATION INTERVAL

1 Front axle. Shell Avania EP Grease or equivalent Weekly

2 Steering cylinder. Shell Avania EP Grease or equivalent Monthly

3 Pivot assembly. Shell Avania EP Grease or equivalent Monthly

Maintenance


TM

Every 10 Hours or Daily Routine Maintenance 1. Check the fuel level. Keep the fuel tank full to

prevent condensation. Fill at end of day.

2. Perform engine preventative maintenance as described in your Engine Operator’s Manual. Engine preventative maintenance should always begin with an engine oil check.

3. Check the hydraulic oil level and fill as required.

4. Check the engine oil. (Page 5-6)

5. Lubricate the required parts. (Page 5-4)

6. Check for damaged, loose or missing decals. Replace decals as needed.

7. Check lights bulbs and replace bulbs if needed.

8. Check battery cables and connections.

9. Check coolant level. Fill as needed.

10. Check for loose, damaged, missing or corroded parts. Repair or replace promptly.

11. Check tires and wheels for correct air pressure, cuts, bubbles, damaged rims or missing lugnuts.

12. Check the emergency brake to ensure proper operation.

50-Hour or Weekly Routine Maintenance 1. Lubricate front wheel bearing. (Page 5-4)

2. Check all battery connections and remove any corrosion. (Check cables daily.)

3. Check primary and secondary air filters. (Page 5-8)

4. Perform the previous maintenance procedures and any described in the Engine Operator’s Manual.

100-Hour or Monthly Routine Maintenance 1. Check air filters. Clean or replace if required. (Page

5-8)

2. Check fuel filter and water separator. Clean or replace if needed. (Page 5-7)

3. Check hydraulic return and charge filters. Clean hydraulic oil strainer if needed. (Page 5-13)

4. Lubricate the required parts. (Page 5-4)

5. Inspect and repair (and grease) all drive train components:

6. Check tired for excessive wear, tire pressure and objects embedded in or between tires.

7. Check bearings, bearing housing, shaft housings and chains for proper lubrication.

8. Check drive chains for correct tightness.

9. Check bushing and bearing for excessive wear.

10. Replace rubber handles, operators seat, frame, floor board insulators and decals as needed.


250-Hour or Quarterly Routine Maintenance 1. Check battery electrolyte level (Page 5-10). Check

battery terminals for corrosion. Check all battery connections and remove any corrosion.

Do not smoke when checking battery electrolyte level as the fumes can explode. Electrolyte is an acid that can burn if it contacts skin or eyes. If contact is made, flush area immediately with water.

2. Change engine oil and replace oil filter (Page 5-6). To assure complete removal of contaminants in the oil, perform the oil change while engine is warm.

3. Check engine belt. Tighten or replace if needed.

4. Lubricate steering cylinder and articulation joint. (Page 5-4)

5. Replace engine air filter. (Page 5-8)


5

Maintenance


TM

55

500-Hour or Semi-Annual Routine Maintenance 1. Change fuel filter. (Page 5-7)

2. Change hydraulic oil and charge filter. (Page 5-13)

3. Check fuses. Replace if needed.

4. Check Neutral Start system. See your LB Performance dealer for service if needed. (Page 5-5)

5. Check emergency brake operation.

6. Check oil lines and fittings for leakage or damage and replace parts as required.

7. Perform the previous preventative maintenance as described in the Engine Operator’s Manual.

Hydraulic oil under pressure can cause serious personal injury. Check for oil leaks with a piece of cardboard. Do not expose hands to possible high-pressure oil. Shut down engine before attempting to tighten oil lines and fittings.

1000-Hour or Annual Routine Maintenance 1. Check air intake hoses for damage and replace if

necessary.

2. Replace hydraulic strainer. (Page 5-13)

3. If equipped with the 11-wheel option, repack rear wheel bearings.

4. Perform the previous preventative maintenance as described in the Engine Operator’s Manual.

Death or serious injury can result from entanglement in moving parts. Do not service the LB Performance PTC-15B while in motion or while engine is running. If the engine must be running to service a component, place transmission in neutral, apply park brake, block wheels, and use extreme caution.

Engine Maintenance In addition to the following maintenance procedures, consult the engine manufacturer’s manual.

Checking the Oil1. Park the machine in a level position and stop the

engine.

2. Clean the area around the engine lubrication oil dipstick.

3. Wait five minutes after engine shutdown removing the dipstick from the engine and checking the oil level.

4. Remove the filler cap and add oil as necessary.

Changing the Oil and Oil FilterEngine crankcase oil and oil filter should be changed after the first 50 hours of service and every 500 hours or every 3 months thereafter. Refer to engine manufacturer’s manual.

NOTE: Drain oil while the engine is still warm (not hot).Warm oil will flow freely and carry away more impurities.

Always make sure the machine is on a level surface when filling and checking oil.

1. Operate the engine until the coolant temperature reaches 140° F (60° C). Shut off the engine.

2. Remove the oil pan drain plug at the bottom of the engine and allow the oil to drain.

3. Reinstall the oil pan drain plug. Make sure it is tightened securely.

4. Clean around the oil filter head, then remove the filter cartridge.

NOTE: The oil filter is located below the engine radiator and is accessed by the door below the radiator.

5. Clean the oil filter head gasket surface.

6. Apply a light film of oil to the gasket surface before installing the new filter.

7. Turn the filter clockwise until its rubber gasket contacts the filter head, then tighten the filter an additional 2/3 to 3/4 turn.

8. Fill the engine crankcase with new oil to the upper line on the dipstick.

Maintenance


TM

3. Drain and reinsert components.

1

2

3

4

Figure 5-2. Water Separator

1 - Pump

2 - Filter Body

3 - Plug

4 - Clip

To clean the water separator:

1. Follow the previous steps for draining the water separator.

2. Loosen and remove the filter body and clean it with light oil.

3. Reinsert and tighten.

Changing Engine Fuel FilterReplace the engine fuel filter semi-annually or every 500 service hours.

Refer to the engine manufacturer’s manual for additional information on engine service. Use manufacturer’s recommendations for engine fuel filter replacement and bleeding the fuel system.

1. Refer to Preparing The Machine For Maintenance and park the machine.

2. Allow the engine to cool completely.

3. Locate the fuel filter on your machine’s engine.

Always check the level on the dipstick before adding more oil. Too much oil can cause as much engine damage as not enough.

NOTE: After replacing the oil filter cartridge, it may be necessary to start the engine and allow the oil to circulate. Stop the engine, wait a few moments, then recheck the oil level with the dipstick. If it is low, add more oil to the proper level on the dipstick.

9. Start the engine and inspect for leaks at the filter and drain plug.

10. Shut the engine off and re-check the oil level with the dipstick. Wait 5 minutes for the oil to drain down before checking.

Fuel SystemKeep the fuel tank full to prevent condensation from forming. Fill the fuel tank at the end of each day.

Diesel fuel is highly explosive. Do not expose fuel to sparks or flames. Do not smoke while performing maintenance on the engine fuel system.

Use ultra-low sulfur diesel fuel. (If operating the machine frequently in cold weather, blended fuels or No. 1 diesel fuel is recommended to prevent fuel filters from gelling. Using No. 1 diesel fuel may reduce engine performance by approximately 10 percent.)

Fuel contaminated by water or dirt can cause severe damage to engine components.

Water SeparatorWater and dirt that gets into fuel settles into the water separator. (Figure 5-2) As it collects, a red float rises. When the float reaches the line on the separator, an error code will appear on the PV480 digital display. It is important to drain it immediately.

If you run out of fuel, it is important to pump the water separator to prime fuel injection lines. Failure to do so can adversely affect performance.

To drain the water separator:

1. Pull retainer clip from plug to disconnect the harness.

2. Unplug the harness, then unscrew the plug.

5

Maintenance


TM

55

NOTE: The fuel filter/ water separator is located on the access door under the hydraulic tank on the left side of the machine.

Wear eye protection and chemical resistant gloves when using solvent for cleaning purposes. Some solvent can cause skin irritation and eye damage.

Wear eye protection when using compressed air for drying or cleaning components. Never point the nozzle at another individual. Use a safety reduction valve to reduce air pressure to a safe level. Compressed air can cause serious personal injury if misused.

4. Using solvent, thoroughly clean the area surrounding the fuel filter. Dry with compressed air.

5. Turn the fuel filter counterclockwise to remove. Clean the mounting surface and remove any loose filter seals on the head-mounting surface.

6. Fill the replacement fuel filters with clean diesel fuel.

7. Lightly lubricate the secondary filter seal with clean engine oil. Turn the filter clockwise until seal contacts filter head. Tighten filter 1/2 to 3/4 additional turn.

8. Using the priming plunger and instructions in the engine manufacturer’s manual, fill the filters with fuel and bleed the fuel system.

9. Start engine and check for leaks. Tighten or replace filter as necessary.

Bleeding the Fuel SystemOccasionally it may be necessary to bleed, or prime, the fuel system. Bleeding the fuel system is required:

1. After the fuel filter and/or hoses have been removed and replaced.

2. After the fuel tank has become empty.

3. Before using the machine after long storage.

NOTE: Refer to the engine manufacturer’s manual for detailed instructions for bleeding (priming) the fuel system.

Cleaning And Checking Fuel Filler Cap



1. Remove filler cap and inspect for damage. Check cap for dirt and clogging.

2. Using solvent, clean cap thoroughly and dry with compressed air.

3. Check filler cap to insure free air flow. Replace if necessary.

4. Install cap.

Air Cleaner System To prolong engine life and prevent dust

and contaminants from entering the engine, check hoses and hose clamps daily. Replace cracked hoses and tighten loose hose clamps.

Do not open the air cleaner assembly unless the air filter restriction gauge indicates an air filter restriction, or engine operation indicates possible air filter restriction.

Replace the primary filter elements monthly or every 100 service hours. Replace the safety element quarterly or every 250 hours.

The air pre-cleaner should not require maintenance or service unless visible damage is apparent.

NEVER operate the engine without an air cleaner. Destruction of internal engine components will occur within minutes.

5. Access to the air cleaner assembly is by way of the left panel behind the driver’s seat.

6. Before changing the air filter elements, thoroughly clean air cleaner assembly.

7. To change the filter elements, remove the air cleaner end cover by releasing the four spring clips.

Maintenance


TM

8. Clean the air cleaner housing thoroughly. Dry using lint free cloths.

9. Inspect hose clamps and tighten as necessary.

10. Install filter element.

11. Install end cover and secure with spring clips. Make sure evacuator valve is located on the bottom of the end cover after installation.

Radiator and Coolant System

Check the engine radiator daily for rocks and debris. A partially blocked radiator will reduce the efficiency of the radiator and can cause overheating and premature failure of the engine.

Always check the radiator coolant level prior to operating the machine. When the engine is cold, the coolant level should cover the radiator core. When the engine is warm, the coolant level should be at the bottom of the filler tube.

Check the coolant freeze protection level before the start of cold weather. Check with the local authorized dealer for information on freeze protection.

Hot engine coolant can cause serious personal injury. SLOWLY loosen the filler cap to relieve pressure before completely removing the cap completely.

1. Shut down engine and allow radiator to cool.

2. Open the engine compartment door.

3. Inspect radiator for leaks, dents, cracks and damaged cooling fins. Repair or replace as necessary.

4. Inspect radiator cap for wear and damage. Perform pressure/temperature test if necessary. Replace cap as necessary.

5. Check coolant level in radiator recovery reservoir located on the left side of the radiator.

6. Add coolant to the reservoir if needed with 50 percent water and 50 percent ethylene-glycol antifreeze.

Draining and Flushing Coolant SystemSee the engine manufacturer’s manual for information on draining and replacing engine coolant, coolant levels, and coolant specifications. Use engine manufacturer’s recommendations for coolant service.

The LB Performance PTC-15B is filled at the factory with a 50/50 mixture of antifreeze and water to protect down to -34º F (-37º C). Some geographical areas may require special antifreeze or coolant practices. Contact the local authorized dealer for additional information.

Hot engine coolant can cause serious personal injury. Shut off engine. Do not remove radiator filler cap until it is cool to the touch. Slowly loosen filler cap to first stop to relieve pressure before removing cap completely.

1. Refer to Preparing The Machine For Maintenance and park the machine.

2. Shut down engine and remove ignition key.

3. Allow engine to completely cool before removing radiator cap.

NOTE: Dispose of used coolant properly. Check with local environmental officials for information on disposal procedures. Coolant is extremely poisonous and will cause death if ingested by people or animals.

4. Open radiator petcock and drain coolant into a suitable container. Dispose of coolant properly.

5. Open engine block drain plugs (see engine manufacturer’s manual). Drain coolant into a suitable container.

6. Using a good quality coolant system flush product, flush the cooling system using the product directions.

7. Close petcock and engine drains. Fill radiator to full level with 50/50 mixture of antifreeze and water. Contact the local authorized dealer for information on local coolant protection levels.

8. Start engine and run for 15 to 30 minutes to purge air from the engine block. Check coolant recovery tank and fill as necessary.

9. Check recovery tank frequently for proper coolant level.

5

Maintenance


TM

55

Electrical System The LB Performance PTC-15B is factory-equipped with a maintenance-free battery. With proper care, the battery will provide years of trouble-free service.

1. Starting an engine depends heavily upon good cranking speed. It is important that the battery is fully charged and that all cables and terminals are clean and properly connected to the battery.

NOTE: A maintenance free battery should rarely require additional electrolyte.

2. Keep the top of the battery clean. When necessary, wash with a baking soda solution (1 part baking soda to 4 parts water) and rinse with fresh water. DO NOT allow the soda solution to enter the battery cells.

3. Inspect the cables, clamps and hold-down bracket regularly. Clean and apply a light coating of grease when needed. Replace corroded or damaged parts.

Death or serious injury can result from electric shock. When servicing the battery, always disconnect the battery ground (-) cable first. Always reconnect the positive (+) battery cable first.

4. If the battery becomes discharged repeatedly, check the electrical charging system. If the engine is difficult to start or the battery seems weak, clean and check the terminal connections. If the problem continues, use a battery tester and check voltage and current draw.

• Shut down engine and remove ignition key.

• Place the positive (red) multimeter lead on the positive (+) battery terminal, and the negative (black) multimeter lead on the grounded (-) battery terminal.

• With the multimeter set at 12 VDC, the battery must show a charge of at least 12 volts. If necessary, charge the battery or perform a load test.

• Start the engine.

• With an operator in the operator’s seat, check the battery charge level. The multimeter should read at least 13.5 volts.

• If the multimeter does not indicate minimum charge, check the roller’s charging system.

Death or serious injury can result from explosions due to explosive gas around the battery. Sparks or flame can ignite this gas causing an explosion. Always shut off the battery charger before disconnecting cables from the battery terminals.

Always wear eye protection when servicing batteries. Caustic solutions can cause serious eye injuries.

5. If the roller is to be stored for more than 30 days, remove the battery from the roller and store it in a cool, dry place. During storage, keep the battery fully charged and check the level of the electrolyte regularly.

When removing or replacing the battery, always disconnect the battery ground (-) cable first. Always reconnect the positive (+) battery cable first.

NOTE: When replacing the battery, discard the old battery properly.

The alternator supplies electrical current for charging the battery and electrical power to the electronic controls. The built-in regulator controls the voltage output. If the wires must be disconnected from the alternator, mark them so they can be reconnected properly.

Never polarize an alternator. Never ground alternator terminals or circuits.

Always disconnect the battery before disconnecting or connecting the alternator. Never disconnect the alternator while the machine is operating. Be sure wiring is properly connected before connecting the battery.

When servicing the electrical system, always remove the battery’s ground cable first followed by the positive cable. Generally, if the negative cable is grounded during removal, sparks will not occur. If the positive cable is grounded during removal, sparks will occur and could ignite explosive gases.

When the battery is connected, remember:

• Disconnect negative (-) battery cable when working on or near the alternator.

• Do not attempt to polarize alternator.

• Make sure alternator wires are correctly connected before connecting battery terminals.

• Do not ground alternator output terminal.

• Do not disconnect or connect alternator wires while battery is connected or while alternator is operating.

Maintenance


TM

• Connect the battery or booster battery in the correct polarity, [positive (+) to positive (+) and negative (-) to negative (-)].

• Do not disconnect battery when engine is running and alternator is charging.

• Disconnect battery cables before connecting battery charger to battery.

FusesThe LB Performance PTC-15B electrical system is protected from overload damage by fuses. If an electrical component fails to operate, check the fuse panel first to make sure that a fuse is not blown. Access the fuse block through the small door on the bolted panel below the instrument panel.

Fuses that blow may be replaced but will continue to blow until the cause of the overload is found and corrected.

Replace fuses and circuit breakers with correct amperage to prevent damage from system overload.

LightingInspect lights daily for proper operation. If a light or group of lights does not function:

• Check the fuse panel located below the instrument panel for a blown fuse.

• Examine all visible wiring connections, ensuring they are securely fastened.

• If the light(s) still does not work, remove the lens from the light and inspect the bulb(s), replacing any that appear damaged or discolored.

• Check lighting mounts for proper grounds.

• If the trouble is not located, inspect wiring harnesses for damage. (Section 6) Always replace or repair the protective loom which covers the wiring to prevent future damage to the wiring harness. Examine the routing of the harness and make sure it is not subjected to the type of excessive movement which causes broken wiring.

Hydraulic System Death or serious injury can result

from entanglement in moving parts. Do not service the LB Performance PTC-15B while it is in motion or while the engine is running. If the engine must be running to service a component, place transmission in neutral, apply park brake, block wheels, and use extreme caution.

Your LB Performance PTC-15B consists of a variable displacement Sauer/Danfoss Series 90 pump and motor which provide drive power for the brush. A gear-type hydraulic pump is directly connected to the Sauer/Danfoss pump, and provides operational pressure for the power steering, brush lift, brush swing and brush drive.

A 25-gallon hydraulic tank and filter(s) complete the hydraulic system. This manual contains general system maintenance guidelines. Detailed service and maintenance information is available directly from the hydraulic component manufacturers.

Hydraulic Fluid Your LB Performance PTC-15B was factory filled with All-Weather All-Temp VG32 hydraulic oil, a multi-grade anti-wear oil for use in equipment where wide temperature ranges are encountered. Its features include excellent pour point depression, high viscosity index, and resistance to oxidation, foaming and corrosion, as well as protection against pump component wear. It is highly recommended for use in mobile and other hydraulic equipment in heavy-duty all-weather service. It meets the FMC Hi-Performance, Hydraulic Oil Grade 22-32 requirements.

Citgo A/W All-Temp VG32 has a pour point of -30° F (-34° C) and a maximum hydraulic reservoir temperature of 160° F (72° C). It will loose one half its life for every 20° F (-7° C) rise in the ambient temperature. Oil life above 200° F (94° C) is in excess of 1000 hours. However, hydraulic oil maintenance intervals should be followed.

Contact your authorized dealer for more details on hydraulic oils, or if you are considering an alternative oil due to availability or climate.

LB Performance PTC-15B performance can be affected if the wrong hydraulic oil is used. Use only as indicated by Lubricant Types in Specifications section.

5

Maintenance


TM

55

2. If leaking fluid is found, it is probably on the pressure side of the hydraulic system. Find and repair the leaking component before starting the roller.

3. Leaks on the suction side of the hydraulic system are more difficult to find. This condition is serious since air or dirt introduced into the hydraulic system causes rapid component wear and eventual failure. Some symptoms of suction leakage are:

• Foaming of hydraulic oil

• Sluggish hydraulic system operation

• Unusual noise in hydraulic pump or motor

• If a suction side leak is suspected, verify that all reservoir connectors and fittings are properly tightened. If the problem persists, replace the defective hose assembly or fitting.

Temporary repairs to hydraulic hoses will fail and can cause serious injury. Never attempt to repair hydraulic hoses with tape, clamps, or cements.

4. The operator should inspect the roller during operation for hydraulic leaks which may only be noticeable while the unit is running.

Checking Hydraulic Oil Level Check the level of hydraulic oil prior to each day’s operation. Hydraulic oil should be visible in the sight gauge. If not, fill the tank until oil is visible in the sight gauge.

1. Refer to PREPARING MACHINE FOR MAINTENANCE and park machine.

2. Make sure all cylinders are retracted.

3. Wait ten minutes for oil to drain after engine has been shut down.

4. Check hydraulic tank sight gauge. The hydraulic oil level should be in the upper half of the sight gauge but never above the upper fill line.

5. Add Citgo A/W All-Temp VG32 hydraulic oil as needed.

Use extreme caution when removing the filler cap to prevent any foreign matter from entering the hydraulic reservoir.

6. Clean the fill cap strainer each time hydraulic oil is added or changed.

Hydraulic Oil Requirements Substandard performance or hydraulic

component failure can occur if mixed manufacturers or grade weights of hydraulic oil are used. Use only as indicated by Lubricant Types in Specifications section.

1. Be sure hydraulic oil selection is compatible with your hydraulic system.

2. Be sure to use mineral base hydraulic oil.

3. Be sure hydraulic oil selection assistance is from a reputable supplier.

Hydraulic oil must provide anti-wear properties that meet or exceed those found in the API (American Petroleum Institute) classification SD, SE or CC crank case oil.

Hydraulic oil viscosity must not fall below 70 SUS (13 cs) in the reservoir under the most adverse conditions. The best viscosity rating is 80–300 SUS (17 cs–65 cs). The viscosity rating at the lowest expected start-up temperature should not exceed 10,000 SUS (2158 cs).

Hydraulic oil must have rust and oxidation inhibitors that will maintain chemical stability. When changing the hydraulic oil with oil other than the specific factory fill oil, the hydraulic system must be completely drained. Be sure to purge or drain all hoses, cylinders, valves, motors and pumps of hydraulic oil. All hydraulic oil filters must also be changed at this time.

Hydraulic System Checks 1. Before each day’s use, inspect the LB Performance

PTC-15B for hydraulic leaks. Check weekly to make sure that all hose fittings are secure and tight.

Hydraulic fluid under pressure will pierce the skin and cause serious injury. Never use your hand to locate hydraulic leaks, use a piece of wood or cardboard to locate leaks. If hydraulic oil has pierced the skin, get immediate medical attention.

Hydraulic fluid under pressure will pierce the skin and cause serious injury. Always wear eye protection when inspecting for leaks in the hydraulic system.

Maintenance


TM

Checking And Cleaning Hydraulic Reservoir Filler Cap



1. Remove filler cap and inspect for damage. Check cap for dirt and clogging.

2. Use solvent to clean cap thoroughly. Dry with compressed air.

3. Check filler cap to insure free air flow. Replace as necessary.

4. Install cap.

Changing Hydraulic Filters1. Refer to PREPARING MACHINE FOR

MAINTENANCE and park machine.

2. Allow the engine to cool completely.

3. Locate the hydraulic filters by removing the panel behind the driver’s seat.

4. Thoroughly clean the filter and filter head with a lint free cloth.

5. Remove the hydraulic reservoir filler cap.

6. Turn the filter bowl counterclockwise to remove. Clean the mounting surface with a lint free cloth and remove any loose filter seals in the filter-head mounting surface.

7. Drain and remove the filter element from the filter bowl.

8. Using solvent, thoroughly clean the bowl. Dry using compressed air.



9. Lightly lubricate the filter bowl seal with clean hydraulic oil.

10. Place element into bowl.

11. Install bowl on filter head and turn clockwise until the seal contacts the mounting surface. Tighten the filter 1/2 to 3/4 additional turn. Tighten filter bowl to 45 ft. lbs. (60.8 Nm) torque.

12. Check hydraulic level in reservoir and fill with Citgo A/W All-Temp VG32 as necessary.

13. Start engine and check for leaks. Tighten or replace filter as necessary.

After changing the filter, idle the engine for 3 minutes with the Direction Control lever in neutral and park brake engaged. At the end of this idling period, disengage the park brake and slowly move the Direction Control lever FORWARD and REVERSE. This procedure will remove any air induced into the system by the removal of the filter. Failure to follow this procedure may cause partial or complete failure of the hydraulic pump.

Draining, Flushing, And Filling Hydraulic Oil ReservoirCondensation that may build up in the hydraulic system is capable of clogging the filter elements. This can lead to insufficient hydraulic fluid at the pump and will degrade performance. Clogged filter elements can damage the hydraulic pump and other system components.

Drain and replace hydraulic oil and filter after the first 100 hours of service, and after every 500 hours of service or seasonally, whichever comes first. The suction strainer should be removed and cleaned at the 500 hour interval or whenever the hydraulic oil is changed.

1. Refer to PREPARING MACHINE FOR MAINTENANCE and park machine.

2. Remove reservoir filler cap.

3. Remove drain plug and drain the hydraulic oil into a suitable container. Dispose of oil properly.

5

Maintenance


TM

55

4. Flush hydraulic reservoir completely.

5. Install drain plug.

6. Replace the suction filter.

7. Replace high-pressure filter.

8. Fill hydraulic oil reservoir to proper level.

9. Install filler cap.

10. Start engine and operate hydraulic control levers several times. Check hydraulic oil sight gauge and fill as necessary.

Pumps And MotorsThe hydraulic pump and motor generally require no regularly scheduled maintenance. Frequent inspection for leaks will indicate the need for service of these components.

Adjusting Priority Relief ValveThe Priority Circuit on the hydraulic pump supplies the power steering with approximately 7 GPM (26.5 l) of hydraulic flow. This flow goes to the steering circuit before any other circuit.

The Priority Relief Valve controls the maximum operating pressure for the power steering. The Relief Valve is located under the brake and 2-speed solenoid valve..

The following are signs that the Priority Relief Valve needs adjusting:

1. Total or partial loss of steering functions or hard steering.

2. Constant noise from hydraulic pump when using steering.

3. Hydraulic oil overheating.

If it becomes necessary to readjust the Relief Valve setting, follow these steps:

1. Plumb a 0 to 5000 psi (352 kg/sq.cm) pressure gauge into the Priority Flow Circuit between the flow divider valve and the steering orbital. Parts needed for this, including a pressure gauge, can be obtained from your authorized dealer.

2. Start the engine and warm the hydraulic oil to at least 100° F (38° C).

3. Set the park brake and be sure the transmission is in neutral. Use the park brake as an extra precaution.

4. Increase engine speed to 2500 RPM.

5. Turn the steering wheel all the way to the left or right until it stops. Continue to hold pressure to the steering wheel until a gauge reading is taken.

6. The pressure gauge should read 1500 +/- 50 psi (105.5 +/- 3.5 kg/sq. cm).

7. Adjust relief pressure by removing the locknut and turning the adjusting screw clockwise to increase pressure and counterclockwise to decrease pressure.

Water Spray System Do not fill water tank with any liquid

other than water or an asphalt release agent. Chemicals can react with heat and asphalt products and cause an explosion.

To prevent damage to the water system during freezing temperatures, disconnect the strainer from the hose assembly so that the water drains from the water tank and pump.

The water system is gravity fed. To drain the tank, disconnect the strainer from the hose assembly located under the front step on the right side of the machine

Run the water pump for 20 seconds to purge any trapped water.

Adjusting Spray PatternThe water tank is located at the front of the Roller directly above the front ballast. The water tank fill cap is located on top of the water tank. Maintain an adequate supply of water in the tank to insure consistent operation of the spray system.

The pressurized water system supplies water to the Roller’s spray nozzles. The water cools the tires and helps prevent asphalt from sticking to them during operation.

The water spray pattern may require occasional adjustment. Check spray patterns periodically at both front and rear tires.

Maintenance


TM

Use the following procedure to adjust the spray pattern.

1. Use an Allen wrench to loosen the set screws on both sides of the spray bar (Figure 5-3).

Figure 5-3. Water Spray Bar

2. Direct the spray pattern from the nozzles to insure complete coverage across the width of the Roller tires.

3. Tighten the set screws. Individual spray nozzles can be adjusted by loosening the wing nut at the end of the spray nozzle. Direct the spray pattern as needed, and tighten the wing nut.

Cleaning Water Spray NozzlesDepending on operating conditions, the water spray nozzles may become clogged or damaged and require cleaning or replacement. Use the following procedure to clean the water spray nozzles:

1. Turn off the engine and set the park brake.

2. Remove the wing nut at the end of the clogged spray nozzle.

3. Disassemble the spray nozzle and remove the inner filter screen cartridge (Figure 5-4).

Figure 5-4. Spray Nozzle Housing

4. Clean the interior and exterior of the spray nozzle housing.

5. Using compressed air and a water-soluble cleaning solvent, remove all contaminants from the filter screen cartridge.

6. Reassemble and operate the water spray system to insure proper delivery and spray pattern.

5

Maintenance


TM

55

Water Pump ReplacementThe water pump supplies a constant flow of water to the water spray bar. The water pump is located under the front step on the right side of the machine.

Follow these steps to replace the water pump.


2. Completely drain the water tank.

3. Remove the bolts securing the water pump to the Roller frame.

4. Remove the electrical connector plug from the water pump.

5. Remove the fittings and hoses from the water pump.

6. Remove the water pump from the Roller frame.

7. Install replacement water pump and reattach all fittings, hoses, and hardware to the pump.

8. Check water pump for leaks and proper operation of the spray system.

ScrapersThe tire scrapers are factory adjusted to insure optimal surface tension. Check scraper springs and scraper blades for excessive wear. Replace scraper springs and blades as required.

Coco MatsThe coco mats provide a more even distribution of water across the face of the tires. With continued use, they will accumulate asphalt build up. Check the mats periodically and replace them when they show excessive wear or asphalt build up.

Tires and Wheels Do not service the machine while it is

in motion or while the engine is running. If the engine must be running to service a component, place transmission in neutral, apply park brake, block wheels, and use extreme caution.

1. Check tires for excessive wear, correct tire pressure, and objects embedded in or between the tires.

Never exceed tire manufacturer’s maximum recommended inflation pressure.

2. Protect tires from contact with petroleum products and chemicals.

3. Check tires and wheels for cuts, bubbles, damaged rims, or missing wheel bolts or nuts.

4. Wheel lug nuts should be checked for tightness weekly. Torque to 85 ft. lbs (115 Nm).

NOTE: See Section 4 for tire pressure adjustments when adding ballast for compaction.

Changing The Tires1. Park the roller on a flat surface.


3. Loosen and remove the lug nuts.

4. Remove bolts and tire.

5. Install repaired or replacement tire on the machine; tighten lug nuts alternately in a star pattern to 85 ft. lbs (115 Nm).

Axles And Brakes Securely support chassis when

removing the wheels. Do not lie under the machine while it is supported only by a jack. Use jack stands on a solid surface to prevent tipping of the machine when it is raised. Block the remaining wheels to prevent rolling of the machine when it is raised.

Front wheel bearings should be removed, inspected, and repacked with a high quality wheel bearing grease after every 500 service hours or seasonally.

To reinstall bearings and hub, tighten the retaining nut until the wheel drags during hand rotation. Then back off the nut 1/8 turn and bend over the locking tab or install the cotter pin, depending upon the design configuration.

Maintenance


TM

Roll Over Protective Structure (ROPS)ROPS structures are not intended as external load carrying members. Do not mount attachments such as pull hooks, winches, side booms, etc., without the ROPS manufacturer’s approval.

Attachments such as mirrors, fans, heaters, lights etc., should be installed following the manufacturers’ guidelines. Typically, these attachments are located in non-critical areas such as roof sheets, enclosure sheet metal or the middle portion of the ROPS legs.

Do not weld or drill on the ROPS structure. This will degrade the ROPS system’s capability and create an unsafe condition as well as expose operators and bystanders to liability damages. Consult the ROPS manufacturer for recertification after adding any attachments to the ROPS structure.

When users fail to inspect and maintain this equipment, ROPS equipment may become structurally inadequate and may fail during normal operation.

Do not make modifications to the basic design, such as raising canopy height or relocating ROPS legs. Recertification is required.

Following are some in-service factors that may degrade a ROPS system’s energy-absorbing or load carrying capability. These factors can create an unsafe condition as well as expose operators and bystanders to liability damages.

1. Structural damage from vibrations and/or loadings during operations.

2. A corrosive environment.

3. Continued use of the machine after a rollover or accident involving structural damage.

4. Unauthorized modifications.

5. Worn or deteriorated isolation mounts.

6. Replacement bolts having less than the correct grade.

7. Failure to maintain proper bolt torque.

NOTE: With periodic inspections, cracks, loose bolts, damage and other normal wear-and-tear related problems can be corrected before they become serious. Regular periodic inspections during maintenance procedures can ensure optimum performance.

Since most ROPS are unique and employed in different service environments, no specific inspection interval can be recommended. Frequent visual checks of mounting hardware, and inspection in conjunction with regular service intervals is suggested.

Replace missing or damaged hardware with the manufacturer’s specified hardware. Re-torque all loose threaded fasteners to the manufacturer’s specifications.

Clean and disassemble the machine as necessary and inspect for cracks in the structure and mounting system. Replace worn or damaged resilient mounts to prevent further damage to the mounting surfaces and to prevent more severe vibration problems.

Cracks are usually associated with weld details and usually show as a line of rust before they appear as a crack. Rust lines should be taken as indications of cracks. Determine the repairability of cracks in the ROPS structure on the basis of the crack details and its effect on the particular design. The manufacturer must be consulted at this step. Some general rules that may be helpful are:

• Enclosure sheet metal cracks can be repaired.

• Small cracks may be repairable. Consult the ROPS manufacturer.

• If damaged by rollover, collision or fire, consult the ROPS manufacturer.

• In all cases, when in doubt, consult the ROPS manufacturer.

• Verify that water drainage paths will not trap water. Trapped water can freeze and crack or deform the structure.

• Extensive paint peeling should be repaired before rust occurs and weakens the structural integrity.

• Check for the presence and operability of a seat belt. The belt should be clean, free of dirt and grease, and the latch should function smoothly.

Inspect the ROPS structure following a rollover, collision or fire. Failure to do so can result in serious injury from operating functionally unsound equipment.

5

Maintenance


TM

55

Storage

Preparing For Long Term StorageA stored machine requires as much periodic maintenance as a machine at work. Stored units must receive periodic scheduled maintenance.

1. Clean the machine. Paint chipped or rusty areas to prevent rusting.

2. Inspect the machine thoroughly and repair worn or damaged parts.

3. Retract all hydraulic cylinders, as far as possible.

4. Coat with grease or rust inhibitor all exposed cylinder rods, seals, and O-rings to prevent cracking.

Some rust inhibitors can destroy painted surfaces. Do not spray rust inhibitor on painted surfaces.

5. Lubricate all grease points. Make sure all grease cavities are filled with grease. See Table 7-1, Maintenance Interval Chart.

6. Remove alternator belt.

7. Remove the battery and store in a cool, dry place.

8. Check air filter restriction gauge. Clean the air cleaner assembly and pre-cleaner. Replace air filter elements if restricted.

9. Top up all fluid levels to minimize condensation forming inside the tanks.

10. Check engine oil level and fill as necessary.

11. Perform specific gravity test on engine coolant. Drain and replace or fill coolant reservoir as needed to prevent freeze damage.

12. Check hydraulic oil sight gauge and fill as necessary.

13. Inspect all air and hydraulic hoses, couplers, fittings and cylinders. Tighten any loose fittings and replace any hoses that are worn.

14. Drain the water system and spraybar lines.

15. If water ballast was used, drain tanks or add antifreeze mix to both front and rear ballast compartments.

16. Check all safety decals. Replace any decals that are damaged or illegible. Refer to Decal Installation in this section.

17. Place transmission lever in neutral, idle the engine a few minutes before shutting it down, and set the park/emergency brake.

18. Remove ignition key and lock any optional panels. Cover seat with plastic, and place a DO NOT OPERATE tag on the steering wheel.

19. Store machine in a dry, protected area. If stored outside, cover with waterproof material.

Periodic Maintenance During StorageIf a unit will not be used for more than two months, refer to Table 4-1, Maintenance Interval Chart, and follow procedures for 100-Hours interval, as well as these preventive maintenance procedures:

1. Keep battery fully charged and check the level of the electrolyte regularly.

2. Check for water in hydraulic fluid. Any machine that is stored for an extended period in a climate that has a wide range of temperatures and/or humidity, will develop condensation on the inside of the tank walls. Check the hydraulic fluid on a regular basis for possible moisture contamination.

Hydraulic oil that is contaminated, must be drained, the filter elements replaced and the tank refilled with LeeBoy approved fluid. Failure to do this could result in premature failure of the pumps and/or motors.

3. Start and run the engine until it is warm. Cycle all hydraulic and/or hydrostatic functions until all components are warm and the hydraulic fluid is up to operating temperature.

4. After the machine is warmed, grease all pivot points. See Figure 4-1, Lubrication Points.

Removing The Machine From Storage1. Follow steps above in Periodic Maintenance During

Storage.

2. Refer to Table 7-1, Maintenance Interval Chart. Check all fluid levels, belt tensions, and bolt torques.

3. Replace alternator belt.

4. Replace battery. Refer to Battery Maintenance earlier in this section for additional instructions.

5. Clean grease or rust inhibitor from all exposed cylinder rods, seals, and O-rings.

Maintenance


TM

WELDMENT

Figure 5-5. Welding

If the machine has been damaged or metal parts worn due to extensive use, minor welding may be necessary for repair. Welding is very dangerous. Only individuals who are properly trained should weld in a dedicated area away from others as even looking at ultraviolet light from the flame can cause serious eye injury.

Welding hazards include toxic fumes, harmful dust, light radiation, burns, combustion from sparks and the potential for extensive damage to the eye. There is also a danger of electric shock. If combustible or flammable materials are nearby, the heat and sparks produced by welding can cause fires or explosions.

TURN THE BATTERY SWITCH OFF AND DISCONNECT BATTERY TERMINALS BEFORE WELDING ON THE MACHINE.

Electrical current can ignite fire or cause an explosion, therefore it is critical to turn off power to the machine. It is also important to grind off the paint to ensure proper ground on the area being welded.

DO NOT MAKE MODIFICATIONS TO THE MACHINE. ONLY weld if needed for repair purposes. Weldment modifications to the machine can void your warranty.

5

Maintenance


TM

55

General Information The troubleshooting chart below identifies the most common symptoms of failure. Use this chart to help identify the failed component.

For specific engine and hydraulic problems not covered here, see the Engine or Hydraulic Pump and/or Motor Manufacturer’s manual.

ANY UNAUTHORIZED REPAIR WILL VOID THE WARRANTY. Do not attempt to service or repair major components such as the engine, hydrostatic pump or motor unless authorized to do so by your LB Performance Dealer.

Troubleshooting Charts

SYMPTOM CAUSE REMEDY

Engine does not crank

Battery weak or dead. Charge or replace battery.

Neutral start switch not activated. Put Direction Control lever in neutral.

Park brake not engaged. Set the park brake.

Faulty ignition switch. Replace switch.

Faulty start solenoid. Replace solenoid.

Faulty starter. Repair or replace

Engine cranks but does not start, or starts hard

Engine cranking speed too low (below 150 RPM).

Clean battery terminal connections. Charge or replace battery.

No fuel in tank. Add fuel to tank.

Debris or dirt in fuel.

Drain small amount of fuel from tank sump into clean container. Inspect for debris. Drain and flush fuel system and change fuel filter.

Water in fuel. Water frozen in fuel lines or fuel filter.

Thaw and/or drain water from fuel tank sump and fuel lines. Install new fuel filter.

Wrong grade of fuel for low ambient temperature. Fuel is gelled in tank or lines.

Warm machine. Drain fuel system and change fuel filter. Refill tank with correct fuel.

Air entering suction side of fuel system.

Check for bubbles in fuel filter. Tighten connections. Inspect fuel lines for damage.

Fuel filter plugged or restricted. Replace fuel filter.

Fuel tank cap vent is clogged.Remove cap. Listen for air entering the tank suddenly. Clean and replace cap.

Intake or exhaust system restrictedRemove restrictions or replace filter elements

Air in low pressure side of fuel system.

Check for air leaks in the low pressure side of the fuel system. Prime fuel system. See engine manufacturer's manual.

Maintenance


TM


Engine cranks but does not start, or starts hard

No voltage to fuel shut-off solenoid.Voltage should be 9 volts with the ignition switch in the ON or START position.

Fuel shut-off valve closed. Open valve.

Insufficient fuel supply to injector pump and nozzles.

Check fuel supply system. Clean or replace fuel filter.

Fuel solenoid is defective.Check/replace defective fuel solenoid. See engine manufacturer's manual.

Fuel transfer pump is defective. Repair or replace fuel transfer pump.

Injection pump malfunctions. See your authorized dealer.

Carbon deposits on injection nozzle. Clean or replace nozzle if needed.

Injection nozzle(s) malfunctions. See your authorized dealer.

Worn piston rings. Low compression.

See your authorized dealer.

Incorrect valve clearances. Adjust clearance.

Blown head gasket. See your authorized dealer.

Engine cranks slowly

Wrong weight oil for low ambient temperature.

Drain and refill with correct weight oil. Change oil filter.

Loose or dirty connections at battery.

Clean battery posts and cable ends. Reinstall cables.

Loose or dirty connections at starter.Clean connections at start relay and starter.

Battery cables damaged or broken. Replace cables.

Battery discharged or failing to take a charge.

Disconnect battery from machine. Recharge battery. If it fails to charge, replace battery. Check alternator output (12 volts), wiring for shorting to ground, and alternator belt tension. Repair or replace components as required.

Starter motor malfunctions. Seized bushings, bent armature shaft, worn bushings, or armature "dragging".

Check starter current draw. See your authorized dealer for starter repair.

Engine surges, stalls, or operates poorly at slow speed

Air entering suction side of fuel system.

Check fuel filter for air bubbles. Tighten fittings and connections. Inspect lines for damage.

Fuel tank cap vent is clogged.Remove cap. Listen for air entering the tank suddenly. Clean and replace cap.

Water or debris in fuel.

Drain water from sump in fuel tank. Check drained fuel for debris. Drain and flush fuel system. Replace fuel filter.

5

Maintenance


TM

55


Engine surges, stalls, or operates poorly at slow speed

Fuel gelled due to low ambient temperature.

Drain fuel system. Refill engine with correct grade fuel. Replace fuel filter.

Fuel filter is clogged.Check for debris in fuel system. Replace filter.

Return line from injection pump to tank is restricted.

Check line for kinks or damage. Check line for debris. Clean with compressed air.

Air filter elements are clogged. Clean or replace air filter elements.

Fuel transfer pump is clogged or defective.

Repair or replace pump. See your authorized dealer.

Carbon deposits on injection nozzle.See your authorized LB Performance dealer.

Injection pump or nozzle(s) malfunctions.

See your authorized LB Performance dealer.

Incorrect valve clearance. Adjust clearance.

Basic engine malfunction. Leaking head gasket, sticking or burnt valves, incorrect valve clearance or timing, worn or broken piston rings.

See engine manufacturer's manual.

Engine power output is low

Operating engine at high altitude.De-rate engine power output for altitudes above 10,000 feet.

Air intake piping restricted. Remove restrictions.

Air cleaner element dirty.Clean or replace air cleaner elements.

Fuel suction line or filter restricted.Check fuel line for restrictions. Replace fuel filter element(s).

Fuel return system restricted. Correct restricted fuel return system.

Water in fuel or wrong grade of fuel.Drain and flush fuel tank and refill with correct fuel. Replace fuel filter.

Fuel transfer pump malfunctioning.Replace fuel transfer pump. See engine manufacturer's manual.

Engine power output is low

Ground speed is too fast.Pull back on Direction Control lever and increase engine RPM.

Excessive load. Reduce load.

Low charge pressure at hydrostatic pump causing park brake to drag.

See service manual for pump.

AFC signal line is defective. See engine manufacturer's manual.

Internal hydraulic system leakage. See your authorized dealer.

Basic engine malfunction. Leaking head gasket, sticking or burnt valves, incorrect valve clearance or timing, worn or broken piston rings.


Maintenance


TM


Engine emits excessive black or gray exhaust smoke.

Restricted air filter element.Check and clean or replace air filter elements.

Incorrect grade of fuel.Drain and flush fuel tank, and fill with correct grade of fuel. Replace fuel filter.

Engine overloaded.Remove load. Run at fast idle to clear the engine.

Incorrect injection pump timing.Repair or replace pump. See your authorized dealer.

Excessive fuel delivery. Injection pump or nozzle(s) malfunctions.


Cranking speed too low (below 150 RPM).

Clean battery terminal connections. Charge or replace battery.

Injection pump or nozzle(s) malfunctions.


Basic engine malfunction. Excessive oil consumption.


Engine noise (abnormal rattle, knock, or squeal)

Low engine oil level. Fill reservoir to correct level.

Lightweight engine oil used in high ambient temperatures.

Drain and fill reservoir with correct weight oil.

Fuel in engine oil.Drain and refill reservoir with correct oil. Check fuel system to find leakage, and repair leaks.

Loose or worn hydraulic pump drive coupling.

Repair or replace coupling.

Injection pump timing is incorrect. See your authorized dealer.

Internal engine component wear. See engine manufacturer's manual.

5

Maintenance


TM

55


Engine does not shut off

Electrical wiring fault is supplying power to fuel solenoid when key is in OFF position.

Repair wiring.

Faulty diode in engine wire harness at alternator.

Check diode wire connection and/or replace diode.

Injection pump fuel solenoid is faulty.Check solenoid for defects or foreign material inhibiting proper operation.

Engine operating on fumes drawn into air intake.

Locate and isolate the source of fumes.

Low idle set too high. Set idle to specifications.

Engine oil pressure is low

Electrical power not being supplied to gauge.

Check fuses.

Incorrect oil level. Too high or too low.

Check for leaks. Add or drain engine oil. Check dipstick calibration.

Oil filter is clogged. Change oil filter.

Oil is diluted with fuel.Replace fuel injector, fuel transfer pump and/or injection pump.

Oil is diluted with coolant. See authorized engine repair facility.

Incorrect oil specifications.

Change oil. Check oil specifications. See Engine Maintenance in this section. See engine manufacturer's manual.

Oil pressure sender or gauge is malfunctioning.

Replace oil pressure sender or gauge.

Oil pressure control valve is faulty.Repair or replace valve. See your authorized dealer.

Oil pump intake screen is clogged. See your authorized dealer.

Loose oil pump drive gear or worn pump housing.


Internal engine component wear. See engine manufacturer's manual.

Engine overheats

Coolant level too low. Add coolant.

Low engine oil level. Fill to proper level.

Oil viscosity is too light. Drain and refill with proper oil.


Radiator fins damaged or obstructed.

Clean, repair or replace radiator fins.

Collapsed or clogged radiator hose. Inspect hoses. Replace if necessary.

Loose or broken fan drive belt.Check belt tension and tighten if necessary.

Cooling fan shroud damaged or missing.

Inspect shroud. Repair, replace or install as needed.

Dirty or clogged air filter element. Clean or replace air filter element.

Maintenance


TM


Engine overheats

Hot air off engine is being recirculated.

Check radiator seal and repair or replace.

Incorrect or malfunctioning radiator cap.

Check the radiator cap. Replace if necessary.

Temperature gauge or sender is malfunctioning.

Repair or replace sender and/or gauge.

Thermostat stuck in closed position.Test thermostat. Replace if necessary.

Dirt, scale or rust in the cooling system.

Flush cooling system with cleaner. Refill with water/antifreeze solution.

Injection pump timing is incorrect. See your authorized dealer.

Water pump is leaking.Repair or replace water pump. See engine manufacturer's manual.

Excessive fuel delivery or injection pump malfunction.


Hydraulic system overheating. See "Hydraulic System Overheats".

Oil in coolant, or coolant in oilLeaking cylinder head gasket or liner packing.


Cracked cylinder or block. See engine manufacturer's manual.

Excessive fuel consumption

Incorrect grade of fuel.Drain and flush fuel tank, and refill with correct grade. Replace fuel filter.

Air system is restricted. Clean or replace air filter elements.

Fuel system is leaking. See engine manufacturer's manual.

Starter motor will not turn

Battery discharged or faulty. Charge or replace battery.

Battery connections.Clean and tighten battery connections at battery and starter solenoid.

Starter motor.

Listen for starter solenoid to click when key is placed in the START position. If solenoid clicks, repair or replace starter motor.

Starter solenoid.

Check for 12 volts at small solenoid connections when key is place in the START position. If 12 volts is present, replace solenoid.

Starter relay.

Listen for relay to click when key is placed in the START position. If relay does not click, check wiring. Repair or replace as necessary.

Starter system circuit breaker.

Check for 12 volts at both sides of the circuit breaker. If 12 volts is not present on either side, check wiring. If 12 volts is available on one side, replace circuit breaker.

5

Maintenance


TM

55


Starter motor will not turn

Key switch.

Check for 12 volts at ignition switch terminal "st" when key is placed in the START position. If 12 volts is available, check wiring harness.

Neutral start switch on pump.

Check for 12 volts on both sides of switch with machine in neutral. If 12 volts is available, check wiring harness. If 12 volts is available on one side only, replace switch.

Major engine malfunction. See your authorized dealer.

Starter solenoid chatters

Loose connection at battery or solenoid.

Clean and tighten connections.

Battery discharged or faulty. Charge or replace battery.

Faulty solenoid. Replace solenoid.

Starter motor turns but will not crank

Starter pinion gear not engaging flywheel ring gear.

Pinion shift mechanism jammed. Repair or replace starter motor.

Pinion gear teeth broken. Repair or replace starter motor.

Flywheel ring gear teeth broken. Replace ring gear.

Starter motor continues to turn after engine starts

Starter solenoid stuck.Gently tap solenoid. Replace solenoid if defective.

Starter pinion gear not disengaging from flywheel.

Gently tap starter motor. Repair or replace starter motor.

Ignition switch malfunction.

Check for 12 volts at "st" terminal with ignition switch in the ON position. If 12 volts is available, replace ignition switch.

Excessive noise when cranking

Pinion gear teeth broken. Replace starter motor.

Flywheel ring gear teeth broken. Replace ring gear.

Major engine malfunction. See your authorized dealer.

No hydraulic power

Low hydraulic/transmission oil level.Add oil to the hydraulic oil reservoir until visible in the sight gauge.

Hydraulic filter is clogged. Replace filter element.

Hydraulic pumps or pump drive coupling damaged, or excessive leakage in hydraulic system.


Hydraulic functions are slow


Air in hydraulic oil. Oil has foamy appearance.

Inspect suction side hoses and fittings to pump for leakage. Tighten fittings or replace hoses and fittings as required.

Engine RPM is too low.Inspect speed control linkage for damage. Repair or replace parts as required, and adjust linkage.

Hydraulic filter is clogged. Replace filter elements.

Low pump flow or excessive leakage in system.


Maintenance


TM


Hydraulic functions make chattering noise


Hydraulic filter restricted. Replace filter elements.

Hydraulic filter relief valve stuck open, or setting is too low.


Air in hydraulic oil. Suction side leakage.

Tighten fittings and inspect hoses for damage. Replace damaged hoses.

Worn pump, loose pump drive coupling, loose pump attaching hardware, leakage in hydraulic system (pump remains in stroke), misalignment between pump and engine.


Hydraulic functions drift or settle Cylinder or control valve leakage. See your authorized dealer.

Hydraulic system overheats [temperature above 200° F (93° C)]


Hydraulic fluid is too thick.Use SAE 30. This will reduce fluid temperature 20° F (-7° C).


Defective temperature gauge, or sender giving wrong temperature reading.

Replace gauge or sender.

Hydraulic pump priority relief valve set incorrectly or defective.

Adjust relief valve [5000 to 5500 psi (351.5 to 386.7 kg/sq.cm)]. Replace if defective. See Pumps and Motors in this section.

Excessive ambient air temperature and high duty cycle.

Operate unit at slower ground speed and maximum engine RPM during hot weather.

Plugged fins on fluid cooler.Clean fins and correct any other problems with cooling air flow.

Hydrostatic pump bypass valve defective or open.

Repair or replace. If valve is open, turn valve clockwise until seated and torque to 7 to 10 ft-lbs (9.5 to 14 Nm). Overtorquing will damage valve.

Worn hydrostatic pump. Repair or replace pump.

Relief valve on pump set too low, or left out when unit was towed.

Adjust setting [5000 to 5500 psi 351.5 to 386.7 kg/sq.cm)]. See service manual for pump.

Foaming hydraulic oil

Oil level is too high or too low.Adjust oil level to full mark on dipstick.

Incorrect type of oil.Drain, flush, and fill the hydraulic oil reservoir with the correct oil Replace the oil filter.

Pump suction screen restricted. Clean the screen.

Air leakage on suction side of pump.Tighten fittings and inspect hoses for damage. Replace damaged hoses.

5

Maintenance


TM

55


Battery uses too much water.Battery is overcharged.

With battery fully charged, check alternator charge rate. Repair or replace alternator.

Cracked or broken battery case. Replace battery.

Cracked battery case.Battery hold down clamps too tight, loose, or missing.

Replace battery and install hold down clamps properly.

Low battery output.

Frozen battery.Replace battery. Keep battery fully charged during cold weather.

Low water level. Fill with distilled water and charge.

Corroded or loose battery cable connections.

Clean and tighten all connections.

Broken or loose battery posts. Replace battery.

Alternator not charging.

Loose, slipping alternator belt. Replace alternator belt.

Low alternator output. Test and replace alternator.

Loose wiring or faulty connection.Repair or replace loose wiring or connector.

Diode at alternator loose or faulty. Tighten connection or replace diode.

Alternator belt loose or broken. Adjust or replace alternator belt.

Alternator charge rate is too high. Battery is hot or boiling.

Alternator malfunctioning.Load test alternator and replace if necessary.

Noisy alternator

Alternator malfunctioning.Load test alternator and replace if necessary.

Bad alternator bearings.Remove alternator belt and turn alternator by hand. If pulley turns hard, repair or replace alternator.

Worn drive belt.Check and replace drive belt if necessary.

Instrument gauges don't work.

Internal alternator malfunction.Load test alternator and replace if necessary.

Faulty gauge or sender. Replace gauge or sender.

Alternator not charging. Repair wiring or replace alternator.

Faulty wiring. Replace wiring or connector.

Unit does not move, or moves in one direction only.

Park brake engaged. Release park brake.

Damaged hydrostatic pump. Repair or replace hydrostatic pump.

Faulty charge valve on pump. Repair or replace charge valve.

Hydrostatic pump relief valves not seated.

Relief valves are turned out 2 turns when towing the Roller. Turn hex nut cartridge in (clockwise) to seat valve.

Relief valves are bypassing oil at low pressure.

Repair or replace relief valve cartridges.

Damaged hydrostatic motor. Repair or replace hydrostatic motor.

Insufficient charge pressure. See "Park Brake Does Not Release".

Control hardware is loose. Check tightness of all linkage bolts.

Maintenance


TM


Unit does not move, or moves in one direction only

Control linkage stripped or broken. Repair or replace linkage.

Low hydraulic oil level.Fill reservoir with correct fluid until visible in sight gauge.

Leaky fitting or broken hose. Tighten and/or replace.

No voltage to Direction Control lever. Check voltage and wiring.

Unit jerks when operating

Fast movement of Direction Control lever.

Move lever slowly when changing speed and/or direction.

Park brake engaged.Release park brake. See "Park Brake Does Not Release".

Engine speed set too low. Run engine at higher RPM.

Low hydraulic fluid level.Fill reservoir with correct fluid until visible in sight gauge.

Hydraulic oil is too heavy. Change oil.

Clogged hydraulic filter. Clean or replace the filter.

Air leaking into hydraulic system.Tighten or replace hoses, fittings and/or filter(s).

Improper fuel, or dirt in fuel line. Drain fuel, clean fuel line.

Hydrostatic pump is malfunctioning. Repair or replace pump.

Steering is difficult

Low hydraulic/transmission oil level.Fill reservoir with correct fluid until visible in sight gauge.

Low steering pressure.Adjust pressure [1450 to 1600 psi (102 to 112.5 kg/sq.cm)].

Steering cylinder bypassing oil. Replace piston seals.

Hydraulic filters clogged.Check filter(s) for contamination and replace if necessary. See Hydraulic Maintenance section.

Hydraulic pump priority relief valve set incorrectly, or defective.

Adjust relief valve [5000 to 5500 psi (351.5 to 386.7 kg/sq.cm)]. Replace if defective. See Hydraulic Maintenance section.

Worn hydraulic pump.Check for worn pump, and repair or replace.

Worn steering orbital motor.Check for worn steering orbital motor, and repair or replace.

Worn steering cylinder. Repair or replace steering cylinder.

Water spray system does not work

Water level too low. Fill the water tank.

Clogged water spray nozzles.Remove, clean and reinstall the water spray nozzles.

Clogged strainer at bottom of tank. Clean or replace strainer.

Water pump is defective. Replace water pump.

Water pump electrical malfunction.Check, replace or repair electrical connectors or fuses.

Faulty pump diaphragm, valves or motor.

Repair or replace.

5

Maintenance


TM

55


Park brake does not hold

Park brake switch not turned ON. Turn park brake switch ON.

Faulty switch or wiring allowing power to brake solenoid valve.

Repair or replace switch or wiring.

Faulty brake.Repair or replace brake on wheel motor.

Park brake does not release.

Engine not running.Engine must be running to release brake.

Park brake switch is ON. Turn park brake switch OFF.

Faulty brake switch. Replace switch.

Loose wiring to brake solenoid. Repair wiring.

Faulty solenoid on brake valve. Replace solenoid.

Low charge pressure to wheel motors.

Adjust charge relief valves on hydrostatic pump to 350 psi (24.6 kg/sq.cm) at neutral. Engine must be at maximum RPM when adjusting charge pressure.

Faulty hydrostatic pump. Repair or replace pump.

Faulty brake.Repair or replace brake on wheel motor.

Two-speed will not shift to high range (default is low range).

Faulty switch. Replace switch.

Faulty relay. Replace relay.

Incorrect method of operation. Shifting allowed only from neutral.

Loose wiring to solenoid valve. Repair wiring.

Faulty solenoid. Replace solenoid and/or cartridge.

Maintenance


TM

PV480 DIAGNOSTIC TROUBLE CODE (DTC) CHART

LEGENDSPN: Suspect Parameter Number DPF: Diesel Particulate Filter FMI: Failure Mode Identifier

EGR: Exhaust Gas Recirculation ECU: Engine Control Unit CPU: Central Processing Unit

NE-G: Negative Ground NE: Neutral G: Ground

SCV: Selective Control Valve MAF: Mass Air Flow PM: Particulate Matter

DC: Direct Current IC: Integrated Circuit EBC: Electronic Brake Control

PLV: Pressure Limiting Valve CAN: Controller Area Network CM: Control Module

DDC: Direct Digital Control SW: Switch TSC: Torque Speed Control

ETC: Electronic Throttle Control CCVS: Current Controlled Voltage Source

MPROP: Manifold Pressure Rail Operating Pressure

EEPROM: Electrically Erasable Programmable Read-Only Memory

SPN FMI DTC SYMPTOM/CAUSE RECOVERY FROM ERROR

29 3Accelerator position sensor 2: High

Battery short circuit out of sensor/harness. Voltage of accelerator position sensor 2 is 4.8V or less.

Forced idle. (Accelerator = 0%)

Diagnostic counter = zero

29 4Accelerator position sensor 2: Low

Ground short circuit or open circuit of sensor/harness. Voltage of accelerator position sensor 2 is 0.3V or less.



91 2Accelerator position sensor correlation error

Deviation from designed correlation in two sensors. Voltage of accelerator position sensor 1 is 4.8V or less.



91 3Accelerator position sensor sensor 1: High

Battery short circuit or open circuit of sensor/harness. Voltage of accelerator position sensor 1 is 4.8V or less.



91 4Accelerator position sensor 1: Low

Ground short circuit or open circuit of sensor/harness. Voltage of accelerator position sensor 1 is 0.3 or less.



100 1 Oil pressure error. Engine oil pressure. Key switch turn OFF.

102 3Boost pressure sensor: High

Failure of sensor. Voltage of boost pressure sensor is 4.9V or above.

Key switch turn OFF.

(Default value is set in consideration with high altitude usage. Engine power drops.)

102 4Boost pressure sensor: Low

Failure of sensor. Voltage of boost pressure sensor is 0.2V or below.



108 3Barometric pressure sensor error: High

Barometric voltage 4.4V or more.



5

Maintenance


TM

55


108 4Barometric pressure sensor error: Low

Barometric voltage 1.6V or less.



110 0 Engine overheat.Overheat of engine temperature greater than 248° F (120° C)


Output limitation: approximately 75% of normal condition. EGR stop. Intake throttle 100% open.

110 3Coolant temperature sensor: High

Open circuit or +B short circuit of sensor/harness. Voltage of coolant temperature sensor is 4.9V or above.


(White smoke increases at low temperature.)

110 4Coolant temperature sensor: Low

Ground short circuit of sensor/harness. Voltage of coolant temperature sensor is 0.1V or less.



132 1 Intake air volume: LowEngine inlet air mass flow rate tacking. (Disconnect turbo blower intake hose.)


132 3 MAF sensor: High

Engine inlet air mass flow rate less than half of target value. MAF sensor voltage: 4.9V or more at normal operating condition.


Engine is not forcibly stopped by ECU. STRONGLY recommend operator stop engine promptly.

132 4 MAF sensor: LowOpen circuit or ground short circuit of sensor/harness. MAF sensor voltage: 0.1V or less.


Engine is not forcibly stopped by ECU. STRONGLY recommend operator stop engine promptly.

132 15 Boost pressure: LowBoost pressure sensor output is below target level in high air flow operating conditions.

Key switch turn OFF. EGR stop.

Engine power is restricted by boost pressure signal accordingly.

157 0 High rail pressure.Actual pressure exceeds the command pressure. Actual pressure ≥ 197MPa (28600 psi or 2010 kgf/cm2


EGR stop.

157 3Rail pressure sensor: High

Open circuit or +B short circuit of sensor/harness. Failure of sensor. Voltage or rail pressure sensor is 4.9V or above.


Engine running noise and white smoke increases. Engine forcibly stopped.

157 4Rail pressure sensor: Low

Ground short circuit of sensor/harness. Failure of sensor. Voltage of rail pressure sensor is 0.7V or less.


Engine running noise and white smoke increases. Engine forcibly stopped.

168 3 Battery voltage: High

Open circuit, short circuit or damage to harness. Failure of battery. ECU recognition of battery voltage is above 16V in 12V system. Faulty starting.


EGR stop.

168 4 Battery voltage: Low

Open circuit, short circuit or damage to harness. Failure of battery. ECU recognition of battery voltage is below 8V in 12V system. Faulty starting or engine may stop completely. (Not monitored during cranking.)


EGR stop.

Maintenance


TM


171 3Intake air temperature built-in MAF sensor: High

Open circuit or +B short circuit of sensor/harness. Intake air temperature built-in MAF sensor voltage: 4.9V or more.


171 4Intake air temperature built-in MAF sensor: Low

Ground short circuit of sensor/harness. Intake air temperature built-in MAF sensor voltage: 0.1V or less.


172 0Intake air temperature: High

Intake air temperature higher than 140° F (60° C).


172 3Intake air temperature error: High

Open circuit or +B short circuit of sensor/harness. Intake air temperature sensor is 4.9V or above.



172 4Intake air temperature error: Low

Ground short circuit of sensor/harness. Intake air temperature sensor is 0.05V or less.



174 0 Fuel temperature high.Fuel temperature higher than 194° F (90° C).


174 3Fuel temperature sensor: High

Open circuit or +B short circuit of sensor/harness. Voltage of temperature sensor in supply pump is 4.9V or above.


174 4Fuel temperature sensor: Low

Ground short circuit of sensor/harness. Voltage of temperature sensor in supply pump is 0.1V or less.


190 0 Engine speed.Engine speed exceeds threshold speed. Engine speed ≥ 3500 min-1 (rpm).


628 2 Program memory. Check-Sum error.Key switch turn OFF.

Engine stopped without delay.

633 7Pressure limiter emergency open.

Combination of fuel leak and one of conditions below:

1. Rail pressure exceeds 191MPa (27700 psi or 1950 kgf/cm2).

2. Within one second after the rail pressure goes below temperature in #1, it increases above.


EGR stop.

(Engine speed may go down due to lack of fuel pressure.)

636 2Crank position sensor pulse number error.

Open circuit or short circuit of sensor/harness. Failure of sensor. Pulse rotation is not 56 teeth. Faulty starting. Engine vibration increases slightly.


636 7

NE-G phase shift.

NE: Crankshaft position sensor.

G: Camshaft position sensor.

Large phase shift between NE and G pulses within +/- 15 degrees. Engine hesitates at start-up.


5

Maintenance


TM

55


636 8No input of NE sensor pulse.

Open circuit or short circuit of sensor/harness. Failure of sensor. No recognition of NE sensor pulse. Faulty starting. Engine vibration increases slightly.


651 3Open circuit of harness/coil in 1st cylinder injector.

Open circuit of harness or injector coil. Engine vibration increases. Injectors that have no error are operated.


652 3Open circuit of harness/coil in 2nd cylinder injector.



653 3Open circuit of harness/coil in 3rd cylinder injector.



654 3Open circuit of harness/coil in 4th cylinder injector.



676 0Glow heater relay driving circuit overheat.

Glow relay coil resistance or load is too high. Faulty starting. White smoke increases.


676 5Open circuit of glow relay driving circuit.

Open circuit of harness or relay coil. Faulty starting. White smoke increases.


679 7 Pressure limiter not open.Rail pressure value is sticking or not enough engine power to open PLV forcibly.


723 2G sensor pulse number error.

After fault opening PLV, rail pressure is above 160 MPa.


Engine stops.

723 8No input of G sensor pulse.

Open circuit or short circuit of sensor/harness. Failure of sensor. No recognition of G sensor pulse. Engine hesitates at start-up.


1077 2 Failure of CPU. CPU fatal error. Engine stops. Key switch turn OFF.

1239 1Fuel leak in high-pressured fuel system.

Fuel consumption is calculated from the difference of fuel pressure of, before and after the injection. Error is detected when excess fuel consumption is found. Engine could stop.


1347 3 +B short circuit of SCV. EGR stops. Key switch turn OFF.

1347 4 SVC drive system error.Open circuit or ground short circuit of SCV.


EGR stops, engine forcibly stops later.

1347 5Open circuit of SCV (MPROP)

Open circuit short of SVC.Key switch turn OFF.

EGR stops, engine forcibly stops later.

Maintenance


TM


1347 7SCV stuck in open position.

Actual rail pressure continuously exceeds the command rail pressure. Discharge request of supply pump goes below 0 mm3/st and the actual rail pressure is 10 MPa for 26 seconds or more. Engine may stop.


1485 2Main relay locked in closed position.

Failure of main relay. Stays active longer than one second without command. Battery goes dead.


3242 0Emergency exhaust gas temperature sensor 1: High

DPF inlet temperature higher than 1319° F (715° C). Engine stops. Inhibit starter relay activation until exhaust temperatures reduces down to 572° F (300° C).

Under 572° F (300° C) and key switch turn OFF.

3242 3Exhaust gas temperature sensor 1: High

Open circuit or +B short circuit of sensor/harness. DPF inlet temperature sensor voltage 4.92V or more.


3242 4Exhaust gas temperature sensor 1: Low

Ground short circuit of sensor/harness. DPF inlet temperature sensor voltage 0.08V or less.



DPF outlet temperature 1508° F (820° C) or more.

Under 572° F (300° C) and key switch turn OFF.

Inhibit starter relay activation until exhaust temperature reduces down to 572° F (300° C).


Open circuit or +B short circuit of sensor/harness. DPF outlet temperature sensor voltage 4.92V or more.



Ground short circuit of sensor/harness. DPF outlet temperature sensor voltage 0.08V or less.


3251 3Differential pressure sensor 1: High

Open circuit or +B short circuit of sensor/harness. DPF differential pressure sensor voltage 4.7V or more.


3251 4Differential pressure sensor 1: Low

Ground short circuit of sensor/harness. DPF differential pressure sensor voltage 0.21V or less.


3252 0 Emission deterioration.DOC is heated due to unburned fuel. Output and accerlerator limitation 50%. EGR stops.

Key switch turn OFF to minimize emission to DPF.

3509 3Sensor supply voltage 1: High

Voltage to sensor is above 5.625V. EGR stops. Faulty starting. Engine may stop. Emission related.


3509 4Sensor supply voltage 1: Low

Voltage to sensor is below 4.375V. EGR stops. Faulty starting. Engine may stop. Emission related.



Voltage to sensor is above 5.625V. Faulty starting. Emission related.


5

Maintenance


TM

55



Voltage to sensor is below 4.375V. Faulty starting. Emission related.



Voltage to sensor is above 5.25V. Faulty starting.



Voltage to sensor is below 4.75V. Faulty starting.


3701 0 Excessive PM 5.PM accumulation more than trigger level. Regeneration Level = 5.


Engine not forcibly stopped by ECU. STRONGLY recommend operator to stop engine promptly.

Must be reset by Kubota service tool.


Diagnostic counter = 0


Diagnostic counter = 0


DOC inlet temperature 1292° F (700° C) or more. Engine stops.


Inhibit starter relay activation until exhaust temperature reduces down to 527° F (300° C).


Open circuit or +B short circuit of sensor/harness. DOC inlet tempereature sensor voltage 4.92V or more.



Open circuit or +B short circuit of sensor/harness. DOC inlet tempereature sensor voltage 0.08V or less.


523523 2Injector drive circuit open in Nos. 1 & 4 cylinder simultaneously.

Wiring harness open circuit. Injectors that have no DTC are operated. Engine vibration increases and may stop.


523523 3

Nos. 1 & 4 cylinder injector short to +B at power supply side, or all cylinder injectors short to +B.

Wiring harness short to +B. Injectors that have no DTC are operated. Engine vibration increases and may stop.


523523 4

Nos. 1 & 4 cylinder injector short to ground at power supply side, or all cylinder injectors short to ground.

Wiring harness short to ground. Injectors that have no DTC are operated. Engine vibration increases and may stop.


523524 2Injector drive circuit open in Nos. 2 & 3 cylinder simultaneously.

Wiring harness open circuit. Injectors that have no DTC are operated. Engine vibration increases and may stop.


523524 3

Nos. 2 & 3 cylinder injector short to +B at power supply side, or all cylinder injectors short to +B.

Wiring harness short to +B. Injectors that have no DTC are operated. Engine vibration increases and may stop.


Maintenance


TM


523524 4

Nos. 2 & 3 cylinder injector short to ground at power supply side, or all cylinder injectors short to ground.

Wiring harness short to ground. Injectors that have no DTC are operated. Engine vibration increases and may stop.


523525 1Injector charge voltage low.

Injector charge voltage low. Failure of charge circuit of ECU. Engine may stop.


523527 2 ECU monitoring error.Failure of monitoring IC of CPU. Engine stops.


523535 0Injector charge voltage: High

EGR stops. Engine forcibly stops 60 seconds later.


523536 2 EGR feedback error.

DC motor feedback control error. During wrong duty feedback, activation of restoration will repeat 30 times. If the restoration was not successfully completed, it will be judged as a feedback error. EGR stops.


523537 2EGR DC motor tempereature error.

Estimated tempereature is 113° F (45° C) or above. EGR stops.


523538 2 QR data error.QR data read error from EEPROM. Nozzle correction is not executed.


523539 2 Pump seizing 1.

Rail pressure of 230 MPa (33400 psi or 2350 kgf/cm2) or more continues one second under the condition of above 800 min-1 (rpm).

Under 800 min-1 (rpm) condition, rail pressure of 220 MPa (31900 psi or 2250 kgf/cm2) or more continues one second under the condition of below 800 min-1 (rpm). [Threshold changes depending upon the engine speed. 700 min-1 (rpm) should be used as a reference.

Key switch turn OFF to minimize PM emission to DPF and avoid extremely high pressure in injection system.

523540 2 Pump seizing 2.

Rail pressure of 197MPa (28600 psi or 2010 kgf/cm2) or more continues one second under the condition of above 800 min-1 (rpm).

Under 800 min-1 (rpm) condition, rail pressure of 220 MPa (31900 psi or 2250 kgf/cm2) or more continues one second under the condition of below 800 min-1 (rpm). [Threshold changes depending upon the engine speed. 700 min-1 (rpm) should be used as a reference.


523541 3 EGR lift sensor: High+B short circuit of sensor/harness. Failure of sensor. Voltage of ECR lift sensor is 4.5V or above. EGR stops.


5

Maintenance


TM

55


523541 4 EGR lift sensor: Low

Open circuit or short circuit of sensor/harness. Failure of sensor. Voltage of ECR lift sensor is 0.3V or less. EGR stops.


523543 2Accelerator position sensor error (CAN).

Accelerator position sensor signal error (sensor/harness open circuit, ground short circuit, etc.).

Diagnostic counter = zero.

CAN signal recovers.

523544 3+B short of air heater relay driving circuit.

+B short circuit of harness. Faulty starting. White smoke increases.


523544 4Ground short of air heater relay driving circuit.

Ground short or open circuit of harness.


523547 2 CAN2 bus off. CAN2 bus off. Key switch turn OFF.

523548 2 CAN-KBT frame error. CAN-KBT frame open circuit error. Key switch turn OFF.

523572 4EGR position sensor failure.

EGR position sensor error signal received via CAN. EGR stops.


523574 3 EGR actuator open circuit.EGR actuator open error signal received via CAN. EGR stops.


523575 7 EGR actuator valve stuck.EGR actuator valve stuck error received via CAN. EGR stops.


523576 2 EGR (DC motor) overheat.EGR (DC motor) temperature error signal received via CAN (exceeds 257° F or 125° C). EGR stops.


523577 2EGR (DC motor) temperature sensor failure.

EGR (DC motor) temperature sensor error signal received via CAN. EGR stops.


523578 2No communication with EGR.

Interruption of CAN. EGR stops. Key switch turn OFF.

523580 2Intake throttle feedback error.

Deviation of throttle position is not corrected in 20 times of duty error recovery action.


523582 3Intake throttle lift sensor: High

Intake throttle lift sensor voltage 4.89V or more.


523582 4Intake throttle lift sensor: Low

Intake throttle lift sensor voltage 0.1V or less.


523589 17Low coolant temperature in parked regeneration.

During regeneration mode, engine warm-up condition is not satisfied because coolant temperature is too low (below 149° F or 65° C).


Leaving from Parked active regeneration status.

523590 16Parked regeneration timed out.

Regeneration incomplete due to low tempereature of DPF.


Leaving from Parked active regeneration status.

523591 2CAN CCVS (parking and vehicle speed) frame error.

CAN CCVS frame time-out error.

Parking SW = off.

Vehicle speed = 0


523592 2CAN CM1 (Regen SW) frame error.

CAN CM1 frame time-out error.

Regeneration inhibit = on.

Parked regeneration SW = off.


Maintenance


TM


523593 2CAN DDC1 (transmission) frame error.

CAN DDC1 frame time-out error. Key switch turn OFF.

523594 2CAN ETC2 (neutral SW) frame error.

CAN ETC2 frame time-out error Key switch turn OFF.

523595 2CAN ETC5 (neutral SW) frame error.

CAN ETC5 frame time-out error. Key switch turn OFF.

523596 2 CAN TSC1 frame error.No request to “TSC1 buffer” continues three times after over-ride control request (other than 0x00).


523598 2 CAN EBC1 frame error. CAN EBC1 frame time-out error. Diagnostic counter = zero

523599 0All exhaust temperature sensor failure.

All exhaust temperature sensor failure (sensor low) simultaneously.


523600 0Initial pump calibration incomplete.

Initial pump calibration incomplete. Diagnostic counter = zero

523601 0

High exhaust gas temperature after emergency high temperature DTC.

All exhaust temperature (T0, T1, T2) reduces down to 572° F (300° C). Engine stops.


523602 0High frequency of regeneration.

Regeneration time interval within 30 minutes occurs three times continously. EGR stops.


523603 15 Overheat precaution.Engine coolant temperature ≥ 230° F (220° C).


523604 2 CAN1 bus off. CAN1 bus off. EGR stops. Key switch turn OFF.

5

Maintenance


TM

55

NOTES

Maintenance


TM

Page

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1



Main Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Joystick Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Joystick Interface Harness . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Work Lights and Turn Signal Harness . . . . . . . . . . . . . . . . . . . 6-13

Engine Harness (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Engine Harness (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Engine Remote Panel Assembly . . . . . . . . . . . . . . . . . . . . . . 6-19

Fuse Block Harness (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

Fuse Block Harness (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . 6-23



Back-Up Alarm Harness . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

Water Pump Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

Ground Jumper Harness . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33




SCHEMATICS

Section 6

TM

NOTES

LB Performance PTC 915B Pneumatic Roller

Schematics

6-2

TM

777

TM


Schematics

ELECTRICAL SCHEMATIC (1 OF 2)

Schematic # 1013990

16813

2021

25262728

30

8586

87

30

8586

87

30

8586

87

30

8586

87

30

8586

87

3087

8586 20A

10A

10A

10A

20A

10A

10A

A1

A6

A11

A2

A3

A10

A8

A13

A10

A15

A

10A

Figure 6-1. Electrical Schematic (1 of 2)

TM


Schematics

NOTES

777

TM


Schematics

Figure 6-2. Electrical Schematic (2 of 2)

125A 150A

87

86 85

30

112 2

1 12 2

531

2

6

62

A

155A

5731

A

7087

1 2

1 2 3 5

30A

6

78

7

123

6

8

1011

13

15

38

161718

2 63 51 7

A

ELECTRICAL SCHEMATIC (2 OF 2)

Schematic #1013990

TM


Schematics

NOTES

777

TM


Schematics

Figure 6-3. Main Harness

RINGTERMINAL

NN

A

FE

M

C

N

W

C

PIN COLOR FUNCTIONWHT

LT BLUSHIELD CAN SHIELD

BLU WAIT TO STARTMAIN GROUNDMAIN POWER

ACCSTARTACC

PIN COLOR LOCATIONABCD

PIN COLOR LOCATION

PIN COLOR FUNCTIONWHT

LT BLUSHIELD

BLU

PIN COLOR LOCATIONLT BLU LOOSE WIRE NN

PIN COLOR FUNCTIONABC

PIN COLOR FUNCTIONPOWER

GROUND

PIN COLOR LOCATION

MAIN HARNESS

Schematic# 1013598

TM


Schematics

NOTES

777

TM


Schematics

Figure 6-4. Joystick Harness

#2

#1

FORWARDREVERSE

NONC

C

NONC

C

(+)AB(-)

12

JOYSTICK HARNESS

Harness #:1012961

TM


Schematics

NOTES

777

TM


Schematics

Figure 6-5. Joystick Interface Harness

NOTES:

ALL INTERNAL CONNECTIONS TO BE SOLDERED

H

NOTE:PLUG ALL HOLES

B

PIN COLOR FUNCTIONNEUTRALPOWER

GROUNDPUMP SIGNAL

PUMP SIGNAL

PIN COLOR FUNCTIONNEUTRALPOWER

GROUNDBLU PUMP SIGNAL

PRP PUMP SIGNAL

PIN COLOR FUNCTIONPOWER

NEUTRAL

PIN COLOR FUNCTIONA PUMP SIGNALBC PUMP SIGNAL

JOYSTICK INTERFACE HARNESS

Schematic # 1013666

TM


Schematics

NOTES

777

TM


Schematics

Figure 6-6. Work Lights and Turn Signal Harness

LEFT REAR

RIGHT REAR

LEFT FRONT

RIGHT FRONT

RED

BLUE

BLUE GREEN

PURPLE

WHITE

PURPLE

NOTES:


ALL MEASUREMENTS IN INCHES

TERMINAL

DT04-08PP

BEACON

B

B

B

PIN COLOR

BLUPRP

WORK LIGHTS AND TURN SIGNAL HARNESS

Schematic # 1013639

TM


Schematics

NOTES

777

TM


Schematics

Figure 6-7. Engine Harness (1 of 2)

TERMINALS

CONNECTOR

LOADRESISTOR

FEMALESPADE

ALTERNATOR

STARTER

INTERFACE

TO MAINHARNESS

WATERIN

FUELCOOLANT

SENSOR

POWERPANEL

ECU

TERMINALS

NOTES:


DIODE

TERMINAL

TO ISOLATIONSWITCH

ENGINE HARNESS (1 OF 2)

Schematic # 1013597

TM


Schematics

NOTES

777

TM


Schematics

Figure 6-8. Engine Harness (2 of 2)

A B C

A B C

WATER IN FUEL PUR

TO MAIN HARNESS

REMOTE PANEL

SENSORWATER IN FUEL

SENSORLOAD

RESISTOR

ALTERNATOR

STARTER

WAIT TO START LAMP GROUND BLU

TERMINAL

THROTTLE INCREMENT LT BLUTHROTTLE DECREMENT GRN

NOTE:

CONNECTOR

ENGINE HARNESS (2 OF 2)

Schematic # 1013597

TM


Schematics

NOTES

777

TM


Schematics

Figure 6-9. Engine Remote Panel Assembly

ENGINE REMOTE PANEL ASSEMBLY

Schematic # 1013512

150A CB

125A FUSE

GRIDHEATERRELAY100A

STARTRELAY100A85

30

8687

DT06-8S1

6G RED

TOALTERNATOR

6G RED

6G RED

TO GRIDHEATER

6G RED

6G RED

234

5678

BLK

BLU/REDBLU/WHTORN/YELORNYEL

PNK/BLK

16"

20"

120"

52"

TOBATTERY

TOISOLATIONSWITCH

#10 RINGTERMINAL

3/8" RINGTERMINAL

3/8" RINGTERMINAL

3/8" RINGTERMINAL

12G RED

C

C

C

CC

TM


Schematics

NOTES

777

TM


Schematics

Figure 6-10. Fuse Block Harness (1 of 2)

FUSE BLOCK HARNESS (1 OF 2)

Schematic # 1012965

R1R2

R3

R4R5

R6F5

F6F7

F8

F1F2

F3F4

E

LT BLU

LT BLU

LT BLU

RED

WHT

BRN

FEMALESPADE

FEMALESPADE

W

FOG

NEUTRAL

HORN

B

TM


Schematics

NOTES

777

TM


Schematics

Figure 6-11. Fuse Block Harness (2 of 2)

FUSE BLOCK HARNESS (2 OF 2)

Schematic # 1012965

R1R2

R3

R4R5

R6F5

F6F7

F8

F1F2

F3F4

D


E

WHT

BRN

FEMALESPADE

FEMALESPADE

TERMINAL

W

TM


Schematics

NOTES

777

TM


Schematics

Figure 6-12. Instrument Panel Assembly (1 of 2)

NOTES:


PLUG C PLUG D PLUG P

PLUG H PLUG M

INSTRUMENT PANEL ASSEMBLY (1 OF 2)

Schematic # 1012498

TM


Schematics

NOTES

777

TM


Schematics

Figure 6-13. Instrument Panel Assembly (2 of 2)

35242313121

OUTLET

G4321

RED

WHT

HYDTEMP

WHT

ESTOP

FOGSPRAY

HEADTOSTART

D1M3

FUEL

LOWCHARGEPRESSURE

C4 C5

C2 C1

ALOAD

RED

RED

D3H2H1

YEL

YEL

D5

D2

RED

RED

M1D4

P4 D11 P3

RED

D12

C

COLOR1 WHT2345 FUEL

ACCACC

1112

COLOR123 ACC45

YEL

1112

COLOR12345

1112

COLOR1 YEL2

COLOR1 RED POWER234

INSTRUMENT PANEL ASSEMBLY (2 OF 2)

Schematic # 1012498

TM


Schematics

NOTES

777

TM


Schematics

Figure 6-14. Backup Alarm Harness

QTY.PART NO.ITEM DESCRIPTION 1 33271-0 8.50 WIRE,16 GA,GRAY 2 36348 1.00 TERM,PUSH-ON,.25,M,18-14,SLV 3 71060 8.50 LOOM,SPLIT,CONVOLUTED,.250 4 851201417 2.00 TIE WRAP,.094X4.00 5 851390204 1.00 TERM,RING,16-14 GA,#10 STUD

102.00

123

4 4

5

BACK-UP ALARM HARNESS

Schematic # 23474

TM


Schematics

NOTES

777

TM


Schematics

Figure 6-15. Water Pump Harness

Part No.Item Qty Description

70.00

.50 .50

34

21465

7

1 71060 5.83 LOOM,SPLIT,CONVOLUTED,.250 2 71862 5.91 WIRE,14 GA,WHITE 3 36348 1.00 TERM,PUSH-ON,.25,M,18-14,SLV 4 851201417 2.00 TIE WRAP,.094X4.00 5 37089 1.00 CONNECTOR,SEALED,SHROUD,1-PIN 6 36164 1.00 TERM,SEALED CONN,16-14 GA,MALE 7 36623 1.00 SEAL,CABLE,14 GA

WATER PUMP HARNESS

Schematic # 28044

TM


Schematics

NOTES

777

TM


Schematics

Figure 6-16. Ground Jumper Harness

Part No.Item Qty Description

1 33608 1.00 TERM,RING,16-14 GA,.312 STUD 2 851390204 1.00 TERM,RING,16-14 GA,#10 STUD 3 33271-1 .33 WIRE,16 GA,BLACK

4.00

13

2

GROUND JUMPER HARNESS

Schematic # 28701

TM


Schematics

NOTES

777

TM


Schematics

M4

M5

X3/M11

2 1

cw

flow out A

A/CB/D

B A

TATB

P

M10N

COOLER/2.F5

-M1

MOTOR, DRIVE

3913164/32 in³

A

R

Y2

1

X -M2

MOTOR, DRIVE

3913164/32 in³

A

R

Y2

1

X

IN

OUT

SL2

L1

X2 X1

A

B

-P136125-04

PUMP, HYDRAULIC, W/EDC

75cc5511 PSI

M3M6

M1

M2

IN

OUT

36123-F2

200 MESH, 15 GPMSTRAINER, SUPPLY

36124-V3

OUT

IN15 PSI

32

4

G1

-V136071VALVE, 2-SPEED / BRAKE

Charge-V2:2

PROPEL CIRCUIT

Figure 6-17. Hydraulic Schematic (1 of 2)

HYDRAULIC SCHEMATIC (1 OF 2)

Schematic # 1013994

TM


Schematics

NOTES

777

TM


Schematics

Figure 6-18. Hydraulic Schematic (2 of 2)

/1.E7

IN

OUT

X259-F1

10 MICRONHYDRAULIC RETURN FILTER

15 PSI

OUT

IN

19ccPUMP, STEERING1012982-P3

3

2

1

-V21013420FLOW DEVIDER, 7GPM

EXT RET

36129-C1

STEERING CYLINDER

EXT RET

36129-C2

STEERING CYLINDER

L

R T

P-M536127STEERING ORBITROL,17.9CIR

IN

OUT

36123-F3

200 MESH, 15 GPMX

ChargeX

-V4280210

OUT IN

STEERING CIRCUIT

HYDRAULIC SCHEMATIC (2 OF 2)

Schematic # 1013994

TM


Schematics

NOTES

Page

Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Yoke Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Wheel Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Scraper Blade Group . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

Coco Mat Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Covers and Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Water System (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

Water System (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26




Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

Electrical Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

Control Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

Relay Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42

Hydraulic Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44

Miscellaneous Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46


ILLUSTRATED PARTS LIST

Section 7

TM



Traction Control Option . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52

Heat Shield Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54

Alphabetical Parts Index (API) . . . . . . . . . . . . . . . . . . . . . . . 7-56

Illustrated Parts List


TM

QUICK REFERENCE

FILTERS/STRAINERS

Engine Description Part #

Oil Filter 1012474-28

Water Separator 982859-07

Fuel Filter 1012474-27

Air Cleaner, Primary 1010076-02

Air Cleaner, Secondary 1012474-25Hydraulic

Hydraulic Filter Element X260

Charge Filter 34464

Suction Strainer 36123

Charge/Return Filter Head X259

Water

Water Strainer 36926

Spray Nozzle 986502-1

AUXILIARY ENGINE COMPONENTS

Description Part #

Engine Belt 1012474-26

Alternator 1012474-23

Starter 1012474-22

ELECTRICAL COMPONENTS

Description Part #

FUSE KIT:

• 10 Amp (5)

• 15 Amp (2)

• 125 Amp (1)

36340

36341

985753

Breaker, 10 Amp 986546

Wheel & Tire

Description Part #

Coco Mat 19533

Scraper Blade 38595

Specifications and designs may change without prior notice. These illustrations do not necessarily show the standard versions.

7



TM

7

MACHINE

Figure 7-1. Machine

1

2

3

411

8

10

79

6

5



TM

Machine Parts List

Item No.

Part Number Qty. Description Remarks

1 19678SRV 1 Canopy

2 Ref. 1 Front Frame

3 Ref. 1 Rear Frame

4 27719SRV 1 Yoke

5 19674 1 Wheel and Tire

6 19591SRV 1 Optional Heat Shield

7 1013067 1 Covers and Panels

8 Ref. 1 Water System

9 1012473 1 Engine and Components

10 Ref. 1 Instruments and Wiring

11 1013112 1 Hydraulics

7



TM

7

CANOPY

Figure 7-2. Canopy

1

2

3

4

7

8

5

6

9



TM

Canopy Parts List

Item No.


Ref. 19678SRV 1 ROPS Group Items 1-4

1 36255 1 ROPS,Trupac Roller

2 81074 8 CSHH, 1.00-8 X 3.75, Gr 8

3 81075 8 Nut, Stovers 1.00-8, Gr C

4 81076 16 Washer, Flat, SAE, 1.000, Hardened

Ref. 19678-01SRV 1 Sunroof Group Items 1-9

5 19914 1 Canopy, Sunroof

6 19928 2 Clamp, Sunroof

7 120-3 6 Washer, Flat, USS, .375

8 102-206-1A 6 CSHH, .375-16 X 1.25, Gr 5

9 80352 6 Nut, Flexloc, .375-16, Full, LT

Ref. 36256 1 Optional ROPS Group

7



TM

7

YOKE ASSEMBLY

Figure 7-3. Yoke Assembly



TM

Yoke Assembly Parts List

Item No.


Ref. 27719SRV 1 Yoke Assembly

1 19215SRV REF Yoke, Dead End Part of Rear Frame

2 19239 3 Pin Retainer

3 19220 1 Yoke, Live End

4 36404 2 Seal, Felt, .63T, 3.60 ID X 6.00 OD

5 36405 2 Seal, Felt, .38T, 2.40 ID X 4.00 OD

6 36140 2 Bearing, Spherical 2.50 ID

7 27718 2 Pin, Yoke, Dead End, Timken Nut


9 19243 REF Yoke Plate, Front Part of Front Frame

10 36407 1 Seal, Felt, .38T, 3.60 ID X 6.00 OD

11 27717 1 Pin, Yoke, Live End, Timken Nut

12 36406 1 Seal, Felt, .63T, 4.00 ID X 6.00 OD


Ref. 36408 1 Seal, Felt, .50T, 4.00 ID X 6.00 OD

Ref. 36409 1 Seal, Felt, .50T, 3.60 ID X 6.00 OD

16 38671 4 Nut, Spl, 2.36-18

17 210170A 4 Washer, Lock, Tang Style

Ref. 5039 3 Fitt, Lube, 90,02 MP

19 118-3 6 Washer, Lock, .375

20 102-203-1A 6 CSHH, .375-16 X .75, Gr 5

Ref. 19503 1 Articulation Lock Link

7



TM

7

WHEELS AND TIRES

Figure 7-4. Wheels and Tires

5

2

1

3

4



TM

Wheels and Tires Parts List

Item No.


Ref. 19674. 1 Wheel And Tire Groups

1 19268SRV 1 Front Axle Assembly (See Fig 7-5)

2 19674 1 Wheel Group, 14 Ply

Ref. 38597 9 Assembly, Tire & Wheel, 7.50-15 NHS

Ref. 81064 72 Nut, Wheel, M16 X 1.5

3 29405 6 Wheel Motor Group (See Fig 7-6)

4 27206SRV 1 Scraper Blade Group (See Fig 7-7)

5 27208SRV 1 Coco Mat Group, 9-Wheel (See Fig 7-8)

Ref. 27759 1 Opt 11-Wheel Assembly (See Fig 7-9)

Ref. 27794 1 Opt Coco Mat With Water For 11-Wheel (See Fig 7-9)

Ref. 27919 1 Opt Traction Control Kit (See Fig 7-10)

7



TM

7

FRONT AXLE

Figure 7-5. Front Axle

HUB INSTALLATION:1. Install item #5E, grease seal, on back of hub.2. Pack the inside bearing with item #15, wheel bearing

grease. Force grease through and around the rollers.3. Place item #5C, bearing cup, firmly into the hub.4. Place item #5D, bearing cone, on the spindle and

insure that it is seated against the spindle shoulder.5. Lubricate grease seal prior to installation.6. Grease front bearing same as rear and fill hub cavity

with grease.7. Install item #14, flat washer, and spindle nut on

spindle. Turn hub as you tighten nut. When apronounced drag is felt in the bearing, back off nut onecomplete slot, and install item #13, cotter pin, and item#5F, dust cap.

8. Rotate wheel and insure hub is not binding.



TM

Front Axle Parts List

Item No.


Ref. 19268SRV 1 Front Axle Assembly

1 19183 2 Mount, Axle

2 19184SRV 2 Pin W/M, Front Axle

3 19211SRV 2 Spindle, Dual 1.12 Offset Hub

4 19212SRV 1 Spindle, Single 1.12 Offset Hub

5 36136SRV 5 Hub Assy, Wheel, 8 On 8.00

5A 36136-01 5 Bearing Cup, Inner

5B 36136-02 5 Bearing Cone, Inner

5C 610230 5 Bearing Cup, Outer

5D 610240 5 Bearing Cone, Outer

5E 36136-03 5 Grease Seal

5F 340040 5 Dust Cap

6 36137 4 Bearing, Composite 2.25 ID

7 36265 8 Washer, Thrust, 2.25 ID, .060T

8 80076 6 Nut, Hex, Jam, .500-13

9 80221 2 CSHH, .375-16 X 1.00, Gr 5

10 80715 6 Set Screw, .500-13 X 1.50, SQHD

11 80996 2 Washer, Flat, SAE, .375

12 81071 5 Nut, Hex, Castle, .750-16 SPL

13 80332 5 Pin, Cotter, .125 X 1.50

14 81070 5 Washer, Flat, Spl, .750 ID

Ref. 91210 1.25 Grease, Wheel Bearing

Ref. 19674 1 Wheel Group, 14 Ply

Ref. 38597 9 Tire Mounted, 7.50-15 NHS, 14 Ply

Ref. 81064 72 Nut, Wheel, M16 X 1.5 (Rear)

Ref. 36136-05 40 Bolt, Wheel, .562 X 1.12 (Front)

7



TM

7

Figure 7-6. Wheel Motor Assembly

WHEEL MOTOR ASSEMBLY



TM

Wheel Motor Assembly Parts List

Item No.


Ref. 29405 6 Wheel Motor Group

1 39131 1 Motor, Hyd, Drive, 915 Trupac

2 19175 2 Mount, Hyd Motor

3 X250 2 Bearing, Spher, ID 1.50, OD 2.4375

4 19176 2 Cover, Bearing, Hyd Motor Mount

5 81057 8 CSSH, .250-20 X .75

6 81058 8 CSSH, .875-9 X 3.00, Gr 5

7 81059 8 Washer, Flat, SAE, .875


9 19182 2 Pin, Hyd Motor Mount

10 36144 4 Bushing, Split 1.5 ID

11 19818 4 Washer, .44 X 2.125 X .134 Thick

12 80162 4 Washer, Lock, .375

13 80219 4 CSHH, .375-16 X .75, Gr 5

14 36131-02 8 Stud, Wheel, M16 X 1.5

7



TM

7

SCRAPER BLADE GROUP

Figure 7-7. Scraper Blade Group



TM

Scraper Blade Group

Item No.


Ref. 27206SRV 1 Scraper Blade Group

1 19517 9 Scraper Blade Holder W/M

2 19524SRV 9 Scraper Blade, Back-Up

3 19530 1 Scraper Blader Rod, Rear

4 19531 1 Scraper Blade Rod, Right, Front

5 19532 1 Scraper Blade Rod, Left, Front

6 36191-1 5 Spring, Torsion, Right Hand

7 36191-2 4 Spring, Torsion, Left Hand

8 38595 9 Scraper, Tire, Flat Curve

9 80206 18 CSHH, .312-18 X 1.25, Gr 5

10 80211 9 CSHH, .312-18 X 1.75, Gr 5


12 80963 36 Washer, Flat, SAE, .312

13 38183 9 Collar, Set, 1.125 X 1.75 X .562

7



TM

7

COCO MAT GROUP

Figure 7-8. Coco Mat Group



TM

Coco Mat Group Parts List

Item No.


Ref. 27208 1 Coco Mat Group, 9-Wheel

1 27211 9 Hanger, Coco Mat, Flat Tire

2 19292 3 Pipe, Water Spray Bar, 915

3 19293 1 Pipe, Spray, 08 NPT x 42.25

4 19294 1 Rod, Lift, .50 OD x 55.25

5 19295 1 Rod, Lift, .50 OD x 40.25

6 19296 1 Rod, Lift, .50 OD x 26.38

7 19533 9 Coco Mat, 6 X 9

8 36173 3 Collar, Set, .88 ID x 1.38 OD x .56

9 70414 54 Ring, Hog

10 80144 18 Washer, Flat, USS, .500

11 80331 18 Pin, Cotter, .125 X 1.25

12 91152 4 Pipe, Cap, .500, Galv

13 99537 2 Pipe, Plug, 08 MP, Square Head

14 99845 2 Pipe, Tee, 08 FP, Galv

15 53175 18 Washer, Nylon, .562 X 2.125 X .06 Thk

7



TM

7

COVERS AND PANELS

Figure 7-9. Covers and Panels

1

47 6 17

2312

1315

8

11109

1416

5 6 7



TM

Covers and Panels Parts List

Item No.


Ref. 1013067 1 Cover & Panel Groups

1 1012469 1 Plate, Radiator Grill

2 100-5-18-12-5F 12 CSHH, 0.3125-18 x 0.75, Gr 5, FT

3 300-5 12 Washer, Flat, 0.3125

4 1012467SRV 1 Plate, Access Panel, RH

5 1012466SRV 1 Plate, Access Panel, LH

6 100-6-16-16-5F 4 CSHH, 0.375-16 X 1.00, Gr 5, FT

7 302-6 4 Washer, Lock, 0.375

Ref. 160450 2 Latch, Engine Access Door

Ref. 122-4-20-8F 8 PHMS, Cross, 0.25-20 X 0.5, FT

8 19199 1 Horiz Crossmember, R Frame, W/M

9 19202 1 Crossmember,Vertical

10 1013011 1 Weldment, Engine Access Panel, Front, Fixed

11 1013006 1 Weldment, Engine Access Panel, Front

Ref. 35812 4 Lock, With Offset Cam

12 19226 1 Cover, Rear Ballast

13 1013072 1 Weldmnet, Engine Cover

Ref. 100-6-16-16-5F 38 CSHH, 0.375-16 X 1.00, Gr 5, FT

Ref. 302-6 38 Washer, Lock, 0.375

14 1012966 1 Assembly, Lower Cover, Console

15 1012499 1 Cover, Instrument Panel

Ref. 81289 4 Washer, Flat, Nylon, .313

16 1009218 1 Cover Weldment, Front Ballast

17 19503 1 Link, Articulation Lock

Ref. 240030 2 Pin, Clevis, 1.00 X 3.25 W/1.5Hd

Ref. 5928 2 Pin, Cotter, .148, #9

Ref. 70395 2.58 Chain, Proof Coil, .250

Ref. 35403 2.58 Sleeve, Abrasion, Nylon, .71Id

Ref. 80185 1 CSHH, .250-20 X 1.00, Gr 5

Ref. 80140 2 Washer, Flat, USS, .250

Ref. 80350 1 Nut, Flexloc, .250-20, Full, LT

Ref. 35560 1 Key, Access Panel Not Shown

7



TM

7

SEAT ASSEMBLY

Figure 7-10. Seat Assembly

1

2

3

6

4

5

7



TM

Seat Assembly Parts List

Item No.


Ref. 1013067 1 Cover & Panel Groups

1 360010B 1 Seat Assy, Black,With Armrest

Ref. 80141 32 Washer, Flat, USS, .313

2 140600 1 Suspension, Seat

Ref. 80208 8 CSHH, .312-18 X 1.00, Gr 5

Ref. 80351 8 Nut, Flexloc, .312-18, Full, LT

3 36371 1 Swivel Assembly

Ref. 21575SRV 1 Sliding Seat Assy Items 4-7

4 21566 1 Base, Seat Slide

5 91291-01 4 Wear Strip, Poly 3.88 LG

6 21573 1 Slide Clamp Weldmnet, Rear

7 21569 1 Slide Clamp Weldment, Front

Ref. 1000835 1 Pull Pin Spring Loaded

Ref. 730-3050 1 Seat Belt

7



TM

7

WATER SYSTEM (1 OF 2)

Figure 7-11. Water System (1 of 2)

10

9

11,12,13,



TM

Water System (1 of 2) Parts List

Item No.


1 6352 24 Hose, 08, Push-On, 250

2 1008851 9 Nozzle, Assy, 08 Pipe Nyl, Str

6 27208 1 Coco Mat Grp, Flat Tire

7 36883 1 Valve, Check, .500 HB, 5 Psi, Poly

8 33164 10 Clamp, Hose, # 10

9 36151 1 Filler, Tank, 4 In

10 1007360 1 Tank, Water, 150 Gal, White

11 100-6-16-16-5 3 CSHH, .375-16 X 1.00, Gr 5

12 300-6 3 Washer, Flat, .375

13 302-6 3 Washer, Lock, .375

25 1005660 1 Pump, Water Spray

26 36926 1 Strainer Assy

29 72712 1 Fitt, 90 06MP -08HB, Poly

31 36176 1 Pipe, Nipple, .500 X .375, Pvc

32 70319 1 Fitt, 90 08MP -08HB, Poly

48 28044 1 Harness, Wire, Water Spray Pump

49 36349 1 Term, Push-On, .25, Fem, 16-14, Slv

50 33607 1 Term, Ring, 16-14 Ga, .250 Stud

7



TM

7

WATER SYSTEM (2 OF 2)

Figure 7-12. Water System (2 of 2)



TM

Water System (2 of 2) Parts List

Item No.


1 6352 24 Hose, 08, Push-On, 250 Psi

2 1008851 9 Nozzle, Assembly, 08 Pipe Nyl, Str

6 27208 1 Coco Mat Grp, Flat Tire (See Fig 7-8)

7 36883 1 Valve, Check, .500 HB, 5 Psi, Poly

8 33164 10 Clamp, Hose, # 10

18 35771 1 Fitt, Tee 08HB, Poly

33 33082 1 Fitt, 90 08MP -08HB

37 70318 2 Fitt, Str 08MP -08HB, Blk Poly

7



TM

7

CUMMINS ENGINE (1 OF 3)

Figure 7-13. Cummins Engine (1 of 3)

123 8

121110

1415

16

201917

18

913

4

414243

38

4635

474849

50

5152

53363734

4039

4445

56

7

262725

2928

31 32

30

33

54 5556 57

58 59

6061

6364

636462

6566

66

67

6870

72717374

69

757778

7779

808283

81

76

6759

55 56

2423

2122

64



TM

Cummins Engine (1 of 3) Parts List

Item No.


Ref. 1012473 1 Group, Engine, Cummins 2.8 T4f

Ref. 1012474 1 Assembly, Engine, QSF2.8 T4f

1 Ref. 1 QSF2.8

2 1012474-23 1 Alternator

3 1012474-22 1 Starter

4 1012474-26 1 Fan Belt, W/O AC

5 1012474-16 1 Fan

6 1012474-15 1 Fan Spacer 3"

7 1012474-14 1 Extended Dip Stick

8 1012474-17 1 Flex and Drive Plate SAE #4,C Mt

9 36125-04 1 Pump, Hydraulic, Piston, W/EDC

10 100-8-13-24-5 4 Cshh, 1/2-13 X 1.5, Gr 5

11 302-8 4 Washer, Lock, 1/2

12 300-8 4 Washer, Flat, 1/2

13 1012982 1 Pump, Hydraulic, Gear, 19CC, SAE A Flange Mount

14 100-6-16-20-5 2 CSHH, 3/8-16 X 1.25, Gr 5

15 302-6 2 Washer, Lock, 3/8

16 300-6 2 Washer, Flat, 3/8

17 1012474-11 1 Filter Head, Fuel/Water Separator

Ref. 988666-05 1 Filter Element, Fuel/Water Separator

18 100-6-16-24-5 2 CSHH, 3/8-16 X 1.5, Gr 5

19 302-6 2 Washer, Lock, 3/8

20 200-6-16-5 2 Nut, Hex, 3/8-16, Gr 5

21 1012474-10 1 Filter Head, Fuel, Remote

Ref. 1012474-27 1 Filter, Fuel

22 100-5-18-16-5 3 CSHH, 5/16-18 X 1, Gr 5

23 302-5 3 Washer, Lock, 5/16

24 200-5-18-5 3 Nut, Hex, 5/16-18, Gr 5

Ref. 1012474-13 1 Filter, Oil, Remote Adapter

Ref. 1012474-12 1 Filter Head, Oil

25 1012474-28 1 Filter Element, Oil

26 100-4-20-16-5 4 CSHH, 1/4-20 X 1, Gr 5

27 302-4 4 Washer, Lock, 1/4

28 1012474-18 1 ECM

29 204-4-20-5 Nut, Lock, Stover, 1/4-20, Gr 5

30 1013512 1 Assembly. Engine Electrical Components

31 100-5-18-20-5 4 CSHH, 5/16-18 X 1.25, Gr 5

7



TM

7



123 8

121110

1415

16

201917

18

913

4

414243

38

4635

474849

50

5152

53363734

4039

4445

56

7

262725

2928

31 32

30

33

54 5556 57

58 59

6061

6364

636462

6566

66

67

6870

72717374

69

757778

7779

808283

81

76

6759

55 56

2423

2122

64



TM


Item No.


32 302-5 8 Washer, Lock, 5/16

33 200-5-18-5 8 Nut, Hex, 5/16-18, Gr5

34 1012481 1 Plate, Air Cleaner Mount

35 100-6-16-16-5F 3 CSHH, 3/8-16 X 1, Gr 5, FT

36 302-6 3 Washer, Lock, 3/8

37 200-6-16-5 3 Nut, Hex, 3/8-16, Gr 5

38 1012474-03 1 Air Filter, AH55642

Ref. 1010076-02 1 Air Filter, Primary

Ref. 1012474-25 1 Air, Filter, Secondary

39 100-4-20-16-5 4 CSHH, 1/4-20 X 1, Gr 5

40 302-4 4 Washer, Lock, 1/4

41 39068 1 Clamp, T-Bolt, 5.28-5.59 Range

42 953521244 1 Hump Hose, Reducer, 5.00-4.00 ID


44 1012482 1 Pipe, Air Intake

45 1011263-04 1 Pre-Cleaner, Tier 4i, 3000


47 1000834 1 Elbow, Rubber, 90, 4.00 X 3.00 ID

48 1012483 1 Pipe, Air Cleaner To Turbo, 3.00


50 986633 1 Reducer, 3.00 To 2.13


52 1012484 1 Pipe, Air Cleaner To Turbo

53 38387 1 Elbow, 2.00 Rubber

54 1013081 1 Radiator, Cummins 2.8 T4f

55 1010076-36 2 Coupler

56 1014075 4 Clamp, T-Bolt, Constant Tension, 2.81-3.13 Range

57 1012485 1 Pipe, Charge Air, Hot Side

58 1012474-30 1 Elbow, 2.50

59 1014075 4 Clamp, T-Bolt, Constant Tension, 2.81-3.13 Range

60 1012486 1 Pipe, Charge Air, Cold Side

61 1012474-06 1 Sleeve, High Temp, 2.50

62 1012474-20 1 Pipe, Coolant, Upper

63 1012474-31 2 Sleeve, High Temp, 1.63

64 36808 1 O-Ring

7



TM

7



123 8

121110

1415

16

201917

18

913

4

414243

38

4635

474849

50

5152

53363734

4039

4445

56

7

262725

2928

31 32

30

33

54 5556 57

58 59

6061

6364

636462

6566

66

67

6870

72717374

69

757778

7779

808283

81

76

6759

55 56

2423

2122

64



TM


Item No.


641014082

4 Clamp, Worm Drive, Constant Torque, 1.56-2.50 Range

65 1014188 1 Weldment, Coolant, Lower

66 1012474-32 2 Sleeve, High Temp, 2.00

671014082

4 Clamp, Worm Drive, Constant Torque, 1.56-2.50 Range

68 1012477 1 Plate, Engine Mount, RH

69 1012476 1 Plate, Engine Mount, LH

70 1012478 2 Plate, Engine Mount, Rear

71 1013079 4 Isolator, Engine Mount

72 100-5-18-24-5F 8 CSHH, 5/16-18 X 1.5, Gr 5

73 302-5 8 Washer, Lock, 5/16

74 200-5-18-5 8 Nut, Hex, 5/16-18, Gr 5

75 36048 2 Mount, Center Bonded

76 1009242-34 2 Mount, Center Bonded Isolator Washer

77 1010076-08 2 Isolator

78 1012480 1 Bar, Radiator Brace, RH

79 1012479 1 Bar, Radiator Brace, LH

80 1012475 1 Weldment, Pipe, Exhaust

81 1009242-06 1 Clamp, Marmon, V-Ban

82 1013985 1 Clamp, Accuseal

83 1012474-09 1 D.o.c., A041B697_Rev_B

Ref. 1012474-01 1 Water Outlet

Ref. 1012474-02 1 Charge Air Inlet, IC9663

Ref. 1012474-29 Filler Cap, Chain Drive

Ref. 988666-17 Sensor, Temperature, Water

Ref. 1012474-24 Filler Cap, Oil

Ref. 1012474-19 EGR Valve

Ref. 1012474-04 Idler Pulley

Ref. 1012474-05 Belt Tensioner

7



TM

7

FUEL TANK

Figure 7-14. Fuel Tank

3

4 5

1

2

67



TM

Fuel Tank Parts List

Item No.


1 24852 1 Tank Weldment, Fuel, 35 Gal

2 38279 2 Fitt, 90 04MP -05HB

3 36105 1 Cap, Fuel, With Lock Lug

4 35370-2 1 Sender, Fuel Level, 24.00 Tank

Ref. 80879 5 Washer, Lock #10

5 81150 5 SCR, Self-Tap, #10-32 X .50

Ref. 99538 1 Pipe, Plug, .750, Sq Head

6 80996 8 Washer, Flat, SAE, .375

7 116-3 8 Nut, Hex, .375-16

7



TM

7

ELECTRICAL GROUP

Figure 7-15. Electrical Group

1

2

4

5

3



TM

Electrical Group Parts List

Item No.


1 1012498 1 Assembly, Instrument Panel (See Fig 7-21)

2 1012960 1 Assembly, Joystick Module (See Fig 7-20)

3 1012965 1 Harness, Fuse Block (See Fig 7-22)

4 20190773 1 Horn Low Pitch

Ref. 36130 1 Kit, Horn

5 109740 Switch-Master Disconnect-Batt

Ref. 70437 1 Battery Boot , Pos(Red)

Ref. 72313 1 Hold Down, Battery

Ref. 1008111 1 Cable, Battery, Neg, 97", Eye/Eye, 1 Awg

Ref. 400020 1 Cable, Battery, Neg, 16", Eye/Post

Ref. 36339 1 Cable, Battery, Neg, 17", Eye/Eye

Ref. 1007411 1 Cable, Battery, Pos, 65", Eye/Eye, 1 Awg

Ref. 800072 1 Cable, Battery, Pos, 16", Eye/Post

Ref. 1013598 1 Harness, Main (See Schematics)

Ref. 1013666 1 Harness, Joystick/Console Interface (See Schematics)

Ref. 1014825 1 Harness, Hydraulic/Fuel System, Trupac B (See Schematics)

Ref. 210893 1 Beacon, Amber, Rotating Light

Ref. 1013639 1 Harness, Work Light & Turn Signal (See Schematics)

Ref. 1003862 4 Work Light

Ref. 140480 1 Turn Signal, W/Hazard, 4-Wire

Ref. 6161 2 Light, Turn Signal, Amber

Ref. 851091608 1 Flasher, Signal

Ref. 851342007 2 Light, Turn/Brake, Red 7



TM

7

CONTROL GROUP

Figure 7-16. Control Group

6 7

3 2 1

4 5



TM

Control Group Parts List

Item No.


1 1012960 1 Assembly, Joystick Module

2 1013448 1 Assembly, Joystick Mount, LH

3 1013449 1 Assembly, Joystick Mount, RH

4 1012968 1 Weldment, Fuse Access Door

5 25812 1 Box, End, Ext Box

6 6436 1 Steering Wheel, 17.00, 36 Spline

7 36130 1 Kit, Horn, Steering Wheel Center

7



TM

7

CONTROL PANEL

Figure 7-17. Control Panel

14 12

3

4

76

513

59

810

1112

15



TM

Control Panel Parts List

Item No.


Ref. 1012498 1 Assembly, Instrument Panel

1 1012498-1 1 Plate, Instrument Panel

2 122-#10-24-6F 6 Mach SCR, PH,#10-24 X .75

3 1012953 1 Kit, Decal, Safety/Ops, TP915

4 1012500 1 Display, PV480, Tier 4f, TP915

5 851391 3 Switch, Toggle, SPST, 2-Pos

6 72086 1 Switch, Toggle, DPDT, 2-Pos

7 851090613 1 Switch, Toggle, SPDT, 3-Pos

8 851090624 1 Switch, Toggle, SPDT, 2-Pos

9 35136 1 Plug, Hole, 1.25, Flush Mt ,Plstc

10 1011147 1 Lighter, Cigarette

11 1010500 1 Light, Indicator, White

12 39146-14 1 Switch, Ignition, W/Heat St

13 1005965 1 Switch, Emer Stop, Base W/Button

14 986546 1 Circuit Breaker, 10A, W/Mount

15 982008-04 1 Ignition Key

7



TM

7

RELAY PANEL

Figure 7-18. Relay Panel

21

3

4

7

89

71211

Horn 2-Speed Spray

Beacon JoystickFlasher

Brake

10

56



TM

Relay Panel Parts List

Item No.


Ref. 1012965 1 Harness, Fuse Block

1 1012965-01 1 Bracket, Fuse Block

2 100-4-20-12-5F 2 CSHH, 0.25-20 X 0.75, Gr 5, FT

3 302-4 2 Washer, Lock 0.25

4 200-4-20-5 2 Nut, Hex, 0.25-20, Gr 5

5 36086 6 Bracket, Relay Mount

6 36085 6 Relay, 12Vdc, Spdt, 40 Amp, 5 Pin

7 122-#10-24-12F 6 PHMS, Cross, #10-24 X 0.75, FT

8 302-#10 6 Washer, Lock #10

9 209-#10-24 6 Nut, Hex, Mach, #10-24

10 36157 2 Body, Fuse Block, 4 Gang, Ato & Atc

11 36341 2 Fuse, 15 Amp, Atc

12 36340 5 Fuse, 10 Amp, Atc

7



TM

7

HYDRAULIC GROUP

Figure 7-19. Hydraulic Group

2

3

2

1

7

1314

12

10

8

9

11

15

16

17

19

18

65

20



TM

Hydraulic Group Parts List

Item No.


Ref. 1013112 1 Hydraulic Group (See Schematics)

1 1013114 1 Tank W/M, Hyd, 16Gal, Trupac

2 37680 1 Cap W/Strainer, Hyd Filler

3 116-#12-12 6 SCR, Slfdrl, Hwh, #12 X 0.75

Ref. 35368 1 Sender, Temp Gauge, 04 Mp

Ref. 36124 1 Inducer, Back Pressure, 15Psi

5 500070 1 Gauge, Sight Level/Temp, Hyd Oil

6 1011817 2 Strainer, Hydraulic Suction, -24 SAE O-Ring

7 1011971 1 Pipe, Plug, 1.50 NPT, Square Head

Ref. 29405 2 Group, Wheel Motor, Dual (See Fig 7-6)

8 19780SRV 1 Solenoid Valve Assembly

9 1013420 1 Valve, Solenoid, 7 Gpm Priority, #12 Ports

10 100-4-20-60-5 2 CSHH, 1/4-20 X 3.75, Gr 5

11 217-4-20 2 Nut, Lock, Flexloc, 1/4-20, Full, LT

12 X259 1 Filter Assy, Hyd, Deluxe III

Ref. X260 1 Filter Element, Deluxe III

13 100-4-20-12-5F 2 CSHH, 1/4-20 X 0.75, Gr 5, FT

14 302-4 2 Washer, Lock, 1/4

15 36129 2 Cyl, Hyd, 3.00 X 10.00 X 1.25 Rod

Ref. 36129-01 A/R Kit, Seal, Steering Cyl

Ref. 21306 4 Pin, Clevis, 1.00 Dia, W/Zerk

Ref. 240030 2 Pin, Clevis, 1.00 X 2.625 W/1.5Hd

Ref. 80336 4 Pin, Cotter, .188 X 1.50

16 140500 1 Motor, Hyd, Power Steering

17 36128 1 Steering Column, 6.00, W/Wire

18 100-6-16-20-5 2 CSHH, 3/8-16 X 1.25, Gr 5

19 302-6 4 Washer, Lock, 3/8

Ref. 1013113 1 Kit, Hose, Cummins 2.8 T4F

20 1013805 1 Plate, Bracket

Ref. 1013583 4 Test Port, Hydraulic

Ref. 1013588-48 4 SMS Test Hose Assembly

7



TM

7

MISCELLANEOUS PARTS

Figure 7-20. Miscellaneous Parts

1

2

3



TM

Miscellaneous Parts List

Item No.


Ref. 1013223 1

Ref. 004684102 Ref.

Ref. 1005882 1

Ref. 1004895 1

Ref. 36263 1

Ref. 39135 1

Ref. 21506 1

1 P70036 1

2 28644 1

Ref. 35952 1

Ref. 80140 4

Ref. 100-4-20-16-5 2

Ref. 80192 2

Ref. 80140 4

Ref. 80350 4

3 985234-01 1

Ref. 71610 4

Ref. 302-4 8

Ref. 81275 4

Decal Group

Strip, Abrasive, 4" X 60’ Roll, Blk

Kit, Decal, Deco

Plate, Serial Number Decal,

Cima, Max Load 3400 Kit,

Kit, Decal, Safety and Ops

Smv Group

Sign, Slow Moving Vehicle Bar,

Smv Bracket,

Decal, Smv Sign Cover

Washer, Flat, USS, .250

CSHH, .250-20 X 1.00, Gr 5

CSHH, .250-20 X .75, Gr 5

Washer, Flat, USS, .250

Nut, Flexloc, .250-20, Full, LT

Manual-Pak Case

Mach SCR, PH, .250-20 X .75

Washer, Lock, .250

Nut, Acorn, .250-20, SS

7



TM

7

11-WHEEL ASSEMBLY OPTION (1 OF 2)

Figure 7-21. 11-Wheel Assembly Option (1 of 2)

NOTE 2:Use item 39, hose, toconnect the twoairmounts together. Onlyone air filler valve isrequired.

NOTE 3:Attach the assembly tothe machine. Bolt item31, base, to the frameusing the slotted holes.Align the assembly andtighten the bolts.

NOTE 1:Apply silicone to bottomof bar to prevent waterleakage.



TM

11-Wheel Assembly Option (1 of 2) Parts List

Item No.


Ref. 27759SRV 1 Optional 11-Wheel Assembly

Ref. 36614 4 Washer, Thrust, 1.50 ID x .062

5 27761 2 Plate, Spacer, Tire Beam Base

6 27769 1 Tire Beam, LH , Assembly

Ref. 27783 1 Tire Beam RH, Assembly

8 80074 2 Nut, Hex, Jam, .375-16

9 27785 2 Airmount Base, Weldment

11 28135 2 Base, 11-Wheel Weldment

12 31167 4 Fitt, Str 04MP -04HB, Push-On

13 38783 4 Bushing, Composite, 1.50 ID, .75

Ref. 36191-1 1 Spring, Torsion, Right

Ref. 38597 2 Tire Mounted, 7.50-15 NHS, 14Ply

18 38698 2 Airmount, 1T14C-1 Series

19 38702 1 Valve, Air, Filler, 02 NPT

Ref. 90772 1 Pipe, Tee, 04 FP, 300#

23 27827 2 Clamp, Airmount, Weldment

24 80315 2 Set Screw, .375-16 X .750

25 102-205-1A 4 CSHH, .375-16 X 1.00, Gr 5

27 102-417-1A 2 CSHH, .500-13 X 4.00, Gr 5

Ref. 28133srv 1 Base, RH Attachment, 11 Wheel Weldment

30 81141 36 Washer, Flat, SAE, .500, Hardened

31 28132srv 1 Base, LH Attachment, 11 Wheel Weldment

32 90763 2 Pipe, Elbow, 90, .250 Street, 300#

33 81272 8 CSHH, .500-13 X 2.00, Gr 8

34 81273 8 CSHH, .500-13 X 2.50, Gr 8

35 871070828 4 Washer, Thrust, 1.50 ID x .032

36 80040 20 Nut, Hex, .500-13

Ref. 80219 2 CSHH, .375-16 X .75, Gr 5

38 32638 1 Pipe, Bush, 04MP -02FP, Stl

Ref. 32882 6 Hose, 04, Push-On, 250

Ref. 33164 4 Clamp, Hose, # 10

Ref. 38962 1 Decal, 11-Wheel Inflation Chart

44 80162 4 Washer, Split Lock, .375

7



TM

7

11-WHEEL ASSEMBLY OPTION (2 OF 2)

Figure 7-22. 11-Wheel Assembly Option (2 of 2)

NOTE 4:Attach to existing watersupply.

NOTE 5:Use item 109, hose, toconnect.

NOTE 6:Connect item 110 to item102 using item 112, hogring.



TM

11-Wheel Assembly Option (2 of 2) Parts List

Item No.


Ref. 27759 1 Optional 11-Wheel Assembly

1 19517 2 Scraper Blade Holder Weldment

2 19524SRV 2 Scraper Blade, Back-Up

3 871075201 2 Collar, Set, 1.00 ID x 1.625 OD x .625

10 27793 2 Rnd, Scraper Blade Support

15 36191-2 1 Spring, Torsion, Left Hand

16 38595 2 Scraper, Tire, Flat Curve

22 80206 4 CSHH, .312-18 X 1.25, Gr 5


28 80963 8 Washer, Flat, SAE, .312

41 80212 2 CSHH, .312-18 X 2.00, Gr 5

Ref. 27919-01 1 Kit, Hose, 11-Wheel

Ref. 27794 1 Opt Coco Mat With Water, 11-Wheel

Ref. 19533 2 Coco Mat, 6 X 9

102 27211 2 Hanger, Coco Mat, Flat Tire

103 27788 2 Pipe, Coco Mat, 11-Wheel

104 71725 4 Elbow, Pipe, 90, .500, Galv

Ref. 33164 4 Clamp, Hose, # 10

106 480010 2 Nozzle, Assembly, 08 Pipe Nyl, 90 Deg

Ref. 6352 4 Hose, 08, Push-On, 250

110 30081 36 Chain, Proof Coil, .188

111 70319 2 Fitt, 90 08MP -08HB, Poly

Ref. 70414 16 Ring, Hog

113 70318 2 Fitt, Str 08MP -08HB, Blk Poly 7



TM

7

TRACTION CONTROL OPTION

Figure 7-23. Traction Control Option

NOTE 1:Tap into drain lines goingto hydraulic reservoir.

NOTE 2:Existing block may needto be removed to installfitting.



TM

Traction Control Parts List Option

Item No.


Ref. 27919 1 Optional Traction Control Kit

Ref. 37118 1 Fuse Holder, In Line, Atc

Ref. 33271-1 1 Wire, 16Ga, Black

Ref. 33271-12 1 Wire, 16Ga, Red, Black Stripe

Ref. 33271-18 10 Wire, 16Ga, Blue, Red Stripe

Ref. 33602 3 Conn, Butt, 16-14 Ga

Ref. 33609 1 Term ,Ring, 16-14 Ga, .375 Stud

7 33898 1 Fitt, Tee 08MJ- 08FJX -08MJ

Ref. 35123 4 Term, Ring, 16-14 Ga, #6 Stud

9 73039 2 Fitt, Str 16MB -12MRS

10 37955 2 Fitt, 90 12MRS -12FRS

11 38686 2 Fitt, 90 16MB -16MRS

Ref. 38728 1 Valve, Hyd, Traction Control, 48GPM

13 38730-027 1 Hose, 16, 16OFS -16OFS, 6000

14 38731-048 1 Hose, 12, 12OFS -12OF9, 6000

15 38731-071 1 Hose, 12, 12OFS -12OF9, 6000

16 70754 1 Fitt, 90 08MJ -06MB

17 71617 2 CSHH, .375-16 X 5.00, Gr 5

Ref. 851391 1 Switch, Toggle, Spst, 2-Pos

19 72552-046 1 Hose, 08, 08FJX -08FJX, 2500

20 80038 4 Nut, Hex, .375-16

21 80996 4 Washer, Flat, SAE, .375

Ref. 36340 1 Fuse, 10 Amp, Atc

Ref. 36348 1 Term, Push-On, .25, M18-14, Slv

Ref. 36349 1 Term, Push-On, .25, Fem, 16-14,

Ref. 38760 1 Decal, Traction Valve

7



TM

7

HEAT SHIELD OPTION

Figure 7-24. Heat Shield Option



TM

Heat Shield Option Parts List

Item No.


Ref. 19591SRV 1 Optional Heat Shield Group

2 19114 6 Hanger Rod, Front Side Curtain

3 19572SRV 1 Fender Curtain, Weldment, RH

Ref. 19589SRV 1 Fender Curtain Weldment, LH

5 19590 2 Front Side Curtain

6 19592 2 Clamping Bar, Front Side Curtain

8 19594 1 Hanger, Front Curtain

9 19595 1 Clamping Bar, Front Curtain

10 19596 1 Front Curtain

12 19598 2 Hanger, Rear Side Curtain

13 19599 2 Clamping Bar, Rear Side Curtain

14 19607 2 Rear Side Curtain

16 19609 1 Hanger, Rear Curtain

17 19610 1 Clamping Bar, Rear Curtain

18 19611 1 Rear Curtain

20 5928 6 Pin, Cotter, .148, #9

21 71622 16 CSHH, .375-16 X .88, Gr 5

22 80162 16 Washer, Lock, .375

23 80208 38 CSHH, .312-18 X 1.00, Gr 5

24 80230 6 CSHH, .375-16 X 2.00, Gr 5



7



TM

7

ALPHABETICAL PARTS INDEX (API)

DESCRIPTION PART NUMBER FIG. NO.ITEM NO.

Air Filter, AH55642 1012474-03 7-13 38

Air Filter, Primary 1010076-02 7-13 Ref.

Air, Filter, Secondary 1012474-25 7-13 Ref.

Airmount Base, Weldment 27785 7-21 9

Airmount, 1T14C-1 Series 38698 7-21 18

Alternator 1012474-23 7-13 2

Articulation Lock Link 19503 7-3 Ref.

Assembly, Engine, QSF2.8 T4f 1012474 7-13 Ref.

Assembly, Instrument Panel 1012498 7-15 1

Assembly, Instrument Panel 1012498 7-17 Ref.

Assembly, Joystick Module 1012960 7-15 2

Assembly, Joystick Module 1012960 7-16 1

Assembly, Joystick Mount, LH 1013448 7-16 2

Assembly, Joystick Mount, RH 1013449 7-16 3

Assembly, Lower Cover, Console 1012966 7-9 14

Assembly, Tire & Wheel, 7.50-15 NHS 38597 7-4 Ref.

Assembly. Engine Electrical Components 1013512 7-13 30

Bar, Radiator Brace, LH 1012479 7-13 79

Bar, Radiator Brace, RH 1012480 7-13 78

Bar, Smv Bracket, T/P 915 28644 7-20 2

Base, 11-Wheel Weldment 28135 7-21 11

Base, LH Attachment, 11 Wheel Weldment 28132 7-21 31

Base, RH Attachment, 11 Wheel Weldment 28133 7-21 Ref.

Base, Seat Slide 21566 7-10 4

Battery Boot , Pos(Red) 70437 7-15 Ref.

Battery, 12V, 1000 Crk Amps 33146-6 7-15 6

Beacon, Amber, Rotating Light 210893 7-15 Ref.

Bearing Cone, Inner 36136-02 7-5 5B

Bearing Cone, Outer 610240 7-5 5D

Bearing Cup, Inner 36136-01 7-5 5A

Bearing Cup, Outer 610230 7-5 5C

Bearing, Composite 2.25 ID 36137 7-5 6

Bearing, Spher, ID 1.50, OD 2.4375 X250 7-6 3

Bearing, Spherical 1.00 ID 36138 7-3 8



Belt Tensioner 1012474-05 7-13 Ref.



TM


Body, Fuse Block, 4 Gang, Ato & Atc 36157 7-18 10

Bolt, Wheel, .562 X 1.12 (Front) 36136-05 7-5 Ref.

Box, End, Ext Box 25812 7-16 5

Bracket, Relay Mount 36086 7-18 5

Bushing, Composite, 1.50 ID, .75 38783 7-21 13

Bushing, Split 1.5 ID 36144 7-6 10

Cable, Battery, Neg, 16", Eye/Post 400020 7-15 Ref.

Cable, Battery, Neg, 17", Eye/Eye 36339 7-15 Ref.

Cable, Battery, Neg, 97", Eye/Eye, 1 Awg 1008111 7-15 Ref.

Cable, Battery, Pos, 16", Eye/Post 800072 7-15 Ref.

Cable, Battery, Pos, 65", Eye/Eye, 1 Awg 1007411 7-15 Ref.

Canopy, Sunroof 19914 7-2 5

Cap W/Strainer, Hyd Filler 37680 7-19 2

Cap, Fuel, With Lock Lug 36105 7-14 3

Chain, Proof Coil, .188 30081 7-22 110

Chain, Proof Coil, .250 70395 7-9 Ref.

Charge Air Inlet, IC9663 1012474-02 7-13 Ref.

Circuit Breaker, 10A, W/Mount 986546 7-17 14

Clamp, Accuseal 1013985 7-13 82

Clamp, Airmount, Weldment 27827 7-21 23

Clamp, Hose, # 10 33164 7-11 8

Clamp, Hose, # 10 33164 7-12 8

Clamp, Hose, # 10 33164 7-21 Ref.

Clamp, Hose, # 10 33164 7-22 Ref.

Clamp, Marmon, V-Ban 1009242-06 7-13 81

Clamp, Sunroof 19928 7-2 6

Clamp, T-Bolt, 2.25-2.53 Range 38376 7-13 51





Clamp, T-Bolt, Constant Tension, 2.81-3.13 Range 1014075 7-13 56

Clamp, T-Bolt, Constant Tension, 2.81-3.13 Range 1014075 7-13 59

Clamp, Worm Drive, Constant Torque, 1.56-2.50 Range 1014082 7-13 64

Clamp, Worm Drive, Constant Torque, 1.56-2.50 Range 1014082 7-13 67

Clamping Bar, Front Curtain 19595 7-24 9

Clamping Bar, Front Side Curtain 19592 7-24 6

Clamping Bar, Rear Curtain 19610 7-24 17

Clamping Bar, Rear Side Curtain 19599 7-24 13

7



TM

7


Coco Mat Group, 9-Wheel 27208 7-4 5

Coco Mat Group, 9-Wheel 27208 7-8 Ref.

Coco Mat Grp, Flat Tire 27208 7-11 6

Coco Mat Grp, Flat Tire 27208 7-12 6

Coco Mat, 6 X 9 19533 7-8 7

Coco Mat, 6 X 9 19533 7-22 Ref.

Collar, Set, .88 ID x 1.38 OD x .56 36173 7-8 8

Collar, Set, 1.00 ID x 1.625 OD x .625 871075201 7-22 3

Collar, Set, 1.125 X 1.75 X .562 38183 7-7 13

Conn, Butt, 16-14 Ga 33602 7-23 Ref.

Coupler 1010076-36 7-13 55

Cover & Panel Groups 1013067 7-9 Ref.

Cover & Panel Groups 1013067 7-10 Ref.

Cover Weldment, Front Ballast 1009218 7-9 16

Cover, Bearing, Hyd Motor Mount 19176 7-6 4

Cover, Hyd Tank T/P 23523 7-19 Ref.

Cover, Instrument Panel 1012499 7-9 15

Cover, Rear Ballast 19226 7-9 12

Crossmember,Vertical 19202 7-9 9

CSHH, .250-20 X .75, Gr 5 80192 7-20 Ref.

CSHH, .250-20 X 1.00, Gr 5 80185 7-9 Ref.

CSHH, .250-20 X 1.00, Gr 5 80185 7-20 Ref.

CSHH, .312-18 X 1.00, Gr 5 80208 7-10 Ref.

CSHH, .312-18 X 1.00, Gr 5 80208 7-24 23

CSHH, .312-18 X 1.25, Gr 5 80206 7-7 9

CSHH, .312-18 X 1.25, Gr 5 80206 7-22 22

CSHH, .312-18 X 1.75, Gr 5 80211 7-7 10

CSHH, .312-18 X 2.00, Gr 5 80212 7-22 41

CSHH, .375-16 X .75, Gr 5 80219 7-3 20

CSHH, .375-16 X .75, Gr 5 80219 7-6 13

CSHH, .375-16 X .75, Gr 5 80219 7-21 Ref.

CSHH, .375-16 X .88, Gr 5 71622 7-24 21

CSHH, .375-16 X 1.00, Gr 5 100-6-16-16-5 7-11 11

CSHH, .375-16 X 1.00, Gr 5 80221 7-5 9

CSHH, .375-16 X 1.00, Gr 5 80221 7-21 25

CSHH, .375-16 X 1.25, Gr 5 80224 7-2 8

CSHH, .375-16 X 2.00, Gr 5 80230 7-24 24

CSHH, .375-16 X 5.00, Gr 5 71617 7-23 17

CSHH, .500-13 X 2.00, Gr 8 81272 7-21 33



TM


CSHH, .500-13 X 2.50, Gr 8 81273 7-21 34

CSHH, .500-13 X 4.00, Gr 5 80722 7-21 27

CSHH, 0.25-20 X 0.75, Gr 5, FT 100-4-20-12-5F 7-18 2

CSHH, 0.3125-18 x 0.75, Gr 5, FT 100-5-18-12-5F 7-9 2

CSHH, 0.375-16 X 1.00, Gr 5, FT 100-6-16-16-5F 7-9 6

CSHH, 0.375-16 X 1.00, Gr 5, FT 100-6-16-16-5F 7-9 Ref.

CSHH, 1.00-8 X 3.75, Gr 8 81074 7-2 2

Cshh, 1/2-13 X 1.5, Gr 5 100-8-13-24-5 7-13 10

CSHH, 1/4-20 X 0.75, Gr 5, FT 100-4-20-12-5F 7-19 13

CSHH, 1/4-20 X 1, Gr 5 100-4-20-16-5 7-13 26

CSHH, 1/4-20 X 1, Gr 5 100-4-20-16-5 7-13 39

CSHH, 1/4-20 X 3.75, Gr 5 100-4-20-60-5 7-19 10

CSHH, 3/8-16 X 1, Gr 5, FT 100-6-16-16-5F 7-13 35

CSHH, 3/8-16 X 1.25, Gr 5 100-6-16-20-5 7-13 14

CSHH, 3/8-16 X 1.25, Gr 5 100-6-16-20-5 7-19 18

CSHH, 3/8-16 X 1.5, Gr 5 100-6-16-24-5 7-13 18

CSHH, 5/16-18 X 1, Gr 5 100-5-18-16-5 7-13 22

CSHH, 5/16-18 X 1.25, Gr 5 100-5-18-20-5 7-13 31

CSHH, 5/16-18 X 1.5, Gr 5 100-5-18-24-5F 7-13 72

CSSH, .250-20 X .75 81057 7-6 5

CSSH, .875-9 X 3.00, Gr 5 81058 7-6 6

Cyl, Hyd, 3.00 X 10.00 X 1.25 Rod 36129 7-19 15

D.o.c., A041B697_Rev_B 1012474-09 7-13 83

Decal Group 1013221 7-20 Ref.

Decal, 11-Wheel Inflation Chart 38962 7-21 Ref.

Decal, Cima, Max Load 3400 36263 7-20 Ref.

Decal, Smv Sign Cover 35952 7-20 Ref.

Decal, Traction Valve 38760 7-23 Ref.

Display, PV480, Tier 4f, TP915 1012500 7-17 4

Drive Plate Assy, SAE #4,C Mt 1012474-17 7-13 8

Dust Cap 340040 7-5 5F

ECM 1012474-18 7-13 28

EGR Valve 1012474-19 7-13 Ref.

Elbow, 2.00 Rubber 38387 7-13 53

Elbow, 2.50 1012474-30 7-13 58

Elbow, Pipe, 90, .500, Galv 71725 7-22 104

Elbow, Rubber, 90, 4.00 X 3.00 ID 1000834 7-13 47

Extended Dip Stick 1012474-14 7-13 7

Fan 1012474-16 7-13 5

7



TM

7


Fan Belt, W/O AC 1012474-26 7-13 4

Fan Spacer 3" 1012474-15 7-13 6

Fender Curtain Weldment, LH 19589SRV 7-24 Ref.

Fender Curtain, Weldment, RH 19572SRV 7-24 3

Filler Cap, Chain Drive 1012474-29 7-13 Ref.

Filler Cap, Oil 1012474-24 7-13 Ref.

Filler, Tank, 4 In 36151 7-11 9

Filter Element, Deluxe III X260 7-19 Ref.

Filter Assy, Hyd, Deluxe III X259 7-19 12

Filter Element, Fuel/Water Separator 988666-05 7-13 Ref.

Filter Element, Oil 1012474-28 7-13 25

Filter Head, Fuel, Remote 1012474-10 7-13 21

Filter Head, Fuel/Water Separator 1012474-11 7-13 17

Filter Head, Oil 1012474-12 7-13 Ref.

Filter, Fuel 1012474-27 7-13 Ref.

Filter, Oil, Remote Adapter 1012474-13 7-13 Ref.

Fitt, 90 04MP -05HB 38279 7-14 2

Fitt, 90 06MP -08HB, Poly 72712 7-11 29

Fitt, 90 08MJ -06MB 70754 7-23 16

Fitt, 90 08MP -08HB 33082 7-12 33

Fitt, 90 08MP -08HB, Poly 70319 7-11 32

Fitt, 90 08MP -08HB, Poly 70319 7-22 111

Fitt, 90 12MRS -12FRS 37955 7-23 10

Fitt, 90 16MB -16MRS 38686 7-23 11

Fitt, Lube, 90,02 MP 5039 7-3 Ref.

Fitt, Str 04MP -04HB, Push-On 31167 7-21 12

Fitt, Str 08MP -08HB, Blk Poly 70318 7-12 37

Fitt, Str 08MP -08HB, Blk Poly 70318 7-22 113

Fitt, Str 16MB -12MRS 73039 7-23 9

Fitt, Tee 08HB, Poly 35771 7-12 18

Fitt, Tee 08MJ- 08FJX -08MJ 33898 7-23 7

Flasher, Signal 851091608 7-15 Ref.

Front Axle Assembly 19268 7-4 1

Front Axle Assembly 19268 7-5 Ref.

Front Curtain 19596 7-24 10

Front Side Curtain 19590 7-24 5

Fuse Holder, In Line, Atc 37118 7-23 Ref.

Fuse, 10 Amp, Atc 36340 7-18 12

Fuse, 10 Amp, Atc 36340 7-23 Ref.



TM


Fuse, 15 Amp, Atc 36341 7-18 11

Gauge, Sight Level/Temp, Hyd Oil 500070 7-19 5

Grease Seal 36136-03 7-5 5E

Grease, Wheel Bearing 91210 7-5 Ref.

Group, Engine, Cummins 2.8 T4f 1012473 7-13 Ref.

Grp, Wheel Motor, Dual 29405 7-19 Ref.

Hanger Rod, Front Side Curtain 19114 7-24 2

Hanger, Coco Mat, Flat Tire 27211 7-8 1

Hanger, Coco Mat, Flat Tire 27211 7-22 102

Hanger, Front Curtain 19594 7-24 8

Hanger, Rear Curtain 19609 7-24 16

Hanger, Rear Side Curtain 19598 7-24 12

Harness, Fuse Block 1012965 7-15 3

Harness, Fuse Block 1012965 7-18 Ref.

Harness, Hydraulic/Fuel System, Trupac B 1014825 7-15 Ref.

Harness, Joystick/Console Interface 1013666 7-15 Ref.

Harness, Main 1013598 7-15 Ref.

Harness, Wire, Water Spray Pump 28044 7-11 48

Harness, Work Light & Turn Signal 1013639 7-15 Ref.

Hold Down, Battery 72313 7-15 Ref.

Horiz Crossmember, R Frame, W/M 19199 7-9 8

Horn Low Pitch 20190773 7-15 4

Hose, 04, Push-On, 250 32882 7-21 Ref.

Hose, 08, 08FJX -08FJX, 2500 72552-046 7-23 19

Hose, 08, Push-On, 250 6352 7-11 1

Hose, 08, Push-On, 250 6352 7-22 Ref.

Hose, 08, Push-On, 250 Psi 6352 7-12 1

Hose, 12, 12OFS -12OF9, 6000 38731-048 7-23 14

Hose, 12, 12OFS -12OF9, 6000 38731-071 7-23 15

Hose, 16, 16OFS -16OFS, 6000 38730-027 7-23 13

Hub Assy, Wheel, 8 On 8.00 36136 7-5 5

Hump Hose, Reducer, 5.00-4.00 ID 953521244 7-13 42

Hyd Oil Specifications RES1001 7-19 Ref.

Hydraulic Group 1013112 7-19 Ref.

Idler Pulley 1012474-04 7-13 Ref.

Inducer, Back Pressure, 15Psi 36124 7-19 Ref.

Isolator 1010076-08 7-13 77

Isolator, Engine Mount 1013079 7-13 71

Kit, Decal ,Deco, TP915 1011142 7-20 Ref.

7



TM

7


Kit, Decal, Safety/Ops, TP915 1012953 7-17 3

Kit, Decal, Tp915 39135 7-20 Ref.

Kit, Horn 36130 7-15 Ref.

Kit, Horn, Steering Wheel Center 36130 7-16 7

Kit, Hose, 11-Wheel 27919-01 7-22 Ref.

Kit, Hose, Cummins 2.8 T4f 1013113 7-19 Ref.

Kit, Hose, Test Port 1013998 7-19 Ref.

Kit, Seal, Steering Cyl 36129-01 7-19 Ref.

Latch, Engine Access Door 160450 7-9 Ref.

Light, Indicator, White 1010500 7-17 11

Light, Turn Signal, Amber 6161 7-15 Ref.

Light, Turn/Brake, Red 851342007 7-15 Ref.

Lighter, Cigarette 1011147 7-17 10

Link, Articulation Lock 19503 7-9 17

Lock, With Offset Cam 35812 7-9 Ref.

Mach SCR, PH, .250-20 X .75 71610 7-20 Ref.

Mach SCR, PH,#10-24 X .75 122-#10-24-6F 7-17 2

Manual-Pak Case 985234-01 7-20 3

Motor, Hyd, Drive, 915 Trupac 39131 7-6 1

Motor, Hyd, Power Steering 36127 7-19 16

Mount, Axle 19183 7-5 1

Mount, Center Bonded 36048 7-13 75

Mount, Center Bonded Isolator Washer 1009242-34 7-13 76

Mount, Hyd Motor 19175 7-6 2

Nozzle, Assembly, 08 Pipe Nyl, 90 Deg 480010 7-22 106

Nozzle, Assembly, 08 Pipe Nyl, Str 986502 7-12 2

Nozzle, Assy, 08 Pipe Nyl, Str 1008851 7-11 2

Nut, Acorn, .250-20, SS 81275 7-20 Ref.

Nut, Flexloc, .250-20, Full, LT 80350 7-9 Ref.



Nut, Flexloc, .312-18, Full, LT 80351 7-7 11






Nut, Hex, .375-16 80038 7-14 7

Nut, Hex, .375-16 80038 7-23 20



TM


Nut, Hex, .500-13 80040 7-21 36

Nut, Hex, 0.25-20, Gr 5 200-4-20-5 7-18 4

Nut, Hex, 3/8-16, Gr 5 200-6-16-5 7-13 20

Nut, Hex, 3/8-16, Gr 5 200-6-16-5 7-13 37

Nut, Hex, 5/16-18, Gr 5 200-5-18-5 7-13 24

Nut, Hex, 5/16-18, Gr 5 200-5-18-5 7-13 74

Nut, Hex, 5/16-18, Gr5 200-5-18-5 7-13 33

Nut, Hex, Castle, .750-16 SPL 81071 7-5 12

Nut, Hex, Jam, .375-16 80074 7-21 8

Nut, Hex, Jam, .500-13 80076 7-5 8

Nut, Hex, Mach, #10-24 209-#10-24 7-18 9

Nut, Lock, Flexloc, 1/4-20, Full, LT 217-4-20 7-19 11

Nut, Lock, Stover, 1/4-20, Gr 5 204-4-20-5 7-13 29

Nut, Spl, 2.36-18 38671 7-3 16

Nut, Stovers 1.00-8, Gr C 81075 7-2 3

Nut, Wheel, M16 X 1.5 81064 7-4 Ref.

Nut, Wheel, M16 X 1.5 (Rear) 81064 7-5 Ref.

Opt 11-Wheel Assembly 27759 7-4 Ref.

Opt Coco Mat With Water For 11-Wheel 27794 7-4 Ref.

Opt Coco Mat With Water, 11-Wheel 27794 7-22 Ref.

Opt Traction Control Kit 27919 7-4 Ref.

Optional 11-Wheel Assembly 27759 7-21 Ref.

Optional 11-Wheel Assembly 27759 7-22 Ref.

Optional FOPS Group 36256 7-2 Ref.

Optional Heat Shield Group 19591SRV 7-24 Ref.

Optional Traction Control Kit 27919 7-23 Ref.

PHMS, Cross, #10-24 X 0.75, FT 122-#10-24-12F 7-18 7

PHMS, Cross, 0.25-20 X 0.5, FT 122-4-20-8F 7-9 Ref.

Pin Retainer 19239 7-3 2

Pin W/M, Front Axle 19184SRV 7-5 2

Pin, Clevis, 1.00 Dia, W/Zerk 21306 7-19 Ref.

Pin, Clevis, 1.00 X 2.625 W/1.5Hd 210060 7-19 Ref.

Pin, Clevis, 1.00 X 3.25 W/1.5Hd 240030 7-9 Ref.

Pin, Cotter, .125 X 1.25 80331 7-8 11

Pin, Cotter, .125 X 1.50 80332 7-5 13

Pin, Cotter, .148, #9 5928 7-9 Ref.

Pin, Cotter, .148, #9 5928 7-24 20

Pin, Cotter, .188 X 1.50 80336 7-19 Ref.

Pin, Hyd Motor Mount 19182 7-6 9

7



TM

7


Pin, Yoke, Dead End, Timken Nut 27718 7-3 7

Pin, Yoke, Live End, Timken Nut 27717 7-3 11

Pipe, Air Cleaner To Turbo 1012484 7-13 52

Pipe, Air Cleaner To Turbo, 3.00 1012483 7-13 48

Pipe, Air Intake 1012482 7-13 44

Pipe, Bush, 04MP -02FP, Stl 32638 7-21 38

Pipe, Cap, .500, Galv 91152 7-8 12

Pipe, Charge Air, Cold Side 1012486 7-13 60

Pipe, Charge Air, Hot Side 1012485 7-13 57

Pipe, Coco Mat, 11-Wheel 27788 7-22 103

Pipe, Coolant, Upper 1012474-20 7-13 62

Pipe, Elbow, 90, .250 Street, 300# 90763 7-21 32

Pipe, Nipple, .500 X .375, Pvc 36176 7-11 31

Pipe, Plug, .750, Sq Head 99538 7-14 Ref.

Pipe, Plug, 08 MP, Square Head 99537 7-8 13

Pipe, Plug, 1.50 NPT, Square Head 1011971 7-19 7

Pipe, Spray, 08 NPT x 42.25 19293 7-8 3

Pipe, Tee, 04 FP, 300# 90772 7-21 Ref.

Pipe, Tee, 08 FP, Galv 99845 7-8 14

Pipe, Water Spray Bar, 915 19292 7-8 2

Plate, Access Panel, LH 1012466SRV 7-9 5

Plate, Access Panel, RH 1012467SRV 7-9 4

Plate, Air Cleaner Mount 1012481 7-13 34

Plate, Engine Mount, LH 1012476 7-13 69

Plate, Engine Mount, Rear 1012478 7-13 70

Plate, Engine Mount, RH 1012477 7-13 68

Plate, Fuse Block 1012965-01 7-18 1

Plate, Instrument Panel 1012498-01 7-17 1

Plate, Radiator Grill 1012469 7-9 1

Plate, Serial Number, Rosco 35355 7-20 Ref.

Plate, Spacer, Tire Beam Base 27761 7-21 5

Plug, Hole, 1.25, Flush Mt ,Plstc 35136 7-17 9

Pre-Cleaner, Tier 4i, 3000 1011263-04 7-13 45

Pull Pin Spring Loaded 1000835 7-10 Ref.

Pump, Hydraulic, Gear, 19CC, SAE A Flange Mount 1012982 7-13 13

Pump, Hydraulic, Piston, W/EDC 36125-04 7-13 9

Pump, Water Spray 1005660 7-11 25

QSF2.8 Ref. 7-13 1

Radiator, Cummins 2.8 T4f 1013081 7-13 54



TM


Rear Curtain 19611 7-24 18

Rear Side Curtain 19607 7-24 14

Reducer, 3.00 To 2.13 986633 7-13 50

Relay, 12Vdc, Spdt, 40 Amp, 5 Pin 36085 7-18 6

Ring, Hog 70414 7-8 9

Ring, Hog 70414 7-22 Ref.

Rnd, Scraper Blade Support 27793 7-22 10

Rod, Lift, .50 OD x 26.38 19296 7-8 6

Rod, Lift, .50 OD x 40.25 19295 7-8 5

Rod, Lift, .50 OD x 55.25 19294 7-8 4

ROPS Group 19678SRV 7-2 Ref.

ROPS,Trupac Roller 36255 7-2 1

Schem, Solenoid Valve 19780SRV 7-19 8

SCR, Self-Tap, #10-32 X .50 81150 7-14 5

SCR, Slfdrl, Hwh, #12 X 0.75 116-#12-12 7-19 3

Scraper Blade Group 27206SRV 7-7 Ref.

Scraper Blade Group 27206SRV 7-4 4

Scraper Blade Holder W/M 19517 7-7 1

Scraper Blade Holder Weldment 19517 7-22 1

Scraper Blade Rod, Left, Front 19532 7-7 5

Scraper Blade Rod, Right, Front 19531 7-7 4

Scraper Blade, Back-Up 19524SRV 7-7 2

Scraper Blade, Back-Up 19524SRV 7-22 2

Scraper Blader Rod, Rear 19530 7-7 3

Scraper, Tire, Flat Curve 38595 7-7 8

Scraper, Tire, Flat Curve 38595 7-22 16

Seal, Felt, .38T, 2.40 ID X 4.00 OD 36405 7-3 5

Seal, Felt, .38T, 3.60 ID X 6.00 OD 36407 7-3 10

Seal, Felt, .50T, 3.60 ID X 6.00 OD 36409 7-3 Ref.

Seal, Felt, .50T, 4.00 ID X 6.00 OD 36408 7-3 Ref.

Seal, Felt, .63T, 3.60 ID X 6.00 OD 36404 7-3 4

Seal, Felt, .63T, 4.00 ID X 6.00 OD 36406 7-3 12

Sealant, Silicone, Clear 33707 7-19 Ref.

Seat Assy, Black,With Armrest 360010B 7-10 1

Seat Belt 730-3050 7-10 Ref.

Sender, Fuel Level, 24.00 Tank 35370-2 7-14 4

Sender, Temp Gauge, 08 Mp 35367 7-19 Ref.

Sensor, Temperature, Water 988666-17 7-13 Ref.

Set Screw, .375-16 X .750, SQHD 80315 7-21 24

7



TM

7


Set Screw, .500-13 X 1.50, SQHD 80715 7-5 10

Sign, Slow Moving Vehicle P70036 7-20 1

Sleeve, Abrasion, Nylon, .71Id 35403 7-9 Ref.

Sleeve, High Temp, 1.63 1012474-31 7-13 63

Sleeve, High Temp, 1.63 1012474-32 7-13 66

Sleeve, High Temp, 2.50 1012474-06 7-13 61

Slide Clamp Weldment, Front 21569 7-10 7

Slide Clamp Weldmnet, Rear 21573 7-10 6

Sliding Seat Assy 21575SRV 7-10 Ref.

Smv Group, Trupac 21506 7-20 Ref.

Spindle, Dual 1.12 Offset Hub 19211 7-5 3

Spindle, Single 1.12 Offset Hub 19212 7-5 4

Spring, Torsion, Left Hand 36191-2 7-7 7

Spring, Torsion, Left Hand 36191-2 7-22 15

Spring, Torsion, Right Hand 36191-1 7-7 6

Spring, Torsion, Right Hand 36191-1 7-21 Ref.

Starter 1012474-22 7-13 3

Steering Column, 6.00, W/Wire 36128 7-19 17

Steering Wheel, 17.00, 36 Spline 6436 7-16 6

Strainer Assy 36926 7-11 26

Strainer, Hydraulic Suction, -24 SAE O-Ring 1011817 7-19 6

Strip, Abrasive, 4" X 60’ Roll, Blk 4684102 7-20 Ref.

Stud, Wheel, M16 X 1.5 36131-02 7-6 14

Sunroof Group 19678-01SRV 7-2 Ref.

Suspension, Seat 140600 7-10 2

Switch, Emer Stop, Base W/Button 1005965 7-17 13

Switch, Ignition, W/Heat St 39146-14 7-17 12

Switch, Toggle, DPDT, 2-Pos 72086 7-17 6

Switch, Toggle, SPDT, 2-Pos 851090624 7-17 8

Switch, Toggle, SPDT, 3-Pos 851090613 7-17 7

Switch, Toggle, SPST, 2-Pos 851391 7-17 5

Switch, Toggle, Spst, 2-Pos 851391 7-23 Ref.

Switch-Master Disconnect-Batt 109740 7-15 5

Swivel Assembly 36371 7-10 3

Tank W/M, Hyd, 16Gal, Trupac 1013114 7-19 1

Tank Weldment, Fuel, 35 Gal 24852 7-14 1

Tank, Water, 150 Gal, White 1007360 7-11 10

Term ,Ring, 16-14 Ga, .375 Stud 33609 7-23 Ref.

Term, Push-On, .25, Fem, 16-14, Slv 36349 7-11 49



TM


Term, Push-On, .25, Fem, 16-14, Slv 36349 7-23 Ref.

Term, Push-On, .25, M18-14, Slv 36348 7-23 Ref.

Term, Ring, 16-14 Ga, #6 Stud 35123 7-23 Ref.

Term, Ring, 16-14 Ga, .250 Stud 33607 7-11 50

Tire Mounted, 7.50-15 NHS, 14 Ply 38597 7-5 Ref.

Tire Beam RH, Assembly 27783 7-21 Ref.

Tire Beam, LH , Assembly 27769 7-21 6

Tire Mounted, 7.50-15 NHS, 14Ply 38597 7-21 Ref.

Turn Signal, W/Hazard, 4-Wire 140480 7-15 Ref.

Valve, Air, Filler, 02 NPT 38702 7-21 19

Valve, Check, .500 HB, 5 Psi, Poly 36883 7-11 7

Valve, Check, .500 HB, 5 Psi, Poly 36883 7-12 7

Valve, Hyd, Traction Control, 48GPM 38728 7-23 Ref.

Valve, Solenoid, 7 Gpm Priority, #12 Ports 1013420 7-19 9

Washer, .44 X 2.125 X .134 Thick 19818 7-6 11

Washer, Flat, .375 300-6 7-11 12

Washer, Flat, 0.3125 300-5 7-9 3

Washer, Flat, 1/2 300-8 7-13 12

Washer, Flat, 3/8 300-6 7-13 16

Washer, Flat, Nylon, .313 81289 7-9 Ref.

Washer, Flat, SAE, .312 80963 7-7 12

Washer, Flat, SAE, .312 80963 7-22 28

Washer, Flat, SAE, .375 80996 7-14 6

Washer, Flat, SAE, .375 80996 7-5 11

Washer, Flat, SAE, .375 80996 7-23 21

Washer, Flat, SAE, .500, Hardened 81141 7-21 30

Washer, Flat, SAE, .875 81059 7-6 7

Washer, Flat, SAE, 1.000, Hardened 81076 7-2 4

Washer, Flat, Spl, .750 ID 81070 7-5 14

Washer, Flat, USS, .250 80140 7-9 Ref.




Washer, Flat, USS, .375 80142 7-2 7

Washer, Flat, USS, .500 80144 7-8 10

Washer, Lock #10 80879 7-14 Ref.

Washer, Lock #10 302-#10 7-18 8

Washer, Lock 0.25 302-4 7-18 3

Washer, Lock, .250 80160 7-20 Ref.

7



TM

7


Washer, Lock, .375 302-6 7-11 13

Washer, Lock, .375 80162 7-3 19

Washer, Lock, .375 80162 7-6 12

Washer, Lock, .375 80162 7-24 22

Washer, Lock, 0.375 302-6 7-9 7

Washer, Lock, 0.375 302-6 7-9 Ref.

Washer, Lock, 1/2 302-8 7-13 11

Washer, Lock, 1/4 302-4 7-13 27

Washer, Lock, 1/4 302-4 7-13 40

Washer, Lock, 1/4 302-4 7-19 14

Washer, Lock, 3/8 302-6 7-13 15

Washer, Lock, 3/8 302-6 7-13 19

Washer, Lock, 3/8 302-6 7-13 36

Washer, Lock, 3/8 302-6 7-19 19

Washer, Lock, 5/16 302-5 7-13 23

Washer, Lock, 5/16 302-5 7-13 32

Washer, Lock, 5/16 302-5 7-13 73

Washer, Lock, Tang Style 210170A 7-3 17

Washer, Nylon, .562 X 2.125 X .06 Thk 53175 7-8 15

Washer, Split Lock, .375 80162 7-21 44

Washer, Thrust, 1.50 ID x .032 871070828 7-21 35

Washer, Thrust, 1.50 ID x .062 36614 7-21 Ref.

Washer, Thrust, 2.25 ID, .060T 36265 7-5 7

Water Outlet 1012474-01 7-13 Ref.

Wear Strip, Poly 3.88 LG 91291-01 7-10 5

Weldment, Coolant, Lower 1014188 7-13 65

Weldment, Engine Access Panel, Front 1013006 7-9 11

Weldment, Engine Access Panel, Front, Fixed 1013011 7-9 10

Weldment, Fuse Access Door 1012968 7-16 4

Weldment, Pipe, Exhaust 1012475 7-13 80

Weldmnet, Engine Cover 1013072 7-9 13

Wheel And Tire Groups 19674. 7-4 Ref.

Wheel Group, 14 Ply 19674 7-5 Ref.

Wheel Group, 14 Ply 19674 7-4 2

Wheel Motor 29405 7-4 3

Wheel Motor 29405 7-6 Ref.

Wire, 16Ga, Black 33271-1 7-23 Ref.

Wire, 16Ga, Blue, Red Stripe 33271-18 7-23 Ref.

Wire, 16Ga, Red, Black Stripe 33271-12 7-23 Ref.



TM


Work Light 1003862 7-15 Ref.

Yoke Assembly 27719 7-3 Ref.

Yoke Plate, Front 19243 7-3 9

Yoke, Dead End 19215 7-3 1

Yoke, Live End 19220 7-3 3

7



TM

7



NOTES

TM

Printed in the U.S.A.

500 Lincoln County Parkway Ext.

Lincolnton, North Carolina 28092

Phone: (704) 966-3300 - Fax Sales: (704) 483-5802

www.lbperformancepaving.com

TM

operations, service, and parts manual · thank you for purchasing the lb performance ptc-15b...

Documents