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TM 5-3895-348-14&P-1 27 MARCH 1981

1. up uon 27 11471 Weapons Sys Dsg Code WS ee GS LLL LE USE TYPEWRITER OR BAL POINT PEN PRESS HARD ASSURE LEGIBILITY ON COPES 959 THA MOAIS Project ede aoe as E 123484 IUE QUANTITY ey ee 3 RT Docuuts are RR REQUEST 15 Use National Stock Number NSN a E QUANT 4720010131355 IN TM 5u 3895 348 145 amp P 1 Page 2A08 rnol or Ez cds OO ARS E t SARANANE GAEE sae wns 29 REQUEST FOR ISSUE OR TURN IN AR 710 2 REQUEST FOR ISSUE OR TURN IN f AR 7 02 COD SINCLE LINE ITEM REQUIEITION SYSTEM DOCUMENT MECHANICA 233 6 5 APPENDIX AMPLE FORMAT MILSTRIP REQUISTITIONS FOR NSN AUS orr VARIARE DATA ELEMENTS PRIOR DEPENDING CN lad ITY DOCUMENT IDEXTIFIER COOL a p 3 00 es Description of Data Document Identifier Code Routing Identifier Code Media Status Code NSN Unit of Issue Quantity Document Number Demand Code Supplementary Address Signal Code Fund Code Distribution Code CC 54 CC 55 56 Project Code Priority Code Required Delivery Date Advice Code 30 AMABLE DATA ELEMENTS 7 p
2. TM 3 220 NBC Nuclear Biological and Chemical FM 21 40 c General Utilization of Engineer Construction TM 5 331A Basic Cold Weather 4 31 70 o etus 31 71 Operation and Maintenance of Ordnance Materiel in Cold Weather 0 to 650 F FM 9 207 Procedures for Destruction of Equipment to Prevent Enemy TM 750 244 3 d Maintenance and Repair Inspection Care and Maintenance of Antifriction TM 9 214 Welding Theory and 8 9 237 Hand Portable Fire Extinguishers Approved for Army TB 5 4200 200 10 e Administrative Storage Administrative Storage of nennen TM 740 90 1 Preservation of USAMECOM Mechanical Equipment for Shipment and Storage TB 740 97 2 APPENDIX B WARRANTY GUIDELINES 1 A warranty period of 12 months applies to the Roller Motorized Steel Wheel Model C350B D Contract Number DSA 700 74 C 9024 manufactured by HYSTER Co after
3. REF HYSTER NAME OF PART REF HYSTER NAME OF PART NO PART NO 1234 QTY NO PART NO 1234 QTY o oa ee NE mnl ut censet cau si e DD 1 18497 CAPSCREW 5 16 UNC X 1 4 8 130845 CLAMP 1 1 15155 OCKWASHER 5 16 4 9 169099 BRACKET AIR CLEANER 1 2 169092 TUBE AIR INLET 1 10 168843 BRACKET MOUNT ING 1 3 115696 CLAMP HOSE 2 11 16691 CAPSCREW 5 16 UNF X 7 8 4 4 169095 HOSE 1 11 15155 LOCKWASHER 5 16 4 5 169100 MANIFOLO AIR CLEANER 1 11 15005 NUT 5 16 UNF 4 6 169098 HOSE 2 12 16374 CAPSCREW 5 16 UNC X 5 8 4 7 112989 CLAMP 4 12 15155 LOCKMASHER 5 16 4 8 169096 AIR CLEANER 2 13 170306 GASKET 1 8 234718 BAR RETA LINER 1 14 16187 BUSHING 1 8 234719 ELEMENT 1 15 168846 RESTRICTION INDICATOR KIT 1 8 138253 UNLOADER 1 FOR GAS ENGINE FIRST USED ON SERIAL NO B89C 3300 146 1546 EM 10 o 8 2 gt 5 4 1 AR Mi a 16 y LIS p 12 17 amp lt lt N z INVE JUIN REF MHYSTER OEPPART REF HYSTER NAME QF PART NO PART NO 123 QTY NO PART 0 1234 QTY 1 223137 AIB TLEANER SEE 1008 1 8 157116 ELBOW 1 2 169428 ACKET AIR CLEANER 2 9 17443 WING NUT 5 16 UN 1 3 115696 CLAMP 1 9 183586 WASHER SEAL ING 1 4 3910 PLATE SUPPORT 1 9 164222 L INK 1 5 828 CAPSCREW 3 8 UNC X 1 1 4 4 9 145639 LOCKNUT 1 5 7428 NUT 3 8 UNC 4 10 163730 HOSE 1 6 390370 HOSE 1 11 127045 CLAMP HOSE 2 112989 CLAMP 1 1
4. AR700 4 Material Management for Using Units Support Units and Installations AR 710 2 Requisitioning Receipt and Issue AR 725 50 Indexes should be consulted frequently for latest change of revisions of references and for new publications relating to material covered in this publication Index of Administrative 310 1 Index of Blank Forms iii i nini 310 2 Index of Doctrinal Training and Organization DA PAM 310 3 Index of Technical Manuals Technical Bulletins Supply Manuals Types 7 8 and 9 Supply Bulletins and Lubrication DA PAM 310 4 Index of Graphic Training Aid and DA PAM 310 5 A 2 Forms Refer to TM 38 750 The Army Maintenance Management System TAMMS for instructions on the use of maintenance forms pertaining to the materiel A 3 Other Publications The following publications contain information pertinent to the major item and associated equipment a Camouflage Gamgoutlage edente ene tede aee e a e i ee e eae de eve FM 5 20 b Decontamination Chemical Biological and Radiological CBR
5. ADJUSTMENT OF FLOW DIVIDER RELIEF VALVE ee STEERING CYLINDER J teret Pee epe eter DESCRIPTION a siete a ero dean ded dean s aS doe dea REMOVAL OF STEERING CYLINDER ees DISASSEMBLY OF STEERING CYLINDER sesane CLEANING AND INSPECTION REASSEMBLY STEERING INSTALLATION OF STEERING BLEEDING THE SYSTEM eorr A EL ce P o De e E e SRL CHECKING RELIEF PRESSURE ii rre eere STEERING TRUNNION DESCRIPTION mE REMOVAL OF GUIDE ROLLS AND STEERING AXLE ASSEMBLY DISASSEMBLY OF AXLE SHAFT ASSEMBLY CLEANING AND REASSEMBLY AXLE SHAFT ASSEMBLY INSTALLATION OF GUIDE ROLLS AND STEERING AXLE ASSEMBLY REMOVAL AND DISASSEMBLY YOKE AND KING PIN ASSEMBLY CLEANING AND INSPECTION REASSEMBLY AND INSTALLATION OF YOKE AND KING PIN ASSEMBLY aiie PARK BRAKE c r MM M m DE SCAIP REMOVAL AND DISASSEMBLY CLEANING AND INSPECTION ect verse sate teat a DI DE HEASSEMBLY AND INSTALLATION Catan RD BRAKE LINING BREAK IN PROCEDURE 3 566 WATER SPRAY SYSTEM GENERA
6. 2 1 9 Air Intake System oen 3 1 4 TRA LEES 4 1 5 Goling eatin 5 1 6 Exhaust System uqa agamaku DLP D M ELI A 6 1 7 Electrical Equipment oi 7 1 13 Operating 6 22 2225202 64000010 aaa a kk 13 1 14 Engine Tune Up ei 14 1 15 Preventive Maintenance Trouble Shooting Storage 15 1 INDEX ALPHABETICAL INDEX 1 PART ENGINE PARTS MANUAL ENGINE LESS MAJOR 65 A1 FUEL SYSTEM A OE aE E aE a B1 AIR SYSTEM RP C1 LUBRICATING SYSTEM aa D1 COOLING SYSTEM E1 EXHAUST SYSTEM eit enano aene Yen enn Y Enn F1 ELECTRICAL SYSTEM G1 This technical manual is an authentication of the manufacturers commercial literature and does not conform with the format and content specified in AR 310 3 Military Publications This technical manual does however contain available information that is essential to the operation and maintenance of the equipment PART SERVICE MANUAL STEEL WHEEL ROLLER C350B CONTRACT NO DSA 700 74 C 9024 OPERATING INSTRUCTIONS C350B STEEL WHEEL ROLLER Starting Set park brake Move throttle bail to neutral vertical position Start engine To Protect En
7. 12 2 1 y BRACKET BATTERY SEE 1805 1 12 15154 WASHER 1 4 2 12 15000 NUT 1 4 UNC 2 13 125 ROO END 1 3 391471 CABLE PULL 1 13 213896 PIN RDD 1 4 393529 PLATE 1 13 15200 PIN COTTER 1 5 393532 U BOL T 1 14 393085 CABLE PUSH PULL 1 5 15175 WASHER 5 16 2 15 392015 SWITCH 1 6 213897 U BOLT 1 l6 392016 CLAMP 1 5 15155 WASHER 5 16 2 17 220501 SCREW 10 UNC 2 7 393530 LEVER 1 17 15002 NUT 10 UNC 2 8 222707 PIN 1 17 391727 SPACER 2 9 85749 SCREW SHOULDER 1 18 382019 SWIVEL 1 9 15175 WASHER 5 16 1 19 392018 BRACKET 1 9 18515 WASHER 5 16 1 20 15024 NUT 1 4 UNF 2 9 15154 WASHER 1 4 1 21 54115 SNAP RING 1 9 15000 NUT 1 4 UNC 1 e aa RA GR Ga 10 LEVER SEE 1010 REF 1 1 23 ge 393322 BRACKET 1 11 393305 PLATE LOCK 1 12 85749 SCREW SHOULDER 2 Dai Ac MAE da ENOTNE ONEN 12 18515 WASHER 5 16 2 a A ae diia Eb orem 2 12 393307 WASHER SPR ING 2A12 HYDRAULIC MOTOR FIRST USED ON SERIAL NO B89C 3401 AND A146C 1700 REF HYSTER NAME OF PART REF HYSTER NAME OF PART NO PART NO 123 QTY NO PART NO 1 2 3 4 ary 393461 MOTOR HYORAULIC 1 25 267030 SPRING RETATNER 6 1 267026 VALVE MANTFOLD 1 26 190601 GUIDE SLIPPER RETAINER H 2 18524 CAPSCREW 5 16 UNC X 3 3 4 6 27 190602 RETAINER SLTPPER 1 3 194402 WASHER 5 28 267031 PISTON 9 4 265732 O RING 2 29 194396 SWASHPLATE FIXED 1 5 n 165064 RING BACK UP 2 30 194397 SHAFT MOTOR 1 6 u 39767 O RING 1 31 190625 BEARING FRONY 1 7 194394 END CAP MOTOR 1 32 194398 HOUS
8. 1811 1 05 2 03 203 1813 1003 2003 1804 1007 1007 1F04 1 07 1 07 1 07 1405 2006 200 1904 1804 1F08 1F08 1F08 2412 2004 2004 2004 1 94 1809 1004 1011 1004 1D08 2004 200 2004 200 200 1 07 2007 2C03 1806 1E04 1 04 1 04 REF ND 165877 165878 165879 165880 165881 165882 165888 165889 165890 165892 165894 165895 165897 165898 165899 165900 165904 165906 165910 165911 165915 165918 165920 165921 165922 165924 165925 166021 166118 166119 166169 166170 166171 166172 166173 166174 166175 166195 166196 166197 166216 166296 166336 166337 166479 166538 166541 166557 166558 166566 166567 166572 166578 166643 166645 166655 166700 166702 166824 166825 PAGE REF G07 NUMERICAL INDEX PART NO 166828 166829 166830 166831 166832 166845 166857 167005 167009 167010 167051 167054 167055 167056 167090 167457 167456 167459 167486 167492 167506 167532 167549 167657 168068 168069 168390 168421 168694 168696 168697 168698 168699 168700 168701 168702 168703 168704 168705 168706 168810 168811 168812 168830 168835 168836 168838 168841 168842 168843 168846 168887 168889 168890 168891 168892 168893 168894 168895 168896 PAGE REF NO PART NO 168897 168898 168899 168901 168904 168941 168947 169009 169092 169095 1690
9. FIGURE 9 62 FIGURE 9 63 FIGURE 9 65 SECTION 9 STEERING TO CYLINDER TO CYLINDER BASE END ROD END TO TANK FROM PUMP FIGURE 9 66 9 18 DELETED PAGES 9 19 THRU 9 22 SECTION 9 STEERING 9 52 STEERING PUMP DETROIT DIESEL UNITS 9 53 DESCRIPTION 9 54 The steering pump Is a positive displacement gear pump It is located at the right rear of the Detroit Diesel engine and is gear driven seg figure 9 82 9 55 pump see figure 9 91 is made up of a housing two gears four bearings a front cover and a rear cover Pressure loading the front bearing assures correct gear to bearing clearance During pump operation pressurized oil is directed to an area between the front cover and bearings forcing them toward the gears Pressure from the outlet side of the pump is against the opposite side of the bearings When the two pressures are balanced a thin film of oil OUTPUT x SUCTION HOSE NP HOSE CONNECTION 2008 CONNECTION 1 gt FIGURE 9 82 9 23 exists between the gears and bearings and actual gear to bearing contact is prohibited 9 56 Oil is prevented from by passing the body and end covers by neoprene gaskets between the components A replaceable low pressure shaft seal is pressed into the front cover Communication of the high pressure and low pressure oil between the bearings and front cover is prevented by a W shaped seal 9 57 DISASSEMB
10. FINAL DRIVE GENERA enei aa E C350B FINAL DRIVE DESCRIPTION snnt REMOVAL AND DISASSEMBLY OF FINAL DRIVE ASSEMBLY CLEANING AND INSPECTION teens REASSEMBLY AND INSTALLATION OF FINAL DRIVE ASSEMBLY STEERING GENERAL wu DESCRIPTION ME STEERING SYSTEM cuisses tette tette ttti tette DESCRIPTION OPERATION MM REMOVAL OF STEERING CONTROL UNIT DISASSEMBLY OF STEERING CONTROL UNIT INSPECTION TTE REASSEMBLY OF STEERING CONTROL UNIT isset nettes INSTALLATION OF STEERING CONTROL UNIT a nettes STEERING PUMP DETROIT DIESEL eene DESCRIPTION 1 eet ha DERE ERR RENE FERE ERE E EEFEFER DISASSEMBLY OF STEERING PUMP 0 0 CLEANING AND INSPECTION REASSEMBLY OF STEERING FLOW DIVIDER DETROIT DESCRIPTION TA OPERA NON s cette mL d te coupe E E REMOVAL OF FLOW DISASSEMBLY OF FLOW DIVIDER CLEANING AND INSPECTION REASSEMBLY AND INSTALLATION OF FLOW
11. 1406 1406 1406 1406 1406 1406 1807 1807 1809 2004 1008 1008 1 03 1 03 1 03 1011 2007 2007 1007 1008 1008 1008 1810 1814 1814 1814 1 05 1co5 1605 1 05 105 1 01 1 01 1012 2003 1405 1405 1405 REF NO 43 rovr NN 37 38 38 35 40 51 42 PART NO 158452 158676 158677 158678 158682 158760 158826 158627 158828 158829 158830 158831 158832 158833 158834 158835 158836 158837 158839 158840 158841 158843 158844 158845 158846 158847 158908 158913 159064 159105 159563 159565 159566 159567 159568 159569 159570 159701 159703 159708 15976 159812 159942 159944 159945 159973 159975 159976 159977 159979 159980 159961 159982 159992 159993 160248 160250 160251 160252 160372 PAGE 1405 1807 1807 1807 1807 181 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 2007 2007 2006 1012 2 03 2 03 2 03 2 03 2603 2 03 2E03 2004 200 1804 2004 2004 1806 1003 1807 1803 1803 1803 1803 1803 1803 1803 1803 1804 1804 1804 1806 1804 1804 1806 REF NO 160374 160376 160378 160379 160381 160382 160445 160600 160601 160602 160603 160604 160622 160650 160773 161094 161145 161146 161147 161148 161149 161150 161151 161152 161153 161154 161155 161156 161158 16
12. Air in system Check reserve oil level fill tank as necessary Check inlet side of pump for vacuum leaks Tighten connections Bleed system Refer to Section 9 Remove and check the relief valve Repair or replace parts as necessary If foreign particles are the cause of malfunction check reserve oil for contamination Whenever oil is con taminated it should be replaced and the filter serviced Make sure sealing surfaces are mating properly Sticky relief valve Bent or deformed cylinder piston or Disassemble check and repair cylinder rod assembly TABLE 5 5 TROUBLE ANALYSIS FOR BRAKE SYSTEM TROUBLE PROBABLE CAUSE CORRECTIVE ACTION Parking Brake Will Cable disconnected clamps loose or Connect cable or related linkage rods Not Apply linkage binding Tighten clamps Free up linkage Adjust linkage as specified in Section 10 Brake lining worn Replace SECTION 5 TROUBLESHOOTING TABLE 5 5 TROUBLE ANALYSIS FOR BRAKE SYSTEM CONT TROUBLE PROBABLE CAUSE CORRECTIVE ACTION Parking Brake Applies Maladjusted Adjust Refer to Section 10 But Will Not Hold Grease or oil on lining Replace lining Locate cause of contamination Worn lining Replace Cables on linkage seized Free up or replace Parking Brake Will Not Adjusted too tightly Adjust as specified in Section 10 Release Or Drags Shoe retracting spring or linkage Replace springs weak broken or disconne
13. 2 Don t work compactor until engine and hydraulic oils are warm 3 Don t let engine idle for extended periods 4 Don t operate compactor with faulty engine governor or with excessive hydraulic pressure Have qualified personnel make these checks 5 Make sure the air cleaner and oil filters are serviced correctly All connections must be tight with no leaks in the system 6 Do add coolant to an overheated engine 7 After working compactor let engine idle a few minutes before stopping 8 Fill fuel tank at the end of the shift when compactor is warm 9 Repair minor defects immediately 10 Adhere to lubrication and maintenance recommendations 1A04 FRAME AND BODY PARTS WATER SPRAY SYSTEM DECALS AND PAINTING INSTRUCTIONS 1A08 FRAME AND COWLING 1A05 SCRAPERS AND 1A06 WATER SPRAY 1407 1A05 FRAME AND COWLING 2032 5 7 35 3 40 eS S 3 26 O 23242523 98 REF HYSTER NAME OF PART REF HYSTER NAME OF PART NO PART NO 123 QTY NO PART NO 1 2 3 4 QTY 27 87393 CAP FILLER WATER 1 1 393083 PLATE COVER RH 1 28 21420 PLUG BREATHER 1 1 390723 PLATE COVER4 LH 1 29 15310 PLUG 1 2 15056 NUT 3 8 UNC 4 30 16597 CAPSCREW 3 8 UNC X 3 4 GS 12 2 15134 WASHER 3 8 30 15156 LOCKWASHER 3 8 12 2 15156 LOCKWASHER 3 8 4
14. m 9 Ep 222 me 2 2 4 HYSTER 112989 NAME OF PART SPIRITED ON SERENE 5 46 HERS TUS ED ONS IH HUNE T 6906 999 3 QTY 1C07 ENGINE MOUNTS CRANKCASE DRAIN AND FILTER HOSES FOR 3 53 DIESEL ENGINE REF MAME OF PART REF HYSTER NAME OF PART NO PART 0 1234 QTY NO PART NO 1234 QTY 1 12948 CAPSCREW 5 8 UNF X 3 G5 3 23 15461 COUPL ING 1 2 21162 WASHER 5 8 1 24 17300 ELBOW 1 3 168836 BRACKET 1 25 99443 HOSE HYDRAULTC 1 164280 MOUNT ENGINE 4 26 14526 ELBOW 1 5 168835 ANGLE 1 27 191782 BRACKET 1 6 15012 NUT 3 4 UNF 9 28 198881 PIPE 1 7 15162 LOCKWASHER 3 4 9 29 14386 PLUG 3 8 1 8 16800 CAPSCREW 3 4 UNF X 2 G5 9 30 OIL FILTER COMES WITH ENGINE 1 9 17505 LOCKNUT 5 8 UNF 10 168830 BRACKET 1 31 16275 PLUG 2 11 18543 CAPSCREW 3 8 UNF X 3 3 4 G5 4 32 16828 CAPSCREW 3 8 UNC X 1 1 4 G5 4 11 15156 LOCKWASHER 3 8 4 33 15156 LOCKWASHER 3 8 6 12 18557 CAPSCREW 7 16 UNC X 1 1 4 G5 2 34 15056 NUT 3 8 UNC 6 13 15157 LOCKWASHER 7 16 2 35 76787 HOSE HYDRAULTC 2 14 164281 WASHER 5 8 3 36 113687 CLAMP 2 15 20512T BRACKET 1 37 15176 WASHER 3 8 2 16 12481 CAPSCREW 5 8 UNF X 4 1 2 G5 1 38 16805 CAPSCREM 3 8 UNC X 1 G5 2 17 15158 LOCKWASHER 1 2 8 39 17307 LBOW 2 18 16830 CAPSCREW 1 2 UNC X 1 1 4 G5 8 40 184313 u BOLT 1 19 168838 1 20 168841 SPACER 1 Em bir BIE m BQ E E u 21 17
15. 1 01 1407 1407 1812 1006 1812 2A11 2 11 2 11 2 11 2A11 2A11 2A11 2A11 2A11 2A11 2A11 2A11 2A11 2A11 2A11 2A11 2A11 2A11 2A11 1812 1col 1813 1605 105 1 05 1505 1405 1405 1008 1008 1008 1008 2A12 2A12 2A12 2A12 2A12 2A12 2A12 2A12 REF NO 17 21 25 267031 382019 390016 390022 390052 390084 390088 390096 390099 390101 390102 390103 390104 390105 390106 390107 390108 390122 390124 390206 390211 390284 390288 390325 390364 390370 390425 390426 390427 390429 390430 390431 390433 390436 390438 390439 390440 390442 390443 390444 390445 390453 390458 390460 390461 390462 3904T1 390479 390494 390497 390500 390501 390502 390503 390504 390505 390506 390507 390508 390511 PAGE REF NO NUMERICAL INDEX PART NO 390512 390663 390613 390677 390679 390681 3906 82 390683 390684 390686 390693 390697 390698 390699 390721 390722 390723 390786 390787 390788 390789 390790 390791 390792 390793 390876 390877 390878 390879 390880 390881 390882 390883 390884 390893 390894 390895 390896 390897 390898 390899 390900 390944 390946 390974 391051 391053 391075 391076 391080 391081 391083 391095 391096 391097 391248 391263 391272 391351 391352 G10 PAGE REF NO 5 5 5 5 4 4 3 3 3 8
16. 165 25 From Level on Each Side 109 From Level on Each Side 90 Total 45 Each Side 2 1 SECTION 2 SPECIFICATIONS C550B 10 16 TON 9071 12700 KG FIGURE 2 1 TABLE 2 2 PERFORMANCE SPECIFICATIONS DESIGN DATA Maximum Travel Speed i MPH 129 vh Inside Turning Radius ed in MAD un Outside Turning Radius 1592 em TABLE 2 3 WEIGHT BALLAST COMPRESSION DATA 1 DEON DATA NEN te BALLAST Compression Ib lineal Ry inch cm 10 14 Ton Guide Roll 8000 3629 Drive Roll 12000 5443 Total 20000 9072 2 2 SECTION 2 SPECIFICATIONS TABLE 2 3 WEIGHT BALLAST COMPRESSION DATA CONT ITEM DESIGN DATA WITHOUT BALLAST Weight Compression Ib kg ib lineal kg lineal inch cm WITH LIQUID BALLAST Weight Compression Ib kg Ib lineal kg lineal inch cm C350B 10 14 Ton Guide Roll 11200 5080 Drive Roll 16800 7620 Total 28000 12700 DELETED PAGE 2 4 SECTION 2 SPECIFICATIONS TABLE 2 6 DETROIT DIESEL ENGINE SPECIFICATIONS DESIGN DATA ITEM ENGLISH METRIC In Line 3 Cylinder 2 Stroke 3 875 In SECTION 2 SPECIFICATIONS TABLE 2 6 DETROIT DIESEL ENGINE SPECIFICATIONS CONT STROKE DISPLACEMENT TORQUE HORSEPOWER INJECTORS COMPRESSION RATIO IDLE SPEED HIGH IDLE SPEED No Load FIRING ORDER EXHAUST VALVE CLE ARANCE OIL PRESSURE 220
17. 8 69 221341 NUT 1 4 UNC 4 18 169144 PLATE DRIVE 69 197068 WASHER 1 4 4 LS ES es ya Esos gt 4 LITT g 71 129563 CLAMP STRAP 20 214931 PLATE MDUNTING od eb da 71 176451 CLAMP 21 es BRACKET PAGE 2A10 REF 8 1 71 15512 CAPSCREW 1 2 UNC X 3 4 22 es LEVER PAGE 2410 REF 2 1 71 15158 LOCKWASHER 1 2 23 130845 CLAMP HOSE 2 9528 QE 24 186227 NIPPLE 1 72 393081 HOSE 26 15995 REDUCER 1 3 186259 COOLER OIL 28 17301 ELBOW I 75 82426 ELBOW 29 393080 HOSE 1 T 391075 BLOCK RUBBER 30 187282 VALVE CHECK 1 18 391076 SPACER 31 190004 POPPET 1 79 18540 CAPSCREW 3 8 UNC X 3 65 32 190003 SPRING 1 79 15056 NUT 3 8 UNC 33 190001 SNAP RING 1 80 215041 CHANNEL 34 190002 WASHER 1 8 5 Be 35 186228 FITTING 1 82 393086 HOSE 36 17585 NIPPLE 1 3 Pes 3T e s FILTER OIL SEE PAGE 2802 i 83 CAPSCREW PG 2806 REF 61 4 38 177457 TEE SPECIAL 85 393078 HOSE 1 38 168812 FITTING SPECIAL P 1 85 CAPSCREW PG 2 11 REF 2 6 39 156607 GASKET 1 86 VALVE SEE PG 2 11 REF 1 1 40 164227 CAP QIL FILLER 1 87 145641 NUT 3 8 UNC 4 40 118742 GASKET 1 87 15134 LOCKWASHER 3 8 4 41 156670 COVER TANK 1 42 15055 5 16 UNC 8 42 15155 LOCKMASHER 5 16 8 43 156696 1 2A10 CONTROL LINKAGE FIRST USED ON SERIAL NO B89C 3401 AND A146C 1700 REF HYSTER NAME GF PART REF HYSTER NAME OF PART NO PART NO 123 QTY NO PART NO 123 QTY 12 18500
18. Secure with cotter pin e Install brake shoes and return springs in position shown seg figure 10 6 f Install brake drum and torque capscrews to 49 ft lbs 6 8 kg m seg figure 10 7 FIGURE 10 5 BRAKE SHOE RETURN SPRING E RE FIGURE 10 6 10 3 SECTION 10 BRAKES FIGURE 10 7 10 10 ADJUSTMENT sed figure 10 8 10 11 The parking brake handlever should be adjusted sufficiently to require at least 80 pounds 36 3 kg to pull it into the applied position Turn the adjusting knob on the handlever clockwise lever in brake off position to increase force required to apply the brake 10 12 Whenever the brake lining wears to the point where the brake cannot be adjusted with the handlever adjusting knob or when new lining is installed because of wear another adjustment must be made This adjustment is made in the linkage on the actuator lever end of the brake cable a Disconnect the brake cable from the actuator lever and loosen the cable end jam nut on the cable b Push the actuator lever arm until the shoes contact the brake drum Adjust cable end until it aligns with the actuator lever arm in the shoe contact position c Connect the cable to the actuator lever and adjust the handlever to obtain maximum braking power 10 13 BRAKE LINING BREAK IN PROCEDURE CAUTION Break in is essential to ensure adequate braking of the unit a Jack the drive roll off the ground b Warm up
19. 138253 138553 138554 138555 138559 138590 138601 138718 138907 138982 138986 139024 139140 139196 139646 139771 139773 140595 140598 141266 141276 141457 141794 141916 142340 142526 142550 143750 144020 144119 144123 144124 PAGE 1014 1014 1015 1015 1014 1014 1014 1014 1014 1014 1014 1014 1014 1014 1014 1014 1014 1 09 1405 1405 1B10 1F07 1407 1 07 1 08 1 08 180 2004 1004 1 09 1 09 1 09 1 09 1612 1812 1006 200 1812 1813 2409 2003 1 09 2E03 2409 1008 2A11 1co3 1008 1008 1 0 1 01 2003 1 01 71810 71 07 1 02 1 01 2413 2801 2413 REF ND 144135 144613 145172 145173 145174 145176 145171 145231 145586 145639 145641 146073 146633 146635 146644 146689 146811 146812 146813 147299 147369 147527 147528 147597 147611 147612 147616 147633 147990 148260 148370 148471 148472 148475 148506 148524 148525 148658 148659 148767 148826 148827 149293 149294 149513 149514 149516 149519 149802 149817 149818 149819 149830 149842 149843 149844 149845 149346 149847 149857 PAGE REF NO G05 NUMERICAL INDEX PART 149858 149867 149868 149869 149870 149863 149867 149888 149889 149892 149919 149929 149934 149945 149952 149965 149976 149977 149978 150194 151315 151316 151399 151837 151840 152230 152231 152232 152234
20. 15687 CAPSCREW 1 4 UNC X 1 1 2 22 177991 22 221341 LOCKNUT 1 4 UNC 23 156133 LOCKNUT 3 8 UNC 24 184814 COVER WATER TANK 24 158445 GASKET 25 158447 PLATE FLOOR 26 184819 STRAINER 26 184818 SNAP RING INCLUDED IN LATCH KIT 180313 HLAST USED ON SERIAL 146C 1535 AND 889C 3239 FIRST USED ON SERIAL NO A146C 1536 AND 889 3240 146 1539 USES PANEL 391081 ZFIRST USED ON SERIAL NO 146 1546 AND 889 3300 CFIRST USED ON SERIAL NO 146 1700 AND B89C 3401 p Wes m auo NNN N s 1A06 SCRAPERS AND MATS 1517 20 21 24 FOR STEERING DRUM FOR DRIVE DRUM Y9 REF HYSTER NAME OF PART 4 REF HYSTER NAME OF PART NO PART NO 123 4 QTY NO PART NO 123 4 QTY 1 169694 BRACKET LH 1 29 15058 NUT 1 2 UNC 2 1 157325 BRACK ET RH 1 30 170551 1 16830 CAPSCREW 1 2 UNC X 1 1 4 G5 4 3 15158 LOCKWA SHER 172 6 31 157315 PLATE SCRAPPER 2 4 15135 WASHER 1 2 8 5 15058 NUT 1 2 UNC 2 32 18588 80LT 1 2 UNC X 1 1 4 4 6 18588 80LT 1 3 UNC X 1 1 4 2 33 15158 LOCKWASHER 1 2 4 89469 COTTER 16 34 15058 NUT 1 2 UNC 4 8 157321 MAT 1 35 157305 BRACKET SCRAPER 1 36 18202 CAPSCREW SPECIAL 2 9 157315 PLATE SCRAP ER 1 36 15026 NUT 3 8 UNF 2 3T 157322 PAWL RAT CHET 2 10 169695 SHAFT 1 38 157302 BRACKET LH I 2 11 169698 SPRING RH 1 9399 a 13 157314 HOOK 2 38 157303 BRACKET
21. 162768 162772 162773 162774 162775 163202 163256 163257 163258 163259 163260 163262 163263 163264 163265 163266 163267 163269 163270 163616 163725 163730 163734 163739 163762 163910 164005 164015 16401T 164021 164022 164023 164025 164026 164027 164029 164030 164031 164034 164038 164043 164050 164056 164065 164083 164084 164085 164086 164087 164091 164097 164128 164134 PAGE 1F04 1F04 1F04 1F04 1 04 1 0 1804 180 1806 1806 1806 1804 1803 1 01 1 01 1 01 1 01 1601 1 01 1601 1 01 1 01 1 01 1 01 1601 1 01 200 2003 100 2 03 2 03 1F03 1 08 1 0 1806 1803 1803 1803 1803 1808 1808 1804 1804 1804 1804 1B04 1806 1806 1806 1806 1405 1F09 1804 1804 1804 1804 1806 1806 2A06 1809 REF NU PART NO 164141 164144 164151 164152 164154 164156 164186 164187 164188 164189 164199 165221 165222 164221 164235 164280 164281 164293 164301 164302 166359 164363 164368 164399 164400 164473 164488 164507 164508 164510 164524 164525 164526 164746 164747 164758 164766 164767 165064 165201 165203 165204 165278 165282 165287 165295 165298 165308 165313 165314 165316 165317 165318 165362 165615 165786 165804 165874 165875 165876 PAGE 1811 1811 1811 1 03 1811 1811 1003 1003 1003 1803 2603 1007 1004 2 06 1812 1
22. 196283 196284 196285 2C03 2005 2D05 2A06 1408 1408 2006 2006 1 2004 1 1 08 2006 2006 2006 1407 2005 2D05 2 12 2412 2412 2A12 2A12 2A12 2A12 2004 2004 2004 1A08 2802 1812 1812 1812 1812 02 1812 1407 1407 1407 1407 PART NO 196431 196434 197068 197549 197551 197861 197862 198028 198029 198214 198881 199398 199400 199401 199562 199839 199840 199841 199933 200555 202004 203920 204120 204121 204223 204773 204966 205127 205698 205723 209627 209830 209866 210614 210615 210616 210617 213255 213256 213257 213264 213265 213266 213274 213275 213276 213589 213609 213610 213611 213612 213614 213615 213616 213617 213618 213619 213620 213621 113624 PAGE 1A07 2A14 2406 1810 1810 1407 1407 2004 2004 2805 1B04 1407 1407 1407 2A09 1810 1810 1 10 1003 1 07 1 09 1405 1405 1405 1 0 2C03 2603 1 07 2A08 1806 200 2005 1812 203 2C03 1008 1008 1008 1008 1008 1008 2806 2806 1808 2805 2A11 2A06 2406 2413 2A06 2A06 2 06 2 06 2 06 2 06 2 06 2 06 NO 213626 213627 213628 213683 213684 213685 213686 213687 213689 213690 213692 213693 213694 213695 213696 213697 213698 213699 213700 213702 213883 213884 213888 213889 213892 213894 213896 213897 2138
23. 212 Fahrenheit is equivalent to 100 Celsius 90 Fahrenheit is equivalent to 32 2 Celsius 32 Fahrenheit is equivalent to 0 Celsius C 32 F LIQUID MEASURE 1Milliltter 0 001 Liters 0 0338 Fluid Ounces 1 1000 Milliliters 33 82 Fluid Ounces APPROXIMATE CONVERSION FACTORS TO CHANGE TO MULTIPLY BY Inches Centimeters 2540 Feet Meters 0305 Yards Meters 094 Miles Kilometers 1609 Square inches Square Centimeters 6 451 Square Feet Square Meters 0093 Square Yards Square Meters 0836 Square Miles Square Kilometers 2590 Acres Square Hectometers 0405 Cubic Feet Cubic Meters 0028 Cubic Yards Cubic Meters 0765 Fluid Ounces Mitldtters 29573 Pints Liters 0 473 Quarts Liters 0946 Gallons Liters 3785 Qunces Grams 28 349 Pounds Kilograms 0 454 Short Tons Metric Tons 0907 Pound Feet Newton Meters 1356 Pounds per Square Inch Kilopascals 6895 Miles per Gallon Kilometers per Liter 0425 Miles per Hour Kilometers per Hour 1609 TO CHANGE TO MULTIPLY BY Centimeters Inches 0394 Meters Feet 3280 Meters Yards 1094 Kilometers Miles 0621 Square Centimeters Square inches 0 55 Square Meters Square Feet 0764 Square Meters Square Yards 196 Square Kilometers Square Miles 0386 Square Hectometers Actes 24n Cubic Meters Cubic Feet 3536 Cubic Meters Cubic Yards 1308 Milliliters Fluid Qunces 0034 Liters Pints 218 Liters Quarts 1057 Liters Gallons 0 264 Grams Ounces 0035 Kilograms Pounds 22 Metric Tons Short Tons 102 Newton Meters Pou
24. 50 31 32 28 25 27 23 17 17 14 19 15 53 26 44 10 20 42 49 16 18 83 22 86 38 20 82 82 82 85 51 22 25 48 49 37 38 35 44 44 44 984326 984336 984383 984474 984477 984513 984565 984581 984632 984645 985218 985222 985228 985265 985266 985273 985274 985275 985281 985287 985299 985567 985576 7 985626 985627 985628 985629 985701 985702 985704 986000 986002 986104 986181 986182 986475 990332 990334 990429 990430 990563 992003 992025 992393 992583 992628 992625 992630 992631 992632 992633 992716 992829 1199286 1199287 PAGE 1 04 1 01 1013 1013 2007 1 03 1 04 1812 1011 1 01 1814 1 01 1co5 1 05 1 05 1005 1605 1013 1013 1C03 1012 1813 1013 1013 1013 1013 1013 1013 1013 1014 1013 1814 1810 1810 1813 1004 1812 1 01 1812 1812 1co2 1813 1812 1 09 1812 1004 1 09 1813 1co1 2006 1004 1 01 2801 REF NO G11 NUMERICAL INDEX PART NO REF NO PART REF NO REF NO PAGE PAGE PAGE TM 5 3895 348 14 amp P 1 By Order of the Secretary of the Army E C MEYER General United States Army Official Chief of Staff J C PENNINGTON Major General United States Army The Adjutant General Distribution To be distributed in
25. 9 27 BACK UP RING LOCK RING SHELL NUT O RING BACK UP RING WIPER SEAL BACK UP RING SECTION 9 STEERING ROD PISTON RING BACK UP RING RETAINER O RING WEAR RING PISTON LOCK NUT FIGURE 9 93 rod movement As one side of the cylinder fills the opposite side is dumping an equal amount of oil Oil is prevented from internally transferring from one side of the piston to the other by a teflon seal ring The cylinder completes its stroke when the piston reaches a retainer At this time hydraulic pressure increases causing the system relief valve to open This prevents excessive pressure buildup in the system NOTE For straight ahead travel the piston is positioned in the center of the cylinder shell 9 78 REMOVAL OF STEERING CYLINDER see figure 9 94 a Disconnect the hydraulic lines from the cylinder and plug or cap to keep out dirt and reduce oil loss b Remove the cotter pin from the trunnion end of the cylinder and remove the plug and ball seat c Remove dirt boot by straightening the connector straps d Pry rod end of the cylinder from the ball stud 9 28 e Disconnect the shell end of the cylinder following steps b through d above f Lift off cylinder and drain DISCONNECT AND CAP FIGURE 9 94 9 79 DISASSEMBLY OF STEERING CYLINDER seg fig a Remove rod end ball joint b Unscrew and remove the retainer c Using a section of hollow round
26. B 12 BLACK c 14 RED D 12 YELLOW E 16 RED F 16 GREEN G 16 BLACK T 5 H 14 BROWN u 2 16 BROWN K 12 WHITE TO CIRCUIT BREAKER L 14 BLUE a 16 BLUE a N 16 GREEN 16 BROWN R 16 BLACK 5 14 YELLOW GEM T 16 ORANGE u 14 WHITE v 16 GREEN w 14 WHITE z 14 GREEN FIGURE 6 5 INSRTUMENT PANEL DETAIL FOR DETROIT ENGINE 6 5 SECTION 6 ELECTRICAL ALTERNATOR WATER TEMP SENDER s p STARTER LIGHTS PARK BRAKE SWITCH SEE INSTRU PANEL BLUE BLACK GREEN BLACK i i Ww SENDER jJ 7 COLOR 9 FIGURE 6 6 ROUTING DIAGRAM FOR DETROIT DIESEL ENGINE SEE FIGURE 6 4 FOR ELECTRICAL SCHEMATIC 6 6 DELETED PAGE 6 7 DELETED PAGES 7 1 THRU 7 21 TRANSMISSION BY PASS VALVE SECTION 7 TRANSMISSION HYDROSTATIC MOTOR ge OIL COOLER BY PASS VALVE HYDROSTATIC PUMP RETURN FILTER HYDRAULIC TANK E 7 me SUCTION FILTER FIGURE 7 32 7 22 SUNDSTRAND HYDROSTATIC TRANSMISSION 7 85 GENERAL 7 86 This section contains a description of the Sundstrand hydrostatic transmission transmission components and their function in their hydraulic circuits Service instructions are given that include removal of components disassembly inspection reassembly and installation procedures 7 87 Checks and adjustments are presented in this section Design and performance specifications are presented Seaton 2 The troubleshooting guide is
27. BEARINQGEQRIVE END SCREW LOCKAASHER WASHER CPLLAR OUTSIO OCK WASHER NUT SHAFT CAPACITOR SLINGER GREASE STATOR CL IP STATOR LEAD ROTOR FRAME DRIVE END TERMINAL PACKAGE GROUND TERMINAL PACKAGE BATT INSULATOR BATTERY TERM WASHER INSULATOR FAN PULLEY REF HYSTER PART NO ir TE L on ee T 36 3T 38 39 40 41 154402 15639 15155 18515 154399 16828 177947 NAME OF PART QTY ARM ADJUST ING CAPSCREM 5 16 UNC X 1 LOCKWASHER 5 16 WASHER 5 16 BRACKET ALTERNATOR HIPH CPSCR 3 8 UNC X 1 1 4 65 5 LOCKMASHER 3 8 BIR L Add 42 42 16805 43 15156 43 15134 5 17155 55 53740 49 154382 CAPSCREW 3 8 UNC X 1 65 LOCKMASHER 3 8 WASHER 3 8 CPSCR 3 8 UNF X 3 1 4 G5 Bigi NUT 3 8 UNF s ac ba BE 3 wh PPTI TUSE OON ERE NO iade eie 2A04 TRANSMISSION AND POWER TRAIN CONTROL LINKAGE 2A09 FINAL DRIVE C3508 2805 FINAL DRIVE 6340A 2807 HYDRAULIC MOTOR 2A11 2A07 HYDRAULIC SYSTEM FIRST USED ON SERIAL NO 889C 3401 AND A146C 1700 1 2 34567 8 INE INED LIY X PZ 22222 9 Z W 1213 14 15 J N Ex Js Qs N 2 T SN E 2 132 y w s geg 42 2A08
28. CAUTION Use only HYSTER APPROVED parts e Install kingpin bearings and lower seal f Install trunnion assembly into the frame and torque bearing retainer nut to the specification listed in 4 99 STEERING CYLINDER BALL JOINTS se figure 4 30 4 100 The steering ball joints should be re packed yearly a Remove rubber dust covers b Disassemble the ball joint on each end of the cylinder c Clean and inspect components d Pack each ball joint assembly with multi purpose grease e Reassemble the ball joints and adjust so there is no end play f Install rubber dust covers CAUTION Damaged dust covers will not keep out contaminants Replace with HY STER APPROVED parts if original dust covers are damaged FIGURE 4 30 STEERING CYLINDER BALL JOINTS 4 21 4 101 REMOVING AND REPLACING STEEL BALLAST see figure 4 31 4 102 The steel ballast can be removed to provide access to the lower engine compartment WARNING Always support ballast securely when removing or installing capscrews 4 103 UNIT STORAGE 4 104 To prevent deterioration of components the following precautions should be taken when storing the roller for any length of time 4 105 WATER SPRAY SYSTEM 4 106 Drain the entire water spray system to prevent freezing of water and the resulting damage to components A drain hole is provided in the tank bottom left corner to drain the tank Be sure to open the pump drain cock
29. Check each part after 6 to 10 strokes across the abrasive After polishing each part rinse clean in solvent and blow dry Keep these parts absolutely clean until they are assembled 9 27 REASSEMBLY OF STEERING CONTROL UNIT CAUTION Observe the shaft to rotor alignment procedures specified in figure 9 2 Do not oil any component prior to reassembly The sealing of one component to another is dependent on lapped surfaces Seepage may occur as a result of dust retained in an oil film Blow all parts dry with compressed air prior to reassembly a Place housing in vise with control end up 9 32 FIGURE 9 35 SECTION 9 SECTISTESRING STEERING Protect 14 hole end and clamp across port surface lightly Drop check valve spring into check hole with large end down see figure 9 33 b Drop check ball into check hole and insure that it rests on top of the small end of the spring within the hole see figure 9 34 Place the check valve seat on hex wrench and screw into threads within check hole so that the machined counterbore of the check seat is towards the ball seg figure 9 35 c Torque check seat to 12 5 ft lbs 1 728 kg m seq figure 9 36 Test check ball action by pushing ball with small clean pin against spring force Ball need NOT be snug against seat for proper function d Install spool within sleeve carefully so that spring slots of both parts will be at same end Rotate while sliding parts toge
30. FIGURE 8 2 8 2 SECTION 8 FINAL DRIVE Consequently the small planet carrier E stationary walks around the ring gear D Planet carrier E is splined to and drives a second sun gear F which rotates in the same direction as but independently of sun gear B Sun gear F then drives the larger planetary gear set G which is capable of turning the ring gear D and the drive drum Ring gear D is attached to the drum The second larger planet carrier H is bolted to the frame and provides the reaction necessary to drive the drum 8 6 REMOVAL AND DISASSEMBLY OF FINAL DRIVE ASSEMBLY a Drain the lubricant refer to Bection 4 NOTE Inspect the lubricant for foreign particles Keep samples for failure analysis b Block the guide rolls front and rear WARNING Do not depend on the parking brake to prevent the unit from moving The brake assembly will be removed prior to the removal of the drive drum c Jack up both sides of the frame so that the weight of the frame is on the jacks and not the drive drum d Remove the scraper bar and bumper assembly mounting capscrews and lift off the assembly e Complete the DRIVE DRUM removal procedure presented ir Section 7 paragraph 7 1 98 f Remove the capscrews in the drum hub Pull the hub using the puller holes provided and appropriate puller bolts jnstall two dow guide pins sed 83 WARNING Connect the drum hub to a hoist prior to complete re
31. GENERAL 5 2 Tables 511 through 5 5 are trouble anal SECTION 5 TROUBLE SHOOTI NG ysis check charts for the individual systems of the compactor TABLE 5 1 TROUBLE ANALYSIS FOR WATER SPRAY SYSTEM TROUBLE Spray Motor Will Not Operate Spray Motor Will Not Turn Off Pump Operates But There ls Little Or No Spray Pattern Spray Pattern Not Completely Covering The Drum s PROBABLE CAUSE Toggle switch open Circuit breaker not Motor brushes worn excessively Toggle switch shorted Insufficient liquid in reservoir Water filter plugged Spray nozzles plugged Pump housing cracked from freezing Spray angle incorrect One or more nozzles plugged Charging system malfunctioning low voltage to moter 5 1 CORRECTIVE ACTION Replace switch Replace breaker Replace brushes Replace switch Replenish liquid supply Clean water filter and tank Clean nozzles and nozzle manifold Replace pump Adjust nozzle manifold so spray pattern completely covers drum Refer to the water spray section Clean nozzle s Check charging system DELETED PAGES 5 2 AND 5 3 SECTION 5 TROUBLESHOOTING TABLE 5 2B TROUBLE ANALYSIS FOR SUNDSTRAND HYDROSTATIC TRANSMISSION TROUBLE PROBABLE CAUSE CORRECTIVE ACTION Unit Will Not Operate Close valve Refer to Section 3 In Either Direction Transmission by pass valve open System low on oil Check oil level
32. HYDRAULIC SYSTEM FIRST USED ON SERIAL NO 889C 3401 AND A146C 1700 KEY dini pm I E C FOR 3 53 DIESEL ENGINE REF HYSTER NAME OF PART REF HYSTER NAME OF PART QTY PART NO 1234 0 PART NO 1234 erc 93825 8 44 17300 ELBOW 1 1 393082 HOSE d 2 f 393087 HOSE 45 17345 CONNECTOR 1 es 46 393156 TANK HYDRAULIC 1 3 111331 CONNECTOR 47 180442 PIPE 1 5 CAPSCREW PG 2806 REF 62 48 156655 PIPE 1 5 18559 CAPSCREW 7 16 UNC X 49 156656 PIPE 1 5 1 3 4 G5 50 14683 CONNECTOR 1 5 15157 LOCKWASHER 7 16 51 17324 ELBOW 1 6 112475 ELBOW 52 15346 NIPPLE 1 7 14603 PLUG 53 14387 PLUG 1 8 ease MOTOR HYDRAULIC PAGE 54 12818 ELBOW 1 9 2412 56 ese HOSE SEE PAGE 2002 REF 26 1 3 eses CARRIER MDOTOR PAGE 2806 57 146073 GAUGE VIEW 1 9 REF 2 58 393254 HOSE 1 11 156690 FLANGE SPLIT 59 17697 NIPPLE REDUCER 1 11 169787 O RING 60 180441 FILTER OIL RETURN LINE 1 13 lt PUMP HYDRAULIC PAGE 2804 60 182291 HEAD 1 4 221565 CAPSCREW 1 2 UNC X 1 1 4 61 180595 ELEMENT 1 e 62 182293 LOCKNUT 1 15 16828 CPSCR 3 8 UNC X 1 1 4 65 63 182292 VALVE BY PASS 1 15 15156 LOCKWASHER 3 8 64 182290 GUIDE BY PASS 1 16 16828 CPSCR 3 8 UNC X 1 1 4 65 65 182288 SPRING 1 16 16815 CPSCR 3 8 UNC X 1 1 2 65 66 182287 SCREW 1 16 15156 WASHER 3 8 67 182289 SPACER 1 3 68 14596 1 17 17112 BOLT 3 8 UNC X 1 1 4 69 190517 J BOLT 2 s 69 190515 U BOLT 2
33. Ln HEAT EXCHANGER BY PASS FIGURE 7 35 SUNSTRAND TRANSMISSION IN REVERSE 7 26 neutral the shuttle valve located in the hydrostatic motor manifold is centered allowing oil from the charge pump to be directed to the cooling circuit by the low charge pressure relief valve Cooling circuit flow in neutral is not admitted to the motor but is directed to the pumps drain circuit through the oil cooler to the hydraulic tank 7 105 OIL COOLER 7 106 The oil cooler is mounted with the engine radiator It is connected between the motor case drain port and the hydraulic tank Excess cooing oil from the low charge pressure relief valve enters the motor case then flows through the case drain line through the pump case to the oil cooler and the tank 7 107 OIL COOLER BYPASS VALVE 7 108 The oil cooler bypass valve prevents high back pressure at the pump case Back pressure can result from cold fluid or a restricted oil cooler passage The valve is set to open at 15 PSI 1 05 kg cm2 pressure at normal operating temperature During cold start conditions or if flow through the cooler becomes restricted the valve opens to allow flow from the pump directly to the hydraulic tank INPUT PUMP DRIVE DRIVE SHAFT MECHANISM PISTONS VARIABLE SWASHPLATE CAPABLE OF OVERCENTER OPERATION PUMP VARIABLE DISPLACEMENT OIL WORK CIRCUIT ANGLE CONTROL SECTION 7 TRANSMISSION 7 109 SHUTTLE VALVE 7 110 W
34. SECTION 8 FINAL DRIVE pie FIGURE 8 26 FIGURE 8 29 FIGURE 8 30 FIGURE 8 27 8 9 h Install the large snap ring figure 8 27 Press the oil seal into the drum hub until it bottoms against the snap ring sed figure 8 28 j Assembly of Inner Planetary Assembly Install the interlocking sun gear in planetary carrier and lock it in place with the snap rings Place the planetary carrier on a protective surface with the long hub of the interlocked sun gear down figure 8 29 k Installation of the Planetary System If the ring removed gear has been clean its FIGURE 8 31 EATR AN WITH 4 CAPSCREWS THEN REMOVE FIGURE 8 32 8 10 SECTION 8 FINAL DRIVE mounting flange and paint it with Loctite Plastic Gasket or equivalent sed figure 8 30 l Do the same to the mating machined surface of the drum see figure 8 31 m Install the ring gear using a pilot stud Using four capscrews seat the ring gear in the drum Remove the four capscrews see figure 8 32 n Insert thrust washer first then needle thrust bearing into the machined pilot of the interlocked sun gear of the inner planetary assembly using a heavy machine grease to hold them in the pilot seg figure 8 33 FIGURE 8 33 FIGURE 8 34 0 Install the small sun gear on the brake shaft Then install the snap ring into its retaining groove see figure 8 34 Assemble brake shaft into inner
35. Use only HYSTER APPROVED filter elements e Screw the assembled filter bowl into the filter head When tightening the center post hold the bowl from turning because it may stretch the o ring out of shape and cause suction leakage Tighten the center post to a maximum of 20 ft lbs 2 8 kg m 4 71 The throw a way return filter should be replaced at 1 000 hours of operation or every year whichever occurs first Always change the return filter if the suction filter is replaced a Unscrew the filter from the filter head and discard the filter b Wipe bottom of the filter using a clean lint free cloth CAUTION Use only HYSTER APPROVED filters c Apply a film of oil or grease to the new filter gasket integral with filter d Hand turn the filter into the filter head until the gasket just makes contact Then tighten one quarter turn only 4 18 SECTION 4 HYSTER CARE MAINTENANCE 4 74 WATER SPRAY SYSTEM 4 75 FILTERS sed figure 4 23 4 76 The non corrosive sump filter normally requires no maintenance because of the self cleaning action of the water washing back and forth in the tank If excessive foreign material accumulates in the tank the filter and the tank will need cleaning The filter can be inspected by removing the tank access plate 4 77 The tank inlet screen filter should be periodically cleaned when the water does not readily pass through The screen lifts out of the tank freely after snap ring is
36. VACUUM CHECK 7 169 The suction filter is equipped with a vacuum gauge which indicates flow from the tank to the charge pump The maximum vacuum at the charge pump inlet should not exceed ten inches 254 mm of mercury at normal operating conditions During cold start up it is acceptable to have a higher reading The unit should not be operated until hydraulic is at normal operating temperature and vacuum is below 10 inches 254 mm of mercury 7 170 ADJUSTMENTS 7 171 DISPLACEMENT CONTROL VALVE NEUTRAL ADJUSTMENT sed figure 7 42 WARNING The drive drum MUST safely blocked off the ground Any movement of control valve spool causes the unit to shift out of neutral and the drum will turn Caution personnel to stand clear of the drive drum FIGURE 7 41 SECTION 7 TRANSMISSION FIGURE 7 42 a Remove end play from centering spring mechanism with lockout Ref A loose and holding the centering spring housing Ref C turn the spring adjusting screw Ref B until the screw is just touching the centering spring washer thus taking the free end play out of the centering spring mechanism This is best done by exerting a light back and forth force on the control valve spool Ref F at the same time adjusting screw is being turned down Care must be taken not to compress the centering spring Ref D beyond its installed height Tighten the locknuts Ref A and recheck the spool Ref F for end play b Ad
37. engine oil specifications MIL L 2104C FUEL STRAINER AND X C SEE PARTS MANUAL 4 8 FILTER D AIR CLEANER FILTER SEE PARTS MANUAL 4 20 NOTE Check air restriction DETROIT DIESEL X indicator on Detroit Diesel Winter Water and ethylene gylcol base anti freeze with rust inhibi tors and anti foaming qualities Summer Water and rust inhibitor MIL 0 A 548 9 Gals 34 1 Itr Approved Oils MIL L 2104 Mobilfluid 423 Shell Tellus 29 Type transmission fluid conforming to Ford Motor Co spec ESW M2C33F or E COOLING SYSTEM DETROIT DIESEL 16 Qts 15 1 ltr NON SECTION 4 HYSTER CARE MAINTENANCE TABLE 4 1 HYSTER CARE MAINTENANCE SCHEDULE CONT FIGURE SCHEDULE HOUR PERIOD Mos ITEM 8 50 100 200 300 500 1000 1 QUANTITY TYPE day wk 2wks mo yr 7 FUEL TANK X 25Gals No 2 Diesel 94 6 fuel 800 GUIDE ROLL AXLE Multi purpose Grease BEARINGS MIL 10924B m m AR 0 Water TRANSMISSION SUCTION SEE PARTS MANUAL FILTER THROTTLE AND TRANS A R Engine Oil 4 61 MISSION LINKAGE MIL L 2104C PARKING BRAKE LEVER Multi purpose Grease 4 82 Lube and Adjustment MIL G 10924B THROTTLE CONTROL Multi purpose Grease t MECHANISM D MIL G 10924B ENGINE OIL FILTER DETROIT DIESEL SECTION 4 HYSTER CARE MAINTENANCE TABLE 4 1
38. seg figure 8 43 y Install the drive drum following the procedure presented in Section 7 paragraph 7 203 Fill final drive with specified lubricant refer to Section 4 Z Install scraper bar and bumper assembly CAUTION Follow transmission start up procedure before returning unit to service FIGURE 8 39 FIGURE 8 40 8 12 FIGURE 8 41 27 94 4 e 24 a HOLES 2 508e 1 91 254 T s 91 lt 159 Cm FIGURE 8 42 SECTION 8 FINAL DRIVE FIGURE 8 43B FIGURE 8 434 8 13 DELETED PAGES 8 14 THRU 8 20 9 1 GENERAL 9 2 This section contains a description of the steering system operation and overhaul instructions for major components Overhaul instructions include removal disassembly inspection reassembly and installation procedures System checks and adjustments are given at the end of steering cylinder repairs Design and performance specifications are given in Troubleshooting instructions are given in Section 5 9 3 DESCRIPTION seb figure 9 1 9 4 STEERING SYSTEM 9 5 The steering system is a hydrostatic operated manually controlled system with provisions for manual steering The steering system has a natural feel for the operator by provide in a direct relation between the steering wheel position and the guide roll position 9 6 Components of the steering system are STEERING CYLINDER TO N FROM TANK
39. which serves as the DA Representative with the contractor in warranty matters NOTE In certain instances the originating organization and the support activity are one and the same c Before you take your equipment to a dealer for repair whether or not it was necessary for you to go through the NMP TARCOM check with your local procurement office to see if a funds commitment document is needed Sometimes even though the majority of the repairs are covered by the warranty there may be a small charge for normal maintenance costs i e oil filters oil etc Further the cause of damage could be determined by the dealer to be directly related to operator abuse In that case the Government may be obligated to pay for tear down services even if the repairs are no longer desired or for the complete cost if repairs are to be completed by the dealer d When the equipment is given to the dealer for repairs find out how long the work will take the extend of the problem if possible and the charges if any which may be involved Leave the name and telephone number of the person to be contacted for pickup of the equipment and specifically state that he should be called as soon as the repairs are finished In addition state he should be telephoned if unexpected problems costs and or delays are encountered Get the name and telephone number of the Service Manager for any required follow up purposes e When you arrive to pick up your equipment af
40. with slight rotating motion see figure 9 45 Bring the spool assembly entirely within the housing bore until the parts are flush at the meter end or 14 hole end of the housing Do not pull the spool assembly beyond this point to prevent the cross pin from dropping into the discharge groove of the FIGURE 9 47 housing With the spool assembly in this flush position check for free rotation within the housing by turning with light finger force at the splined end 554 10019 S 46 Hold the parts in this flush position and rest the 14 hole end of the assembly on the protective block on the vise and clamp lightly across the port face with the vise NOTE It is good service policy to replace all seals when unit is reassembled They are available in kit form NOTE Do not force the spool into the housing if it will not slide In freely The assembly tolerance is so close that the temperature of your hand can expand metal of the spool enough that it will not slide in the housing l Check the condition of the o ring seal on the check plug and replace it if necessary Install the check plug in the check hole with a steady pressure while rocking it slightly so that the o ring feeds in smoothly without cutting see figures 9 47 and 9 48 m Position the cap locator bushing with large O D chamfer UP partly into end of housing sed figure 9 49 Insure that it seats against spool assembly flat and smooth by rotating with finger tips n Check
41. 123 1 20 50 END 2007 20 17 CAPSCREW 3 8 UNC X 5 GS 23 WASHER 1 2 nod 23 LOCKNUT 1 2 UNF 25 V BELT SET 1806 REF 7 25 169948 MANIFOLD PUMP INLET 25 169947 MAN 25 179805 25 12949 25 164368 25 18425 Lpe b 26 177455 OSE TO FILTER 26 HOSE TO FILTER 26 CONNECTOR 26 O RING ity 21 seses STUD BALL 2005 REF 9 HHH ge ELELO e 29 110177 NIPPLE FILTER END SSU Ee 2D04 STEERING SYSTEM REF HYSTER NAME OF PART REF HYSTER NAME OF PART NO PART NO 123 NO PART NO 123 4 31 181366 HOSE FROM STEERING PUMP 1 32 16561 EL BON 2 43 15306 PLUG 1 32 16588 LOCKNUT 1 43 175873 ELBOW 1 32 16486 O RING 1 44 169128 VALVE FLOW DIVIDER 11 1 33 18347 SCREW 1 4 UNC X 2 1 2 2 5 BODY be 1 33 15154 LOCKWASHER 1 4 2 46 161878 VALVE RELTEF 1 33 15054 NUT 1 4 UNC 2 47 191873 1 3 16989 EL BOW 1 48 161874 O RING be 1 35 89440 HOSE TO TEE 1 49 187436 SPRING He 1 36 16542 CONNECTOR 1 50 PISTON JE sd IP 1 36 16587 LOCKNUT 1 51 16165 ELBOW HOSE TO TEE EIE 1 36 16485 O RING 1 52 157532 HOSE 6 1 37 126121 HOSE TO STEERING CONTROL j 1 53 141908 ELBOW 45 DEGREE 1 38 15343 BUSHING 1 53 16487 O RING othe 1 39 17775 NIPPLE 1 54 16882 ELBOW DIE 1 39 16588 LOCKNUT 1 55 TEE SPECIAL SEE 2A05 39 16486 O RING 1 55 REF 32 40 127
42. 152235 152236 152237 152238 152239 152608 152609 152612 152621 152728 152780 153025 153069 153070 153685 154023 154026 154028 154029 154208 154221 154222 154382 154399 154402 154440 154473 154474 154475 154476 154494 PAGE REF NO PART 154560 154565 154193 154794 155056 155105 155164 155369 155370 155367 155431 155437 155443 155445 155452 155453 155455 155459 155460 155464 155467 155806 156133 156175 156180 156181 156182 156183 156184 156185 156186 156187 156192 156193 156194 156195 156196 156197 156200 156201 156204 156205 156206 156220 156223 156224 156242 156243 156245 156289 156605 156607 156610 156611 156625 156655 156656 156663 156670 156690 PAGE REF PART 156696 156776 156777 156940 156954 156958 156960 156961 157065 157116 157118 157119 157121 157302 157303 157305 157309 157312 157313 157314 157315 157318 157321 157322 157325 157335 157342 157343 157356 157360 157364 157532 157587 157588 157629 157630 157631 157705 157823 157873 157938 157942 157947 157954 158045 158114 158115 158116 158161 158162 158163 158164 158165 158186 158187 158193 158406 158439 158445 158447 PAGE 2406 2 03 2 03 2003 1008 1008 1008 1008 1 03 100 1808 1808 1806 1 06 1406 1406 1406 1406 1406 1 06 1406 1406
43. 185918 185919 186155 186227 186228 186259 186260 18630 186305 186420 187157 187238 187282 187436 188426 189248 189280 189281 189282 189283 189286 189287 189288 189303 189329 189330 189331 189332 189333 189334 189335 189585 189586 189609 189611 189612 189613 189614 189648 190001 190002 90003 190004 190047 190515 190516 190517 190519 190520 190573 190575 190576 190577 190578 REF NO PART NO 190580 190581 190582 190583 190584 190585 190586 190587 190588 190589 190590 190591 190592 190593 190594 190595 190596 190597 190598 190599 190600 190601 190602 190603 190604 190605 190606 190607 190611 190612 190613 190614 190615 190616 190617 190618 190619 190620 190621 190622 190623 190624 190625 190626 190627 190628 190629 190630 190633 190635 190636 190637 190638 190639 190640 190641 190642 190643 190644 190645 PART NO 190646 190647 190648 190649 190650 190651 190652 190653 190654 1906 5 190658 190725 190726 190731 190735 191140 191194 191341 191342 191345 191409 191412 191414 191416 191421 191756 191757 191782 191873 192205 192208 192319 192326 192327 192335 192427 193006 194190 194393 194394 194395 194396 194397 194398 194402 194846 194847 194851 194882 195033 195341 195342 195343 195344 195856 196154 196281
44. 6 22 YELLOW 14GA 2 18 1 2 8 B m 5 EA HYSTER NAME OF PART REF HYSTER NAME OF PART PART NO 123 QTY 0 PART ND 1234 QTY 159563 LIGHTING GROUP 1 10 182677 BULB 12 VOLT 1 139646 HEAD LIGHT 10 164301 LENS 1 156776 ELEMENT SEALED BEAM 1 10 164302 BASE 1 149519 RETAINER ELEMENT 1 11 159570 WIRE PANEL LIGHT GROUND 1 156777 SHELL 1 12 159569 WIRE SWITCH TO PANEL LIGHT 1 149513 BUSHING PI VOT 1 13 62886 SWITCH L IGHT 1 149514 WASHER 1 14 60416 A WIRE FUS ED 1 149516 NUT 1 15 21778 FUSE 20 1 42958 CONN ECTOR FEMALE 3 16 TIT SWITCH IGNIT ION AND START 1 03 159566 WIRE FRONT LTGHTS 1 16 REF 29 AND 1 05 REF 20 1 124359 CLAMP 1 17 SWITCH TOGGL Ey 1F03 REF 26 132131 CLAMP 1 17 1 05 REF 16 1 132131 CLAMP 4 18 107173 1 15913 LOCKWASHER 5 16 4 19 124359 CLAMP 1 15055 5 16 UNC 4 20 124359 CLAMP 1 159567 WIRE REAR LIGHTS 1 20 15913 LOCKWASHER 5 16 1 73510 CONNECTOR FEMALE 2 TO 1 WIRE 2 20 15055 5 16 UNC 1 159568 WIRE REAR LIGHT TO CONNECTOR 1 21 166197 WIRE LTGHT SWITCH TO CONNECTOR 1 159565 LIGHT PANEL 2 22 16637 WASHER O 562 2 125 30375 134938 158452 164141 173218 196431 243608 984326 G02 NUMERICAL INDEX 30968 134936 257 SSRIS 164194 ires 172885 cetero 5 196285 243606 an 984275 issues 1199287 G03 NUMERICAL INDEX
45. Be sure that a new HYSTER APPROVED filter and gasket are installed 4 16 x 2 ew SUNDSTRAND FIGURE 4 22 SERVICING THE HYDRAULIC SYSTEM 4 61 LUBRICATION THROTTLE AND TRANSMISSION LINKAGE see 4 62 Place a few drops of engine oil on the detent plate and crank arm connections every 100 hours of operation or at two week intervals 4 17 SECTION 4 HYSTER CARE MAINTENANCE 4 63 HYDRAULIC SYSTEM figure 4 22 NOTE The steering system and the hydrostatic transmission system share a common reservoir located under the right hand operators seat 4 64 FILLING THE TANK 4 65 Check the oil level when the hydraulic system is cold and with the steering cylinder fully extended The oil in the hydraulic tank should be visible through the sight gauge or slightly above gauge level when the oil is cold Add oil when no longer visible in the sight gauge until oil fills the sight gauge window CAUTION Do not completely fill the tank with oil Air space is designed into the tank for expansion at warm temperatures Pressurization will occur in the tank at operating temperature No attempt should be made to vent the hydraulic system 4 66 CHANGING THE HYDRAULIC OIL 4 67 After each 1 000 hours of operation or yearly whichever occurs first the hydraulic oil should be drained from the tank and replaced with new oil This removes dirt water and mechanical wear particles that have accumulated in the tank A
46. CAPSCREW 3 8 UNF X 5 8 WASHER 3 8 SWIVEL NUT 1 4 UNF LINK NUT 10 UNF CAPSCREW 3 8 UNC 3 1 2 NUT 3 8 UNC TNS CABLE je 1 CABLE EMERGENCY STOP of fe 1 CABLE THROTTLE of 1 CABLE CONTROL of fo 1 CLAMP 1 WASHER 1 4 1 SWIVEL f 1 SPRING 4 2 NUT 4 10 UNF E 1 SCREW 10 UNF X 1 1 BRACKET 1 SCREW 19 UNF X 1 2 1 NUT 10 1 PIN COTTER 1 BRACKET 1 ROO END SEE 2 10 REF 13 1 1E03 FUEL SYSTEM FOR 3 53 DIESEL ENGINE REF HYSTER NAME OF PART REF HYSTER NAME OF PART NO PART NO 1234 QTY NO PART NO 1 2 3 4 QTY 1 157704 1 13 15056 NUT 3 8 FILTER MOUNTING 2 1 67353 GASKET 1 13 15156 LOCKWASHER 3 8 FILTER MOUNTING 2 2 181771 TANK FUEL 1 13 15129 7 16 FILTER MOUNTING 2 3 15055 NUT 5 16 UNC 2 14 169122 BRACKET 1 3 15155 LOCKWASHER 5 16 2 15 16805 CAPSCREW 3 8 UNC X 1 65 2 3 18515 WASHER 5 16 2 15 16815 CAPSCREW 3 8 UNC X 1 1 2 65 1 4 164363 TIE CONSOLE 1 15 15156 LOCKWASHER 3 8 3 5 14271 ELBOW 1 16 FILTER SECONDARY COMES W ENGINE 1 6 169119 HOSE 1 17 156133 LOCKNUT 3 8 UNC 4 7 14358 ELBOW 45 DEGREE 3 18 169446 HOSE 1 7 160622 VALVE CHECK 1 19 119074 CLAMP 2 8 172833 HOSE 1 20 169118 HOSE 1 9 14273 ELBOW 1 21 16863 ELBOW 45 DEGREE 2 10 154494 TUBE 1 22 16192 VALVE SHUT OFF 1 11 169120 BRACKET 1 22 15360 ELBOW 1 12 16377 CAPSCREW 7 16 UNC X 1 G5 2 23 156606 GAUGE FUEL LEVEL 1 12 15157 LOCKWASHER 7 16 2 26 16101 CONNECTOR 1 1 1 13 FILTER P
47. CONTROL UNIT SECTION 9 STEERING 1 an engine mounted hydraulic power pump 2 the gooseneck mounted power steering control unit 3 double acting hydraulic steering cylinder 4 steering wheel 5 hydraulic fluid reservoir common with the transmission hydraulic reservoir 6 hydraulic lines and fittings 9 7 STEERING CONTROL UNIT 9 8 DESCRIPTION see figure 9 2 9 9 The steering control unit is an open center rotary actuated unit consisting of three major section 1 a column section 2 control section DETROIT ENGINE PUMP TO POWER STEERING CONTROL UNIT FIGURE 9 1 SECTION 9 STEERING METERING SECTION CONTROL CHECK VALVE CONVERTS SECTION UNIT TO HAND OPERATED PUMP FOR EMERGENCY POWER OFF STEERING COLUMN i 7 SPOOL AND SLEEVE ASSEMBLY INSTALLED SO THAT PINISIN _ LINE WITH VALLEY SLEEVE OF ROTOR CENTERING SPRINGS RETURN VALVE TO NEUTRAL SPRING SET FIGURE 9 2 9 2 3 a metering section The column section provides a means of mounting and actuating the control and metering sections The control section distributes the oil to and from the metering section The metering section determines the quantity of oil delivered to the control section 9 10 The column section consists of a splined shaft and housing assembly The unit steering wheel is splined to one end of the shaft The opposite end of the shaft is splined into the control sectio
48. Drain the mechanism by removing the drain plug with the communication hole at its extreme low After all the oil drains out rotate the hole to its high extreme Add 4 quarts 3 8 liters of diesel fuel Install the plug Rotate the drum one and one half revolutions so the plug ends up at its extreme low Remove the plug and allow all diesel fuel to drain prior to filling with fresh lubricant 4 94 STEERING 4 95 GUIDE ROLL AXLE BEARINGS sed figure 4 28 4 96 The guide roll bearings should be lubricated daily with multipurpose grease There are two grease fittings one on each end of the guide roll shaft Apply pressurized grease into the grease fittings until movement of the old grease around the seal is observed 4 97 TRUNNION ASSEMBLY see figure 4 29 4 98 The kingpin and oscillator shaft bearing should be repacked yearly NOTE Refer td Section 9 df the C350B SERVICE MANUAL part number 599661 for the detailed procedure for disassembling and assembling trunnion components a Remove the trunnion assembly from the main frame b Remove oscillator shaft assembly Clean inspect and re pack kingpin and oscillator shaft bearings d Install oscillator shaft bearings and new FIGURE 4 28 LUBRICATING GUIDE ROLL AXLE BEARINGS KINGPIN BEARINGS 227 FIGURE 4 29 TRUNNION ASSEMBLY SECTION 4 HYSTER CARE MAINTENANCE seals Torque bearing retainer nut to specifications listed in Gedion 2
49. HYSTER CARE MAINTENANCE SCHEDULE C350B 6 Qts 5 7 SAE 90 Multi purpose gear oil MIL L 2105B 24 TRANSMISSION RETURN SEE PARTS MANUAL 4 71 FILTER C25 25 ENGINE BLOWER SCREEN X 4 27 D 26 ENGINE CRANKCASE X 4 254 BREATHER D owe ee 28 STEERING CYLINDER X 4lb 11 kg Multi purpose Grease BALL JOINTS MIL 10924B X z Check A R As Required C Change C25 next to C indicates hours for first change D Detroit Diesel engine for complete instructions Refer to engine manufacturer s manual 4 4 should be used to locate the applicable maintenance procedure shows the location of all maintenance points 4 7 HYSTER CARE MAINTENANCE PROCEDURES SECTION 4 HYSTER CARE MAINTENANCE DELETED PAGE 4 6 SECTION 4 HYSTER CARE MAINTENANCE FIGURE 4 6 DETROIT DIESEL FUEL FILTER AND FUEL STRAINER 4 17 DETROIT DIESEL FUEL STRAINER AND FILTER sed figure 4 6 4 18 Drain approximately 1 4 pint of fuel from each filter bowl daily to remove dirt and water accumulations A drain cock is located in the bottom of each filter bowl for this purpose The filter elements in the strainer and filter must be replaced at the time interval specified in Table 4 1 Replace the elements as follows a With the engine shut down place a suitable container under the bowl of the strainer or filter and open the applicable dr
50. Identifier Code AOE CONUS A05 OCONUS 4 6 Routing Identifier Code Always S9C 7 Media Status Code 8 22 FSCM and Part Number Leave Blank Enter In Block 1 under Identification Data 23 24 Unit of Issue 25 29 Quantity 30 43 Document Number 44 Demand Code 45 50 Supplementary Address 51 Signal Code 52 53 Fund Code 54 56 Distribution Code CC 54 F for CONUS See AR 725 50 for OCONUS CC 55 56 Weapon Systems Code 57 59 Project Code 60 61 Priority Code 62 64 Required Delivery Date 65 66 Advice Code 67 80 Blank IDENTIFICATION DATA Lower half of DD Form 1348 6 complete Blocks 1 thru 9 34 APPENDIX L MAINTENANCE AND OPERATING SUPPLY LIST NOMENCLATURE Roller Motorized Steel Wheel 2 MAKE MODEL Drum Tandem 10 14 Ton CCE HYSTER C350 D MFR PART NO NSN 3845 00 578 0372 SERIAL NO RANGE DATE N A TO Feb 79 2 1 MFR PART NO 3 4 QTY REQ 6 COMPONENT OR QTY REQ APPLICATION NAT L STOCK NO DESCRIPTION F INITIAL NOTES OPN Fuel Tank 9140 00 286 5296 Diesel Fuel DF2 55 gal drum Engine Crank case 9150 00 189 6727 Oil Lubricating OE HDO 10 1 qt 9150 00 186 6668 MIL L 2104C 5 gal 9150 00 186 6681 Oil Lubricating OE HDO 30 1 qt 9150 00 188 9858 MIL L 2104C 5 gal Hydraulic Reservoir 9150 00 189 6727 Oil Lubricating O0 4DO 10 1 qt 9150 00 186 6668 MIL L 2104C 5 gal Final Drive 9150 01 035 5392 Oil Lubricating GO80W 90 1qt 9150 01 035 5393 MIL L 2105C 5 gal 9150 01 035 5394 55 gal 35 MAINT
51. MAIN PLATE a THROTTLE SHAFT UPPER CONTROL THROTTLE CABLE ENGINE FORWARD STOP STOP CABLE SCREW x MAIN REVERSS THROTTLE STOF CABLE SCREW fl DETROIT DIESEL HAND UNITS ONLY THROTTLE CABLE FIGURE 7 44 7 35 b Place Direction Throttle Bail in detonated neutral position c Adjust wire stop A at lower throttle crank for 1 16 in 1 59 mm gap between swivel and wire stop d Adjust position of upper throttle link B ball joint in slot of throttle actuator arm C so that full stroke of throttle is obtained when Direction Throttle Bail is stroked from stop to stop LENGTHEN upper throttle link B to reduce throttle stroke or SHORTEN link to increase throttle stroke NOTE Throttle stroke should be identical in forward and reverse Check for bent or binding linkage if a problem exists e Adjust friction nuts D so Direction Throttle Bail will stay in any position f Adjust the neutral safety switch adjustment bracket E so that the switch will just barely be activated when the Direction Throttle Bail is in neutral position 7 174 TRANSMISSION REPAIR 7 175 Should it become necessary to perform repairs to the Sundstrand transmission during the warranty period certain parts components or kits may be replaced without affecting or violating the warranty 7 176 The following parts components or kits may be replaced in the field as an assembly without
52. Pump Replace spring and ball Check seat Replace all springs 6 Refer to Section 9 Replace centering springs 6 Refer to Section 9 Remove burr with 600 grit abrasive paper on a flat surface Remove sharp edges from abrasive paper to prevent scratches Drain and flush complete hydraulic system Change suction and return filters Refill system with specified hydraulic fluid Refer to Section 4 Refer to troubleshooting Gear Pump SECTION 5 TROUBLESHOOTING TABLE 5 4 TROUBLE ANALYSIS FOR STEERING SYSTEM CONT TROUBLE PROBABLE CAUSE CORRECTIVE ACTION STEERING CONTROL UNIT Handpump Cont No Response Cont Hoses clogged Replace or flush hoses Wrong Response To Steering Wheel Hose incorrectly installed Refer to Section 9 for hose routing Metering star gea to slot in shaft Realign star gear and shaft Refer to misaligned Section 9 STEERING CYLINDER No Motion Of Hydraulic Cylinder No oil or insufficient oil being supplied to cylinder Check the hydraulic system for defective pump or pump drive vacuum or pressure leak in lines low oil level low relief setting at pump Repair defective unit Slow Cylinder Motion Insufficient oil being supplied to cylinder Check hydraulic system as described above Worn cylinder piston packing Replace packing Spongy Or Jerky Action
53. REF PART REF PART REF REF PAGE NO PAGE NO NO PAGE NO PAGE NO G04 NUMERICAL INDEX PART REF REF PART REF PART REF PART REF NO PAGE NO PAGE NO PAGE ND ND PAGE NO 30375 1COB 99599 119878 128846 1 09 T 34507 2806 99600 119963 128848 1 09 11 37065 2806 99601 121062 128851 1 09 1 37562 1CO2 99602 121384 128852 1 09 16 39347 2804 9960 122296 129444 2007 39671 2803 99609 122300 129445 2007 39673 2803 99610 122333 129446 2007 1 39759 2808 99611 122336 129447 2007 2 39767 2412 99612 122343 129563 2406 71 42958 2E03 99613 2 122345 129985 1F03 9 43740 1 09 99614 122346 130676 1 07 46 44301 2806 99615 122347 130845 1806 62 44322 2807 99623 122348 131119 1F0 amp 24 44326 2806 99631 123672 131172 1F08 59 44525 2005 39636 123615 131173 1 08 59 53123 1F03 99637 124215 131174 1 08 59 53124 1F08 99641 126216 131461 2003 28 54107 2807 99644 124217 132131 1206 47 54115 2 10 99646 124218 132546 2007 20 54761 2006 99647 124219 132547 2007 21 54860 2 03 99663 124239 132728 1 07 19 54861 2 03 99668 124297 132739 1003 34 4863 203 99109 124359 132818 1FO4 16 54864 2 03 99722 124588 132820 1F04 22 54865 2 03 99723 124751 132823 1F04 23 54871 2C03 99124 125509 132853 1F05 15 54872 2 03 99125 125519 132893 1804 54873 2 03 99727 125520 132972 1F03 8 55528 1F04 99728 125522 133469 1812 51 55580 1 09 99742 125830 133535 2007 18 55585 1 08 9975
54. RH 2 14 16691 CAPSCREW 5 16 UNF X 7 8 G5 1 14 18515 WASHER 5 16 2 39 184331 BRACKET MAT 1 14 15025 NUT 5 16 UNF 1 40 157309 BRACKET SCRAPER 1 15 18588 BOLT 1 2 UNC X 1 1 4 2 41 18497 CAPSCREW 5 16 UNC X 3 4 1 16 15158 LOCKWASHER 1 2 2 41 18515 WASHER 5 16 1 17 15058 NUT 1 2 UNC n 2 41 15114 NUT 5 16 UNC 1 18 16634 CAPSCREW 3 8 UNF X 1 G5 1 42 157314 HOOK 1 18 15006 NUT 3 8 UNF 1 43 157318 PLATE 1 19 157343 PLATE LOCK ING 1 44 142 PIN ROD END 1 20 169697 SPRING RH 1 45 15212 COTTER 3 32 X 3 4 1 20 169698 SPRING LH 1 46 157321 MAT 1 21 169699 SHAFT 1 LESLIE x 22 157315 PLATE SCR APP ER 1 1 89469 COTTER 16 Bs ae reseed 48 18590 CAPSCREW 1 2 UNC X 2 1 2 G5 2 23 16085 CAPSCREW 1 2 UNC X 1 374 G5 4 48 15158 LOCKWASHER 1 2 2 23 15158 LOCKWASHER 1 2 4 48 15058 NUT 1 2 UNC 2 23 15058 NUT 1 2 UNC 48 67326 SPACER 2 24 157335 BUMPER 1 49 18588 80LT 1 2 UNC X 1 172 6 25 184335 BRACKET LH 1 49 15158 LOCKMASHER 1 2 6 25 184337 8RACKET RH 1 49 15058 NUT 1 2 UNC 6 26 16830 CAPSCREW 1 2 UNC X 1 1 4 G5 4 50 157313 SHAFT 2 26 15135 WASHER 1 2 4 50 58933 SNAP RING 2 26 1515B LOCKWASHER 1 2 4 51 157312 SPRING 2 27 16825 CAPSCREW 5 16 UNF X 1 G5 1 53 169696 SPRING RH 1 27 18515 WASHER 5 16 2 53 169697 SPRING LH 1 27 15005 NUT 5 16 UNF 1 54 19936 ROLL PIN 5 16 X 3 3 4 1 28 157342 PLATE 1 29 16830 CAPSCREW 1 2 UNC X 1 1 4 G5 2 SoS inte 29 15158 LOCKWASHER 1 2 2 1A07 WATER SPRAY SYSTEM r T REF HY
55. Teeth Inner Planet Gears 47 Teeth Ring Gear 108 Teeth Outer Sun Gear Cage 29 Teeth Outer Planet Gears 47 Teeth GEAR BEARING BORE Inner Planet Gears 1 9800 1 9810 In 50 317 50 292 mm 2 5312 2 5322 In 64 292 64 318 mm Outer Planet Gears PLANETARY SHAFT O D Inner Planet Gears 0 9998 0 9993 In 25 395 25 382 mm 1 1868 1 1873 30 145 30 157 mm Ovter Planet Gears SECTION 2 SPECIFICATIONS TABLE 2 9 FINAL DRIVE AND DRUM ASSEMBLY SPECIFICATIONS CONT DESIGN DATA caste aa PLANETARY SYSTEM TORQUE Inner Planet Capscrews 15 ft Ibs 2 073 kg m Outer Planet Capscrews 15 ft Ibs 2 073 kg m Drum Hub Capscrews 120 ft Ibs 16 584 kg m Planet Anchor Flange 200 10 ft Ibs 27 64 Capscrews 1 38 kg m Anchor Flange to Outer Planetary Hub 12 Point Capscrews 120 ft Ibs 16 584 kg m MOTOR HOUSING TORQUE Housing to Frame Capscrews 88 ft Ibs 12 162 kg m Motor Mounting Capscrews 115 ft Ibs 15 893 kg m Bearing Carrier to Drum Capscrews 130 ft Ibs 17 966 kg m Bearing Carrier to Lock plate Capscrews 105 ft Ibs 14 511 kg m Bearing Carrier Shimming 0 002 In 0 0508 mm Preload to 0 003 In 0 0762 mm End Play TABLE 2 10 STEERING SYSTEM SPECIFICATIONS DESIGN DATA ENGLISH METRIC SYSTEM TYPE Hydrostatic HYDRAULIC TANK CAPACITY 9 Gallons dlso supplies 34 1 5 transmission OIL TYPE SAE 10W
56. Viscosity Index 90 Approved Oils Mobilfluid 423 Shell Tellus 29 Type Transmission Fluid conforming to Ford Motor Co specification No ESW M2C33F or E RELIEF PRESSURE Detroit Diesel 1500 50 PSI 105 5 3 5 kg cm SECTION 2 SPECIFICATIONS TABLE 2 10 STEERING SYSTEM SPECIFICATIONS CONT DESIGN DATA ENGLISH METRIC RELIEF VALVE SETTING 1500 PSI 105 5 kg cm HYDRAULIC PUMP Detroit Diesel Only Type Pump Output at 2400 Engine RPM and no Pressure Restriction External Gear 18 6 GPM NOTE Flow divider controls to 6 5 1 0 GPM 70 4 LPM NOTE Flow divider controls to 24 6 4 LPM ROTATION VIEWED FROM SHAFT END Counterclockwise PUMP DIMENSIONS Gear Diameter 2 1965 2 1970 55 791 55 804 mm Gear Width 1 1545 1 550 In 29 324 39 370 mm Gear Lash 0 006 0 010 In 0 152 0 254 mm Gear to Body 0 00175 In 0 043 mm Body Bore 2 199 2 200 In 55 855 55 880mm Bearing Diameter 2 1970 2 1975 In 55 804 55 8 17mm Bearing Bore 0 995 1 000 In 25 273 25 400 mm Bearing Width Bearing to Shaft Between Flats 1 9990 1 9993 In Total 0 0025 In 0 0002 0 0005 in 50 775 50 782 mm Total 0 0635 mm 0 0051 0 0127 mm FLOW DIVIDER Detroit Diesel Only Input Rating 30 GPM 114 LPM Contralled Flow 6 5 1 0 GPM 25 4 LPM Relief Setting 1500 50 PSI 105 5 3 5
57. With the swashplate tilted to either side of center one side will be forward vehicle motion with one main circuit line to the motor being high pressure and the other being return The opposite tilt of the swashplate reverses the vehicle direction and it also reverses the 7 28 SECTION 7 TRANSMISSION high pressure and return functions of the main circuit lines 7 126 When the transmission is in neutral the swashplate in the hydrostatic pump is also in neutral and the cylinder pistons are not stroking In this mode no oil is being pumped into the main circuit therefore the cylinder block assembly in the motor is stationary and the motor output shaft does not turn 7 127 CHARGE PUMP 7 128 A charge pump is a part of the hydrostatic pump assembly Whenever the engine is running oil is being drawn from the tank through the suction filter by the charge pump 7 129 CHECK VALVES 7 130 There are two 2 check valves in the hydrostatic pump assembly With the transmission in neutral both check valves will open allowing charge pressure to lubricate the system With the transmission out of neutral one of the valves will be closed and the other open The valve on the high pressure side of the main circuit will be held closed by high pressure The other valve will admit oil from the charge pump to the low pressure side of the cylinder block assembly to maintain adequate oil in the loop 7 131 SERVO CONTROL SYSTEM 7 132 Contr
58. a work time figure in the appropriate subcolumn s the lowest level of maintenance authorized to perform the function listed in Column 3 This figure represents the active time required to perform that maintenance function at the indicated category of maintenance If the number or complexity of the tasks within the listed maintenance function vary at different maintenance categories appropriate work time figures will be shown for each category The number of man hours specified by the work time figure represents the average time required to restore an item assembly subassembly component module end item or System to a serviceable condition under typical field operating conditions This time includes preparation time troubleshooting time and quality assurance quality control time in addition to the time required to perform the specific tasks identified for the maintenance functions authorized in the Maintenance Allocation Chart e Column 5 Tools and Equipment Column 5 specifies by code those common tool sets not individual tools and special tools test and support equipment required to perform the designated function f Column 6 Remarks Column 6 contains an alphabetic code which leads to the remark in Section IV Remarks which is pertinent to the item opposite the particular code 12 TM 11 5805 244 34P APPENDIX C Section Il MAINTENANCE ALLOCATION CHART ROLLER MOTORIZED STEEL WHEEL 2 DRUM TANDEM 10 14 TON CCE
59. affecting violating or voiding the transmission warranty Charge pump Check valves Motor manifold assembly High pressure relief valves Displacement control valve pump Pump or motor shaft seals 7 177 The proper procedures for replacement of the above components are presented in the following paragraphs NOTE Unauthorized repairs to transmission components other than those listed paragraph 7 176 may void the warranty Contact Hyster Company before attempting to perform repairs other than those presented in this manual CAUTION When working on all hydraulic equipment cleanliness is very important Before removing any of the transmission components clean the immediate area to 7 36 SECTION 7 TRANSMISSION prevent dirt from entering the transmission CAUTION Whenever a component of the hydrostatic system has been re moved the transmission start up procedure MUST be performed before the unit can be started operated or returned to service 7 178 HYDROSTATIC PUMP REMOVAL a Remove the suction line at the filter and plug or cap hose and fitting b Disconnect control linkage from servo control lever c Disconnect the hydraulic lines at the top of the pump d Disconnect the high pressure lines from the pump end housing Plug or cap all hoses and fittings WARNING Use a hoist and sling arrangement to support the weight of the pump e Remove the capscrews securing the pump
60. air dry new seal parts b Install the seal springs into the aluminum seal retainer Install the new o rings dry on stationary steel part of seal into retainer so notch is located in pin in retainers seg figure 7 65 c Install large o ring O D of retainer see figure 7 65 FIGURE 7 67 7 42 SECTION 7 TRANSMISSION d Install new o ring in 1 0 of bronze rotating part of seal see figure 7 66 e Wrap a piece of plastic around the drive shaft and slide the rotating bronze part over the shaft making sure It is sealed Do not press on seal surface see figure 7 67 f Install stationary seal and retainer into place and press the retainer in so the snap ring groove is open see figure 7 68 g Close the snap ring with pliers Install snap ring FIGURE 7 08 with tapered edge out h For ease of installation start snap ring in groove with the side opposite the snap ring holes see figure 7 69 TAPERED EDGE OUT 7 198 REMOVAL OF DRIVE DRUM a Complete the hydrostatic motor removal procedure presented in paragraph 7 179 Sundstrand Remove the figure 7 70 drive shaft from the center of the drum see b Support the frame on both sides at the rear of the unit Block the unit at the front and rear of the guide roll to prevent movement WARNING The brake assembly will be removed prior FIGURE 7 69 to drum removal Block the machine safety to prevent movement c Complete brake assembly remo
61. and lock ring then lift the horn button assembly from the steering wheel see figure 9 3 b Remove steering wheel jam nut and use a puller to remove steering wheel Then remove the two countersunk mounting capscrews from the gooseneck see figure 9 4 FIGURE 9 4 SECTION 9 STEERING c Remove gooseneck access plate see figure 9 5 d Disconnect the two hydraulic hoses and the water spray hose Plug or cap all hoses and fittings see figure 9 6 NOTE Mark the hydraulic hoses as to their position with respect to the steering cylinders e Disconnect the inlet hose from the pump and the return hose from the tank Plug or cap all hoses and fittings Remove the control unit and hoses from the gooseneck opening se figure 9 7 DISASSEMBLY OF STEERING CONTROL UNIT see figures 9 2 and 9 8 9 21 ACCESS P LATE FIGURE 9 5 FIGURE 9 6 SECTION 9 STEERING a Place the unit in vise control end up Clamp across port surface and opposite side of housing lightly Remove the two capscrews that fasten column to lower unit Remove column and set aside Mark the capscrew holes so that the ports will be in the proper direction when reassembled se figure 9 9 b Clamp unit in vise across mounting plate edges with meter end up and remove 7 capscrews see figure 9 10 C Lift off metering section see figures 9 11 9 12 and 9 13 d Remove control assembly from vise and check for free r
62. and must generally be rotated slightly as they are withdrawn seel figure 9 20 k Using a small bent tool or wire the check valve seal can be removed by pushing on it reaching it through the out port Do not pry against edge of hole in housing bore seg figure 9 21 1 Place housing in vise control end up and unscrew check valve seat with 3 16 inch hex wrench see figure 9 22 m Up end the housing and tap slightly with butt of hand Hold check valve hole toward lowest corner and remove check valve seat ball and spring see figure 9 23 SECTION 9 STEERING FIGURE 9 22 FIGURE 9 20 9 8 FIGURE 9 23 SECTION 9 STEERING FIGURE 9 24 FIGURE 9 27 FIGURE 9 25 FIGURE 9 28 FIGURE 9 26 FIGURE 9 29 n In spool assembly push the cross pin to loosen from spool sleeve assembl cross and set aside seg figure 9 25 o Push inside lower edge of spool so that spool moves towards splined end and remove carefully from sleeve see figures 9 26 and 9 27 p Push centering spring set out of spring slot in spool see figures 9 28 and 9 29 9 22 INSPECTION 9 23 Each part should be rinsed carefully in clean solvent even such exterior parts as all capscrews and all seals that appear to be reusable If in doubt replace with new seals It is good service policy to replace all seals when unit is reassembled They are available in kit form Rinsing and cleaning can be done while ot
63. at sight gauge on side of unit Replenish with approved oil listed in Section 4 Locate and repair leaks causing loss of oil Faulty control linkage to pump Check the linkage from control levers to pump arm to make sure it is connected and free to operate Refer to Section 7 for adjustment procedure Faulty control linkage inside pump Refer to Section 7 for pressure check procedure Refer to Section 7 for pressure check procedure Refer to Section 7 for replacement of charge pressure relief valve Low or zero charge pressure a Charge pressure relief valves in charge pump or motor manifold damaged or stuck open b Suction filter or hose from tank to charge pump clogged c Charge pump drive shaft sheared Internal damage to pump or motor Service filter flush suction line from tank to charge pump Refer to Section 3 Replace the charge pump Refer to Probable Cause Internal damage to pump and motor Refer to Section 4 for approved oil Cold or improper oil Refer to manufacturer s warranty policy 5 4 SECTION 5 TROUBLESHOOTING TABLE 5 2B TROUBLE ANALYSIS FOR SUNDSTRAND HYDROSTATIC TRANSMISSION CONT TROUBLE PROBABLE CAUSE CORRECTIVE ACTION Unit Will Not Operate Low and fluctuating charge pressure Refer to Section 7 for proper pressure In Either Direction check procedure Cont Check all fittings especially around fi
64. d FIGURE 7 100 of oil C350B only Reassemble the brake refer to seston doy 2121 figure 7 100 m Fill final drive with lubricant refer to Bection 4 n Install the hydrostatic pump and motor Replenish transmission lubricant supply refer to Section 4 p Follow transmission start up procedure before returning unit to service 7 204 INSTALLATION OF HYDROSTATIC MOTOR 7 205 Install the hydrostatic motor by reversing the procedure presented in paragraph 179 Note the following a The motor mounting surface should be coated with a plastic sealer b Torque the motor mounting bolts to 75 ft lbs 10 4 kg m c Torque the high pressure lines to 35 ft lbs 4 8 kg m Connect by pass valve linkage d After installation the transmission start up procedure must be completed before returning the unit to service 7 206 HYDROSTATIC PUMP INSTALLATION 7 207 Install the hydrostatic pump by reversing the procedures presented paragraph 7 178 Take note of the following a Torque pump mounting capscrews to 75 ft lbs 10 4 kg m b Torque high pressure line capscrews to 35 ft Ibs 4 8 kg m CAUTION Follow transmission start up procedure before returning unit to service 7 208 CLEANING THE HYDRAULIC SYSTEM CAUTION The importance of cleaning the entire hydraulic system after any component failure cannot be over emphasized If a failure occurs in either the hydrostatic dri
65. designed to help keep the drums clean when rolling asphalt To activate 3 21 the water spray system push the water spray switch to the ON position This will produce pressurized water spray on the Guide Roll and Drive Roll drums The pressurized supply to the Guide Roll drum can be turned off if conditions dictate by rotating the Front Spray Shut off lever The water spray switch should be in the OFF position when the water spray system is not needed CAUTION Do Not operate water system without water Damage to pump may result 3 23 UNIT SHUTDOWN sed figure 3 1 a Set the Direction Throttle bail to the neutral position b Setthe Park Brake Control Lever to the BRAKE ON position UP C position Set the IGNITION key to the off vertical d On units equipped with a diesel engine pull the ENGINE STOP out Hold in this position until the engine stops NOTE f the Detroit Diesel engine fails to stop pull out the EMERGENCY STOP lever Reset the control as specified in paragraph 3 28 Troubleshoot the system to determine the malfunction bed fore operating the unit again e Position the Vandalism Shield over the instrument panel If the unit is to be left unattended lock the shield 3 24 EMERGENCY ENGINE STOP Detroit Diesel Only sed figure 3 1 3 25 A manually operated EMERGENCY STOP Control is mounted on the instrument panel to shut down the Detroit Diesel engine in the event of a serious e
66. filters d Replace pump or motor with a new or overhauled pump or motor NOTE If either unit is considerably worn or damaged carefully check and clean the other unit pump or motor Refer to Section 7 for system start up procedures Check the linkage from control levers to pump arm to make sure it is con nected and free to operate Refer to Section 7 for adjustment procedures Unit Operates In One Faulty control linkage to pump Direction Only Refer to manufacturer s warranty policy 5 5 SECTION 5 TROUBLESHOOTING TABLE 5 2B TROUBLE ANALYSIS FOR SUNDSTRAND HYDROSTATIC TRANSMISSION CONT TROUBLE PROBABLE CAUSE CORRECTIVE ACTION Faulty high pressure relief valve Unit Operates In One Direction Only Cont Refer to Section 7 for pressure check procedures Charge check valve faulty Replace and check pressure Defective control valve Replace and check pressure Neutral Difficult Or impossible To Find Faulty controls or linkage to pump Refer to Section 7 for adjustment procedures Oil level low Check oil level at sight gauge on tank Replenish tank with approved oil listed in Section 4 System Operating Hot Oil cooler clogged Clean oil cooler air passages Oil cooler being bypassed Inspect cooler bypass valve Clean or replace Arrow on valve should point up in the line t
67. is started 7 212 SUNDSTRAND TRANSMISSION START UP PROCEDURE a Block the drive drum safely off the ground b After the transmission has been installed remove the threaded plug from the top of the main pump housing sed figs 7 103 Install a 600 PSI 42 19 kg cm2 pressure gauge with a short section of hose The port is 7 16 x 20 straight thread with o ring Low charge pressure may be checked at the motor case port as shown in figure 7 102 c Check all fittings to be sure that they are tight LOW CHARGE PRESSURE CHECK PORT FIGURE 7 102 7 52 SECTION 7 TRANSMISSION d Fill the pump and motor cases through the upper case drain openings with specified oil ETE All fluid should be passed through a 10 micron filter Reinstall and tighten case drain line e Loosen the charge pump line coming from the filter reservoir See figure 7 103 f Fill the reservoir and hoses with specified oil see Section 2 Install and tighten the hoses see figure 7 103 WARNING Disconnect the push pull cable from the pump until after Initial start up This will allow the pump to remain in neutral see figure 7 104 g Pull out the engine coil wire or close the 45 FIGURE 7 103 FIGURE 7 104 injector rack and turn the engine over until charge pressure reaches 30 PSI 2 1 kg cm2 or more h Start the engine and maintain a 750 RPM speed for five 5 minutes This will allow the system to fil
68. oM 15 2 B REF HYSTER NAME OF PART REF HYSTER NAME OF PART NO PART NO 123 QTY NO PART NO 123 4 QTY 1 CONTROL STEERING 1 14 124359 CLAMP 2 1 COLUMN STEER ING 1 15 SWITCH IGNITION SEE 1 03 REF 29 2 BRUSH HORN 1 15 AND 1 05 REF 20 1 3 WASHER CON TACT SEE 200 1 16 121062 WIRE 1 4 eases SPRING CON 1 17 53124 FUSE 10 AMP 1 5 INSULATOR CONTACT 18 15004 NUT 1 4 UNF 2 5 REF 32 1 18 15912 LOCKWASHER 1 4 2 6 163910 KIT HORN BUTTON 1 19 103739 REL AY CHORN 1 6 166169 COVER WEATHER 1 20 132131 CLAMP T T 166174 SCREW 3 21 15055 NUT 6 B 166171 CUP CONTACT 1 21 15913 LOCKWASHER 5 16 6 9 166173 CAP CONTACT 1 22 164767 WIRE 1 10 166172 SPRING 1 23 126364 HORN 1 11 166175 PLATE BASE 1 24 16836 CAPSCREW 5 16 UNC X 3 4 G5 1 12 166170 BUTTON HORN 1 25 164758 CLIP 1 13 164766 WIRE l KEY 1F09 ALTERNATOR C FOR 3 53 DIESEL ENGINE ee NAME OF PART QTY REF NO HYSTER PART NO 12883 128836 128838 138559 128848 128851 128842 128852 138554 128831 138553 202004 235950 16713 128842 128841 128834 128835 55580 128840 152234 15223 15479 138955 196047 2237 52238 154794 152239 126358 164083 1 2 3 RETAINER BEARING DIODE NEGATIVE BLACK BEARING S R E SPRING CAPACITOR HEAT SINK TERMINAL PACKAGE DIODE POSITI VE NUT LOCKWASHER HOLDER AND BRUSH SPRING BRUSH GASKET
69. pressing out the outer planetary assembly to prevent damage to the drum hub n Disassembly of drive drum hub Remove the oil seal for replacement Check that companion flange seal surface is smooth seg figure 8 10 FIGURE 8 11 0 Pry out the snap ring with a large screwdriver or medium size pry bar Replace if worn or scored see figure 8 11 p Turn the drum hub over and place it in an arbor press Using an appropriate size pusher press out the large bearing sed figure 8 12 q Place the inner planetary assembly on a protected surface with the interlocked sun gear down r Clean the webbed portion of each of the three planetary pinion gear and mark their position with respect to the planetary carrier see figure 8 13 FIGURE 8 13 8 5 SECTION 8 FINAL DRIVE NOTE Since the planetary pinions are extremely hard a punch is not effective To mark these planetary pinions paint a small portion of each gear with a light color paint and etch either 1 2 or 3 on each gear NOTE The planetary carrier can be marked corre spondingly with a punch s With the planetary pinion gears and carrier properly marked unlock and remove one pinion gear capscrew lockplate and spacer see figure 8 14 t Push the pinion gear riding pin out of the FIGURE 8 14 FIGURE 8 15 carrier and gear Lift out planetary pinion gear thrust washers and bearings seg figure 8 15 CAUTION The bearing cones will f
70. removed FIGURE 4 23 WATER FILTER 4 78 MANIFOLD AND NOZZLES see figure 4 24 4 79 The nozzles are mounted so they receive water from the center of the manifold tube where corrosion and sediment are minimized This eliminates most of the nozzle plugging problems Periodically the end caps on the water spray manifold should be removed and the sediment blown from the manifold 4 80 STORAGE 4 81 Drain the entire water spray system to WATER MANIFOLD NOZZLE ASSEMBLY SEDIMENT 1583 FIGURE 4 24 CLEANING MANIFOLD AND yoy NOZZLES takes E 2 DRAIN COCK SUCTION SHUT OFF VALVE FIGURE 4 25 PUMP DRAIN COCKS 4 19 SECTION 4 HYSTER CARE MAINTENANCE prevent freezing of water and the resulting damage to components A drain hole is provided in the tank bottom left corner to drain the tank Be sure to open the pump drain cock sed figure 4 25 The suction shutoff valve should be open when draining the pump so all the water from the suction side is removed Water in the pressure side of the system should be blown out with compressed air 4 82 PARKING BRAKE seelfigure 4 26 4 83 LUBRICATION 4 84 The parking brake lever assembly should be lubed after each 100 hours of operation or every two weeks This will prevent the adjusting threads from rusting 4 85 ADJUSTING 4 86 The parking brake lever should be adjusted sufficiently to require at least 80 pounds 36 3 kg t
71. see figure 9 105 e Install outer bearing grease seal and outer solid spacer into each drum seg figure 9 106 f Install split spacers thrust washers and slotted nuts seg figure 9 107 g Working at each end separately torque slotted nut to 200 ft Ibs 27 7 kg m back off to 25 ft Ibs 3 5 kg m then retorque to 45 ft Ibs 6 3 kg m or next higher slot Install cotter pin see figure 9 108 NOTE Ensure that the drums are on a flat level surface Placing one drum on a pallet and the other drum supported with a lift truck or hand dolly will allow the drums to easily assemble together h Check to see If clearance between guide rolls is within specifications If correct clearance does not exist remove one drum and adjust shim pack between center spacer and bearing to maintain 010 030 25 76 mm clearance se figure 9 109 9 33 SECTION 9 STEERING INNER BEARING CUP FIGURE 9 102 FIGURE 9 105 i ac co MAGN E 53 CAUTION RUBBER LIP MUST CAUTION RUBBER LIP MUST FACE FACE AWAY FROM BEARING x AWAY FROM BEARING OUTER SOLID OUTER SPACER BEARING FIGURE 9 106 FIGURE 9 103 FIGURE 9 107 FIGURE 9 104 9 34 SECTION 9 STEERING 9 96 INSTALLATION OF GUIDE ROLLS AND STEERING AXLE ASSEMBLY a Lift axle shaft assembly so it parallels the position of the steering yoke see figure 9 110 b Lift the gooseneck up until the steeri
72. the engine s e figure 4 16 When using anti freeze drain the system and add an anti freeze of ethylene glycol base Preston Permaguard Zerex etc Test the anti freeze solution to determine the freezing point Record this information on a tag and attach it to the radiator overflow pipe 4 115 ENGINE CYLINDERS 4 116 Over a long period of storage the cylinder walls may rust due to moisture condensation within the cylinder To prevent rusting of cylinder walls the or fuel injectors should be removed and a small amount of engine oil squirted into each cylinder Turn the engine over several times with the starter to spread the oil on the entire cylinder wall Replace the or fuel injectors Repeat this procedure prior to starting after storage 4 117 BATTERY 4 118 A fully charged battery will maintain itself for a long period of time if kept cool and disconnected The electrolyte in the battery should be checked periodically to insure a proper level If it is low add clean drinking water until proper level is obtained Check the electrolyte specific gravity periodically and recharge the battery as necessary This is especially important if freezing temperatures are expected Clean and dry the battery especially the terminals Coat the terminals with HYSTER APPROVED battery terminal coating to prevent corrosion Support Ballast Securely Before Removing Capscrews Weight 1500 to 5500 pounds FIGURE 4 31 2 5 1
73. unit Hydraulic oil temperature 100 F LUBE ADJUSTING THREADS FITTING i FIGURE 10 8 10 4 SECTION 10 BRAKES c Adjust brake handlever to 40 Ib 18 2 kg pull d 1 Using full throttle gradually pull brake handlever on until transmission is almost to stall and hold for 5 seconds 2 Release brake for 60 seconds and then repeat steps 1 and 2 20 times e Adjust brake handlever to 80 lbs 36 3 kg minimum pull 11 1 GENERAL 11 2 This section contains the water spray system description checks adjustment and service repair information Refer to Section 2 Water Spray System Specifications Hyster Care Maintenance Instructions are contained in Section 4 and a troubleshooting guide is presented in Section 5 11 3 DESCRIPTION 11 1 11 4 The Water Spray System consists of a water tank Inlet screen sump filter water pump and motor spray manifolds bars associated lines and fittings electrical switch and a circuit breaker Refer to Section 6 for electrical schematic The water pump is centrifugal type pump The pump is mounted in a cavity recessed into the bottom of the water tank and accessible from under right hand side of unit 11 5 The Water Spray System is activated when the operator turns the water spray switch to the ON position SUMP FILTER GUIDE ROLE MAI FG LO PEPE FRONT SPRAY SHUT OFF FILTER SUCTION SHUT OFF SECTION 11
74. unit as shown When checking water spray motor brushes be sure ignition key switch and water spray switch are in the OFF position before inspecting brushes Support heavy components securely BEFORE attempting to remove them Always block the unit securely to prevent movement while performing maintenance or repairs THIS MANUAL CONTAINS COPYRIGHTED MATERIAL AND IS PUBLISHED WITH PERMISSION OF HYSTER COMPANY AND DETROIT DIESEL ALLISON DIVISION OF GENERAL MOTORS CORPORATION TM 5 3895 348 14 amp P 1 TECHNICAL MANUAL HEADQUARTERS DEPARTMENT OF THE ARMY NO 5 3895 348 14 amp P 1 WASHINGTON DC 27 March 1981 OPERATOR S ORGANIZATIONAL DIRECT SUPPORT GENERAL SUPPORT AND DEPOT MAINTENANCE MANUAL INCLUDING REPAIR PARTS INFORMATION AND SUPPLEMENTAL OPERATING MAINTENANCE AND REPAIR PARTS INSTRUCTIONS ROLLER MOTORIZED STEEL WHEEL 2 DRUM Tandem 10 14 TON CCE HYSTER MODEL C350B D NSN 3895 00 578 0372 CONTRACT NO DSA700 74 C 9024 REPORTING OF ERRORS You can help improve this manual If you find any mistake or if you know of a way to improve the procedures please let us know Mail your letter or DA Form 2028 Recommended Changes to Publications and Blank Forms direct to Commander US Army Tank Automotive Materiel Readiness Command ATTN DRSTA MBS Warren MI 48090 A reply will be furnished to you Page VOLUME 1 Service Manual Supplemental Operating Maintenance and Repair Parts Instructions and Parts Manual SERVICE M
75. 0 RPM THERMOSTAT SETTING DESIGN DATA ENGLISH METRIC 4 5 In 11 4 cm 159 3 Cubic Inches 2610 cc 202 ft Ibs at 1500 RPM 27 9 kg m at 1500 RPM 80 at 2200 RPM N 45 17 to 1 550 RPM 3040 RPM 1 3 2 0 025 In Cold 0 023 In Hot 0 635 mm 0 584 mm 30 PSI 2 1 kg cm 165 1859 F 74 859 C NOTE For additional engine specifications refer to engine manufacturer s service literature TABLE 2 7 WATER SPRAY SYSTEM SPECIFICATIONS TANK CAPACITY PUMP TYPE OPERATING PRESSURE NOZZLE FLOW TOTAL NOZZLE ORIFICE DESIGN DATA ENGLISH METRIC 200 Gallons 757 Liters Centrifugal 0 5 0 7 kg cm at 800 RPM Non adjustable 7 10 PSI at 800 RPM Non adjustable Approx 0 25 GPM 0 95 LPM 0 040 In 1 016 mm 2 6 DELETED PAGE 2 7 SECTION 2 SPECIFICATIONS TABLE 2 8B SUNDSTRAND HYDROSTATIC TRANSMISSION SPECIFICATIONS DESIGN DATA ENGLISH METRIC HYDRAULIC TANK CAPACITY 9 Gallons also supplies steering 34 Itrs OIL TYPE SAE 10W Viscosity Index 90 Approved Oils Mobilfluid 423 Shell Tellus 29 Type F Transmission Fluid conforming to Ford Motor Co specification No ESW M2C33F or E OIL FILTERS Suction 10 Micron Return 33 Micron Oil Cooler By pass Valve Opens 15 PSI Opens ot 1 kg cm2 SECTION 2 SPECIFICATIONS TABLE 2 8B SUNDSTRAND HYDROSTATIC TRANSMISSION SPECIFICATIONS SYSTEM PRESSURES At 100 15090i Temp and
76. 0 SEAL OIL 191757 PUMP STEER ING 1 19 169009 SNAP RING 1 192327 COVER l 1 20 97887 BEARING 2 147990 VAL VE CONTROL l 1 21 97846 SHAFT 3 192326 PLUG 1 1 22 236018 KEY 4 176037 O RING 1 1 23 97850 SNAP RING 5 236024 SPRING 1 1 24 982161 GASKET STEERING PUMP TO 6 236026 PIN 1 1 24 DRIVE ADAPTER 7 133820 CAPSCREW 4 4 25 168889 ADAPTER STEERING PUMP 8 119963 GASKET 111 26 983271 STUD ADAPTER TO TIMING GEAR 9 96952 SPRING 1 26 HOUSING 9 155056 SPRING 1 26 15005 NUT 5 16 UNF 10 133816 PLATE PRESSURE lj 1 26 15155 WASHER SPRING 5 16 11 54T6T PIN 2 2T 168890 GASKET ADAPTER TO TIMING 11 236011 PIN 2 27 I GEAR HOUSING 12 159064 KIT CARTRTOGE 11 28 HOUSING TIMING GEAR 1 03 12 133817 X IT CARTRIDGE 1 28 REF 30 12 192319 RING l 29 COVER TIMING GEAR HOUSING 12 164525 RING eof 1 29 1603 REF 2 13 147528 ROTOR lise 30 168887 GEAR STEERING PUMP 13 164526 ROTOR 1 31 983331 NUT STEERING PUMP RETAINING 14 157527 KJT VANE 10 VANES 1 31 992633 WASHER 14 236012 KTT VANE 1 32 GEAR IDLER 1 03 REF 26 15 176038 NARING l 1 16 176039 f RING 1 1 INCLUDEO IN SEAL KIT 133821 17 wanes BODY 111 REF HYSTER NAME OF PART NAME OF PART NO PART NO 1234 QTY NO PART NO 123 QTY 16 162072 SEAL WIPER 1 1 390663 STEERING CYLINDER 1 17 390124 SOCKET 1 2 162065 PISTON 1 17 157823 SOCKET BALL 1 3 162066 BEARTNG 1 18 133535 PLUG ADJUSTMENT 1 162067 BARREL 1 20 132556 SPRING 1 o 21 13
77. 045 CLAMP 56 PUMP STEERING 2007 41 169130 HOSE TO TEE 1 REF HYSTER NAME OF PART REF HYSTER NAME OF PART NO PART NO 1236 QTY NO PART 0 1234 QTY 163616 CONTROL STEERING 1 21 n 189586 BALL STEEL 1 8 1 241103 CONTROL 1 22 158843 1 1 158826 CAPSCREW 7 23 158844 PLUG SEAL 1 2 158827 CAP END 1 24 158845 _ O RING 1 3 158828 GEAR SET 2 25 165316 COLUMN ST EER ING 1 4 158829 SPL INE 1 25 165317 TUBE AND FLANGE 1 5 158830 SPACER 1 26 165318 SHAFT 1 6 138907 SPACER 1 21 159764 SNAP RING 2 7 158831 PLATE 1 28 159703 BEARING _ 1 8 158832 DRIVE 1 29 138145 RING RETAINING 2 1 9 138145 CAP SCREW 4 30 159812 CAPSCREW 3 8 UNC X 3 4 2 10 158833 CAP HOUSING 1 31 165201 TERMINAL ANO WIRE 1 11 15883 amp SEAL OIL 1 32 194851 INSULATOR CONTACT 1 12 158835 SEAL QUAD RING 1 33 165203 SPRING CONT 1 13 158836 RUSHING CAP LOCATER 1 34 165204 WASHER CONT ACT 1 13 198028 RACE BEARING 2 35 194847 RING CONTACT x 1 13 198029 LOCATOR BEAR ING 1 36 194846 INSULATGR CONTACT RING 1 13 209627 NEEDLE BEARING THRUST 1 37 241102 KIT HORN BRUSH 1 14 158837 O RING 1 38 16606 SCREW 2 15 0 sesse HOUSING VAL VE 1 39 155314 TERMINAL WIRE 1 16 aies SLEEVE AND SPOOL 1 40 165313 CONNECTOR 1 17 158839 P IN CENTER ING 1 41 161865 MUT 13 16 NEF 1 18 158846 015 2 19 n 158840 SPRING CENTERING 6 INCLUOED IN SEAL KIT 158847 20 n 158841 SPRING 1 nINCLUDED IN CONTROL PARTS KIT 1895
78. 1 2 3 4 GROUP COMPONENT MAINTENANCE MAINTENANCE Category NUMBER ASSEMBLY FUNCTION ENGINE Engine Assembly Test Service Replace Repair Overhaul Engine Mounts Replace Cylinder Block Test Replace Repair Cylinder Sleeve Replace Cylinder Head Replace Repair Overhaul Crankshaft Replace Main Bearings Replace Drive Pulley Replace Flywheel Replace Pistons amp Connecting Rods Replace Repair Rings amp Bearings Replace The subcolumns are as follows C operator crew F direct support D depot O organizational H general support 13 Section Il MAINTENANCE ALLOCATION CHART ROLLER MOTORIZED STEEL WHEEL 2 DRUM TANDEM 10 14 TON CCE 1 2 3 4 6 GROUP COMPONENT MAINTENANCE MAINTENANCE Category NUMBER ASSEMBLY FUNCTION REMARKS Rocker Arms Replace Valve Springs Test Replace Valves Exhaust Adjust Replace Repair Camshaft Bearings amp Gears Replace Oil Cooler Service Replace Oil Pan Replace Repair Oil Pump Oil Pressure Regulator Adjust Replace Oil Filter Assembly Service Replace Oil Filter Element Replace Exhaust Manifold Replace Repair The subcolumns are as follows C operator crew F direct support D depot O organizational H general support 14 Section Il MAINTENANCE ALLOCATION CHART ROLLER MOTORIZED STEEL WHEEL 2 DRUM TANDEM 10 14 TON CCE 1 2 3 4 6 GROUP COMPONENT MAINTENANCE MAINTENANCE Category NUMBER A
79. 1 2 turn at a time until the motor housing is piloted into and bottomed against the frame sed figure 7 92 FIGURE 7 92 NOTE The frame motor housing capscrews will turn hard as the drum is being pulled into position by these cap screws Torque the capscrews per specification Install the drive shaft d Install snap ring on brake shaft C350B only see figure 7 93 e Turn the drive shaft from the motor housing end until the oil holes in the outer planetary hub are horizontal with the floor and above center C350B only seg figure 7 94 f Install scraper bar and bumper assembly if removed during disassembly FIGURE 7 93 NOTE BRAKE mm SHAFT NOT fff SHOWN 50 HOLES ARE VISABLE A OIL HOLES SECTION 7 TRANSMISSION g Install two alignment bolts and spline the planetary anchor flange on to the outer planetary hub C350B only see figure 7 95 Install two capscrews in two remaining holes and torque to 120 ft lbs C350B only 16 6 kg m NOTE The alignment mark on the anchor flange should be aligned to the alignment mark on the planetary hub C350B only h Insert three equally spaced capscrews Torque these capscrews to 15 ft lbs 2 074 kg m and then remove them see figure 7 96 FIGURE 7 96 i Measure the distance between the frame and the planetary anchor flange Take this measurement in three equally spaced locations The best method of measurement is t
80. 1159 161160 161161 161195 161200 161201 161244 161245 161246 161252 161291 161292 161296 161297 161381 161382 161383 161385 161388 161389 161390 161395 161396 161397 161398 161399 161500 161501 161502 161403 161404 PAGE NUMERICAL INDEX REF NO G06 PART 161405 161406 161407 161409 161411 161412 161416 161418 161419 161422 161423 161424 161425 161429 161430 161431 161440 161446 161448 161449 161451 161452 161453 161454 161455 161456 161457 161459 161460 161461 161462 161463 161489 161491 161492 161493 161494 161495 161496 161500 161501 161502 161503 161504 161505 161506 161509 161513 161514 161515 161517 161518 161519 161520 161522 161524 161527 161529 161530 PAGE REF NO PART NO 161531 161532 161533 161535 161536 161537 161539 161540 161543 161544 161545 161546 161548 161550 161551 161552 161553 161598 161606 161607 161613 161648 161665 161666 161670 161671 161675 161678 161680 161682 161683 161865 161874 161878 162065 162066 162067 162068 162069 162070 162072 162073 162074 162075 162076 162278 162532 162533 162534 162535 162536 162537 162538 162539 162540 162541 162542 162543 162544 162545 PAGE REF NO m m ONO 26000 PART NO 162688 162726 162728 162730 162731 162732 162766
81. 13 amp 2B03 HYDRAULIC SYSTEM 2A06 LIGHTING eem 2E03 OL Res L a a m l a u i 2802 DECALS AND PAINTING INSTRUCTIONS 1A08 iia 1704 SCRAPERS AND 5 1A06 SERVO CONTROL VALVE 2B01 ELECTRICAL SYSTEM 4 236 AND 3 53 DIESEL 1F05 STEERING ee 2D04 STEERING CYLINDER 2D07 ENGINE NOUNTS 3 53 DIESEL 1C07 STEERING PUMP 3 53 DIESEL 2D07 STEERING SYSTEM 2D03 STEERING TRUNNION AND DRUMS 2D05 EXHAUST SYSTEM 3 53 DIESEL 1C08 FINAL 4 4 2B05 FRAME AND 2 1A05 THROTTLE LINKAGE eene 1D07 WATER SPRAY SYSTEM 1407 A03 UNIT IDENTIFICATION UNIT SERIAL NO 9 2 4 5 1 amp 2 The first letter and number denote the design series and model of the unit 3 The second letter denotes the plant at which the unit was manufactured 4 The number series denotes the serial number of the unit 5 The final letter denotes the year of manufacture starting with A in 1957 The letters I O and Q will not be used Parts Referred To
82. 1500 2000 RPM engine speed Charge Pump Pressure Transmission in Neutral Transmission in Forward or Reverse Main Pump Pressure Control Pressure Trans mission in Forward or Reverse Case Pressure Suction Oil HYDRAULIC PUMP Type Swashplate Angle Maximum Displacement Maximum Pressure Rating Maximum Case Pressure Minimum Main Port Pressure Maximum Allowable Case Temperature Maximum Shaft Speed At No Load At 4700 PSI 330 5 kg cm2 Charge Check Flow Rating Charge Pump Displacement Port Sizes Main Line Inlet Outlet Ports 2 Case Ports Inlet and Outlet Charge Pump Inlet Control Lever Movement DESIGN DATA ENGLISH METRIC 190 220 PSI Controlled by Relief Package in Charge Pump 150 180 PSI Controlled by Relief Package in Hydraulic Motor 5500 200 PSI 45 PSI approximately 40 PSI Max Normally 10 PSI 10 In HG Maximum Variable Displacement Axial Piston 18 Max Either Side of Center 4 2 Cubic Inches per Revolution at 189 Swashplate Angle 5500 PSI 40 PSI 130 PSI Above Case Pressure 1809 F 3000 RPM 2810 RPM 10 GPM 0 75 Cubic Inch Per Revolution 9 GPM Max at High Idle 3 8 16 Thread Four Bolt Split flange Boss 7 8 14 UNF 2B O ring Boss 7 8 14 UNF 2B O ring Boss 26 Either Direction from Center Above case pressure 2 9 13 4 15 5 kg cm Controlled by Relief Package in Charge Pump E 10 5 12 7 kg cm2 Controlled by Relief Package in d
83. 169787 156954 190641 267025 194393 5126447 157321 156961 79792 APPENDIX G ADDITIONAL REPAIR PARTS 30076 30076 28 Description Hose Radiator Upper Hose Radiator Lower Element Engine Oil Filter Element Primary Fuel Filter Element Secondary Fuel Filter Sender Oil Pressure Sender Water Temperature Breaker Circuit Fuse 5 Ampere V Belt Alternator Element Hyd Oil Filter Seal Element Kit Hyd Oil Filter Seal Kit Steering Control Parts Kit Steering Control Seal Kit Steering Cyl Kit Minor Steering Pump Element Light Seal Beam Bulb 12 Volt Fuse 20 Ampere Fuse 10 Ampere O Ring Hose Flange Element Air Cleaner Seal Kit Manifold Valve Kit Hyd Sys Manifold Seal Kit Hyd Sys Belt V Matched Fan Cocoa Mat O Ring Air Cleaner Battery 12 Volt APPENDIX H SAMPLE FORMAT DA FORM 2765 PART NUMBER REQUEST CONUS Requester DATA eC Weapons Sys Dsg Code Eurum sorer unu W SERES E Ime s USE TYPEWRITER OR SAL POINT PRESS HARD ASSURE LEOIBILITY ON ALL COMES Code 58 Tite wOLLIGS SHANA IT JE it Use National Stock Number NSN mum s 4 72001013135 5 RR TM 5 3895 348 14 amp P 1 Page 2A08 s OS 14 09 oori Tr OCONUS Requester m
84. 2 181329 GASKET 1D09 THROTTLE LINKAGE FIRST USED ON SERIAL NO 889C 3401 AND A146C 1700 1D10 THROTTLE LINKAGE FIRST USED ON SERIAL NO 889C 3401 AND A146C 1700 KEY leo PER ae 996 8 FES GN PF OR G8S ENG He C FOR 3 53 DIESEL ENGINE n TG G S we REF HYSTER NAME OF PART NO PART NO 123 4 1 391649 LEVER 2 391569 SHAFT 3 391729 SUPPORT L 4 16598 CAPSCREW 3 B UNC X 7 8 4 15156 WASHER 3 8 5 16215 CAPSCREW 3 8 UNC X 1 5 15086 NUT 3 8 UNC 6 16816 CAPSCREW 3 8 UNC X 1 3 4 6 15156 WASHER 3 8 6 15056 NUT 3 8 UNC 7 157938 BUSHING FL 8 157587 DISK 8 19880 PIN 9 157588 PLATE 10 157942 STUD SPECTAL 10 177964 SPRING 10 15127 WASHER 1 4 10 15004 NUT 1 4 UNF 11 15004 NUT 1 4 UNF 11 15312 WASHER 1 4 12 161607 JOINT BALt 12 15127 WASHER 1 4 13 15024 NUT 1 4 UNF 14 157954 LINK 15 213892 BEARING 15 15134 WASHER 3 8 15 15212 COTTER 16 213894 CRANK 17 15026 NUT 3 8 UNF 17 15156 WASHER 3 8 18 161606 SWIVEL 18 16752 SCREW 410 UNF X 3 8 18 15127 WASHER 1 4 18 15200 COTTER REF HYSTER PART NO 161606 15200 164400 213255 153070 15512 15158 16651 161252 15923 1500 145641 169140 213266 213257 124359 15127 169135 154560 15002 16701 169134 16708 15002 15200 169136 IPIE NAME OF PART 1234 C 5 re A CR am CABLE THROTTLE PLATE
85. 21 175347 175825 175873 176037 176038 176039 176040 176451 176452 176454 176510 176511 176535 176538 176892 176893 177308 177407 177455 177456 177457 177458 177459 177543 177561 177562 177563 177565 177567 177568 177569 177574 177575 177576 177588 177894 177947 177964 177989 177991 178144 178149 178215 179641 179644 179645 179646 179647 179648 179667 179805 PAGE 1 017 1203 1812 1811 1813 1 01 1 01 101 1 03 1003 1013 200 2006 2006 2006 2006 2406 2003 1804 1814 1D12 1813 1 01 1 07 1 07 1003 1011 2003 2003 2406 2003 2004 1806 1804 1804 1808 180 1806 1 0 180 1 0 1004 1504 1 02 1F03 1812 1008 1405 LAOS 2806 2805 1 01 2808 2808 2808 2808 2808 2808 2808 2003 REF NO 19 22 13 51 26 29 180257 180313 180397 160441 180442 180444 180595 181077 181329 181366 181763 181770 181771 181774 181859 181898 182287 182288 182289 182290 182291 182292 182293 182483 182645 2182677 182943 183057 183067 183075 183076 183421 183428 183543 183547 183569 183570 183571 183572 183575 183586 184055 184313 184317 184320 184321 184322 184324 184325 184327 184331 184335 184337 184814 184818 184819 184820 184824 184825 184837 PAGE NUMERICAL INDEX REF NO G08 PART 184841 184842 185699 185902 185903 185917
86. 2547 SEAT SPRTNG 1 5 b 223640 ROD PISTON 1 22 14122 A CLAMP 1 6 162069 LOCKNUT 1 23 15517 1 2 UNF X 2 1 2 1 7 162070 NUT BEARTNG 1 23 15158 LOCKWASHER 1 2 1 8 162073 RING WEAR 1 23 15008 NUT 1 2 UNF 1 9 162076 RING PISTON 1 24 15483 PLUG 2 10 162074 O RING 1 25 15284 COTTER 1 4 X 3 172 2 11 57664 O RING 1 12 162075 RING BACK UP 1 INCLUDED IN SEAL KIT 223681 13 165615 RING LOCK 1 14 79974 O RING 2 55 Qoi 0096 9405 15 155105 RING 8ACK UP 1 STEERING PUMP FOR 3 53 DIESEL ENGINE REF HYSTER NAME OF PART REF HYSTER NAME OF PART 0 PART 0 12 3 4 QTY NO PART NO 1 23 4 QTY 169150 PUMP STEER ING 1 10 155806 GASKET SEAL 1 1 129446 5 6 12 158908 COVER FRONT 1 2 129447 WASHER 6 13 235933 SEAL SHAFT 1 3 170078 COVER REAR 1 129445 KIT MAJOR 1 4 166941 GASKET SEAL 2 158913 KIT MINOR 1 5 800 1 129444 1 5 168947 BEAR ING 4 T 984513 GEAR OR IVEN 1 INCLUDEO IN MAJOR KIT 8 GEAR DR VE 1 INCLUDEO N MINOR KIT 9 206 KEY 1 ZINCLUDED IN GEAR KIT 2D07 STEERING CYLINDER AND SOCKETS 12131415 167 22 23 REF HYSTER 2E02 OPTIONAL EQUIPMENT LIGHTING SYSTEM Q 400 0 un gt gt m gt a 2E03 LIGHTING SYSTEM 2 3 4 5 6 1 6 8 19 6 2 BLUE 16GA E 4 5 3 a 9 BLUE 1664 C3 ES 20 eA 4 BLUE 16GA 10 2 N GREEN 16GA 2
87. 3 At other than neutral setting the shuttle valve establishes a connection between one of the low charge pressure relief valves and whichever branch of the main circuit is at low pressure This connection provides a control of charge pressure and a path for excess oil to escape to the cooling circuit When the two branches of the main circuit are reversing their high pressure and low pressure functions the spring centered design of the shuttle valve closes the valve to prevent loss of high pressure oil 7 154 LOW CHARGE PRESSURE RELIEF VALVE 7 155 The low charge pressure relief valve works with the shuttle valve to control pressure in the charge circuit and to remove excess oil to the cooling circuit This valve will allow additional oil to dump if the high pressure relief valves cannot dump fast enough under excessive conditions Excess oil will be ported through the drain circuit to the oil cooler It is operative only when the transmission is not in neutral 7 156 PRESSURE CHECKS 7 157 Pressure checks imperative troubleshooting the hydraulic system 7 158 CHECKING NEUTRAL CHARGE PRESSURE seg figure 7 37 7 159 Neutral charge pressure can be checked at the transmission pump as follows a Remove the threaded plug from the charge pressure port Install a 600 PSI 40 kg cm gauge equipped with a short section of hose Make sure the gauge is accurately calibrated NOTE Use a 7 16 x 20 o ring adapter in th
88. 31 158439 HOOD 1 3 158452 BUMPER GROMMET TYPE 2 ga H89303 GUARB KANDAE HTHU Mice NOM 189288 COWL GAS 1 32 236 8 MES EE 1 32 189648 GUARD VANDALTSM 3 53 DIESEL 1 4 391373 COWL 3 53 DIESEL 1 32 15055 NUT 5 16 UNC 4 32 18515 WASHER 5 16 4 5 164524 EYEBOL 5 16 UNC 1 32 15155 LOCKWASHER 5 16 4 5 95675 SPRING 1 32 16597 CAPSCREM 3 8 UNC X 3 4 G5 2 5 18515 WASHER 5 16 2 32 15156 LOCKWASHER 3 8 2 5 145639 LOCKNUT 5 16 UNC 1 33 15055 NUT 5 16 UNC 4 6 109983 A SEAT 2 33 18515 WASHER 5 16 4 T 233157 CUSHTON BACK 1 33 15155 LOCKWASHER 4 T 136112 COVER 1 34 15005 NUT 5 16 UNC 8 8 233155 FRAME 1 34 16775 LOCKWASHER 5S 16 8 9 233156 CUSHTON SEAT 1 34 15175 WASHER 5 16 8 9 136111 COVER 1 35 158449 PLATE COVER 1 10 148260 SCREW 4 36 15056 NUT 3 8 UNC 6 12 164065 2 36 15156 LOCKWASHER 3 8 6 13 WASHER 1 4 4 37 181859 BUMPER 2 14 16709 SCREW 1 4 UNC X 3 4 4 37 15002 NUT 10 UNF 2 15 204120 ADJUSTER WITH LATCH 2 37 15152 LOCKWASHER 3 16 2 16 204121 ADJUSTER WI THOUT LATCH 2 38 16634 CAPSCREW 3 8 UNF X 1 65 1 17 233163 SPRING LATCH 1 38 15006 NUT 3 8 UNF 1 18 203920 STUD 8 38 15156 LOCKWASHER 3 8 1 38 16818 CAPSCREW 5 16 UNF X 3 4 G5 1 38 15155 LOCKWASHER 5 16 1 20 391612 PANEL INSTRUMENT 38 18515 WASHER 5 16 1 20 261162 TAPE SPONGE RUBBER BULK 38 15005 NUT 5 16 UNF 1 20 261158 TAPE SPONGE RUBBER BULK 39 166296 PLUG 2 21 15058 NUT 1 2 UNC 40 170686 PLUG 2 21 15158 LOCKWASHER 1 2 22 177989 LATCH 22
89. 311 EL80W 1 E d 22 19689 NIPPLE 1 1008 EXHAUST SYSTEM FOR 3 53 DIESEL ENGINE oO r e En pe yn E meen REF HYSTER NAME OF PART REF HYSTER NAME OF PART NO PART NO 1 2 3 4 QTY 0 PART 0 123 QTY 1 169116 TAILPIPE 1 8 169114 SHIELO HEAT 1 2 30375 CLAMP 6 9 16805 CAPSCREW 3 8 UNC X 1 G5 4 3 153025 MUFFLER 1 9 15156 LOCKWASHER 3 8 4 192208 STRIP 1 9 15176 WASHER 3 8 4 5 16828 CAPSCREW 3 8 UNC X 1 1 4 65 2 10 169109 PIPE EXHAUST 1 5 15156 LOCKWASHER 3 8 2 11 192205 STRIP FORMED 2 5 15056 NUT 3 B UNC 2 12 15529 CAPSCREW 3 8 UNC X 1 2 6 169112 PIPE 1 12 15156 LOCKMASHER 3 8 2 7 169115 SWIVEL EXHAUST 1 12 15056 NUT 3 8 UNC 2 AIR FILTER GAS 1D02 FUEL SYSTEM AIR FILTER 4 236 AIR FILTER 3 53 DSL CARBURETOR FUEL INJECTION PUMP 4 236 DSL FUEL INJECTION SYSTEM 4 236 DSL FUEL OIL LIFT PUMP 4 236 DSL FUEL PUMP GAS FUEL SYSTEM GAS FUEL SYSTEM 4 236 FUELS SYSTEM 3 53 GOVERNOR DS umata u St M SECONDARY FUEL FILTERO040236 DSL SECONDARY FUEL FILTER 3 53 DSL THROTTLE LINKAGE 1D04 1D04 1E04 1E04 1D13 1D12 1E01 1D03 1D03 1D11 1E03 1D03 1E01 1E03 1D07 1D05 AIR FILTER L MU
90. 36069 236070 236074 236075 236078 236081 236082 237011 237014 237017 239995 239996 241102 241103 242165 242166 242361 243165 243166 243167 243575 243576 243577 243578 243579 243580 243581 243582 243583 243584 243585 243586 243587 243588 243589 243590 243591 243592 243593 243594 243595 243596 243591 243598 243599 243600 243601 243502 243603 243604 243605 243606 PAGE 1 09 2006 2006 2006 2006 2006 1 07 1 07 1 07 1F07 1 07 1 07 1 08 1 08 1 08 2802 2802 2802 2808 2808 200 200 2801 2801 180 2A11 2A14 2al4 2801 2801 2801 2801 2801 2801 2801 2801 2801 2801 2801 2801 2801 2801 2801 2801 2801 2801 2801 2801 2801 2801 2801 2801 2801 2A14 2801 2801 2801 2801 2801 2801 REF ND 47 41 22 45 45 43 34 42 PART NO 243608 243609 243610 243611 243612 243613 243614 243616 243620 243621 243622 243623 243624 244900 245782 249291 249292 249466 250256 252778 253993 253999 254050 254051 254052 254053 254054 254055 254056 254057 254058 254059 254061 254062 254063 254064 254065 254066 254067 255610 257600 257601 259964 259965 259966 259967 261158 261162 262280 262281 262282 262283 265732 265788 267025 267026 267027 267028 261029 267030 PAGE 2801 2801 2801 2801 2801 2801 2801 2801 2801 2801 2801 2801 2801 180
91. 45 SHIM 020 AR 28 156205 SEAL OIL 1 59 178155 CARRIER BEARING 1 29 21327 SHAFT 1 30 37065 SNAP RING 1 60 392189 COUPL ING 1 31 156206 CAPSCREW 1 2 UNF X 2 1 4 4 61 213611 CAPSCREW 1 2 UNC X 1 1 4 4 32 156192 SNAP RING 1 62 18588 CAPSCREW 1 2 UNC X 1 1 2 G5 12 33 128528 BOLT 5 8 UNC X 1 1 4 G8 16 62 15158 LOCKWASHER 1 2 12 34 37562 CAPSCREW 1 2 UNF X 1 1 4 G5 3 3t 156186 PLATE 3 156185 PLATE LOCK 3 37 180397 PIN GROOVE 3 38 15318 PLUG 1 2C02 BRAKE AND LINKAGE PARKING BRAKE AND LINKAGE 2C03 PARKING BRAKE AND LINKAGE 36 3 REF HYSTER NAME OF PART REF HYSTER NAME OF PART NO PART NO 1234 QTY PART NO 1 2 3 4 QTY 1 204773 LEVER PARKING BRAKE 1 29 16782 CAPSCREW 5 16 UNC X 2 1 4 65 4 1 210614 LEVER HANDLE 1 30 156242 PLATE SUPPORT LH 1 2 204966 KNOB 1 31 16080 CAPSCREW 3 8 UNC X 3 4 2 3 PIN ROLL 1 32 163739 CAPSCREW SPECTAL 12 4 WASHER SPRING 1 33 15225 COTTER 1 8 X 1 1 5 O RING 1 34 21110 NUT CASTLE 1 amp SCREW ADJUSTING 1 35 156245 SPACER 1 7 54871 PIN 1 36 191140 BRAKE 1 B 54863 LINK 1 36 191351 DRUM BRAKE 1 9 T7584 BRACKET MOUNTING 2 37 163734 PLATE BACK ING 1 10 119878 SPACER 1 38 172264 LEVER DPERAT ING 1 11 127876 CLAMP 1 39 191345 BRAKE SHOE AND LINING 2 12 127875 SPACER 2 40 77717 SPRING RETURN 1 13 127874 SPACER 2 4l 194190 KIT PAWL 2 14 54861 PIN 1 2 164199 ROLLER 1 15 18515 WASHER 1 43 142 PIN ROD END 1 16 15213 COTTER 3 32 X 1 1 44 15212 CO
92. 5 4 1 ENGINE Ql eL 4 1 ENGINE OIL FIETER itt i Lear tenth Well aaa aaa ike LUBRICATING THROTTLE AND TRANSMISSION HYDRAULIC SYSTEM ih Rt sh au uta eee Avila tue tup oa eL paa ela pe abe Da pa epe Ae adus aeu Mp eT CHANGING THE TRANSMISSION 5 WATER SPRAY SYSTEM ueteri e etate odes 4 18 FI JEERS2 a a A ae MANIFOLD AND NOZZLES 1 A i Da mE PARKING BRAKE E LUBRICATION eor ER ADJUSTING PEE FINAL DRIVE ASSEMBLY eee naa ge CHECKING LUBRICANT LEVEL uuu u rte rt Loco Lec debe oL Ee FLUSHING THE FINAL DRIVE Ng ie GUIDE ROLL AXLE BEARINGS i ch ah TIRUNNION ASSEMBLY STEERING CYLINDER BALL JOINTS 1 L rennen REMOVING AND REPLACING STEEL BALLAST eene eene nnns UNIKSTORAGE EN WATER SPRAY SYSTEM DRUM BALLAST STEERING CYLINDER EE SYSTEM iiM ata ENGINE COOLING SYSTEM aa teret cee eee ENGINE e HAGA AA HAMMAR RDA RASRA gis EE SECTIONS 5 TROUBLESHOOTING TROUBLE ANALYSI
93. 6 126121 133573 1C03 6 55590 1F08 99172 126319 133575 1 05 9 55894 1F08 99779 126358 133578 1 02 7 55901 1F07 99780 126364 133579 1 02 6 55965 1F07 99786 126380 133580 1 02 4 65978 1 08 100434 126381 133696 160 39 55983 1205 101618 127045 133816 2005 10 56998 2805 101985 127644 133817 2006 12 57664 2007 103739 127645 133820 2006 7 58933 1 06 106483 127804 133821 2006 60416 2 03 107173 127874 134102 1809 16 62429 2A06 109983 127875 134796 1 0 50 62886 2 03 110177 127876 134813 1 05 10 67326 1 06 111114 127906 134814 1 05 29 67353 1003 111120 128408 134915 1014 82 67660 1408 111331 128436 134919 1013 33 67661 1A08 111770 128444 134920 1013 29 68965 2411 112475 128528 134921 1013 32 69240 1407 112989 128831 134923 1013 56 73470 2003 113349 128834 134924 1013 55 73510 2 03 113687 128835 134925 1013 54 74751 1F05 115696 128836 134926 1013 53 75225 2A06 115983 128837 134928 1013 50 76230 2003 116486 128838 134929 1013 57 76787 1 05 118667 128839 134930 1014 60 76817 2406 118742 128840 134931 1014 59 77115 2807 118807 128841 134932 1014 61 77328 1F03 119074 128842 134933 1014 64 77584 2 03 119236 128844 134935 1014 79 77717 2C03 119379 128845 134936 101 T9 PART NO 134938 134939 134940 134941 134942 134943 134944 134948 134949 134950 134951 134953 134954 134956 134957 134958 134959 135416 136111 136112 136122 136125 136516 137697 137698 137699 137852 138145
94. 6 4 2 393320 PLATE COVER 1 5 18515 WASHER 5 16 4 2 393317 DECAL NOISE 1 5 16836 CAPSCREW 5 16 UNC X 3 6 4 3 393316 DECAL 1 6 168718 CLAMP 1 4 222031 8 6 193772 HOSE CRANKCASE VENT 1 5 393562 YOOL BOX 1 393563 PAINT MILITARY GREEN AR 1B02 DETROIT DIESEL ENGINE SERTES 3 53 NOTE FOR SERVICE OF THIS ENGINE SEF YOUR DFTROITDIESEL MANUAL AND CONTACT YOUR LOCAL DETROIT PFALFR POWER UNIT etek ie repe Dara mnm FE COOLING SYSTEM 1809 ira wrrrrc BOA ip GB rea mr rnm me A ENGINE MOUNTS 3 53 DSL 44 ICO ibe PEE s EXHAUST SYSTEM 3 53 DSL 2 1 08 KEY Pur EP TP EPTPERUN C FOR 3 53 DIESEL ENGINE REF HYSTER NAME DF PART 0 PART NO 1234 1 169105 RADIATOR 2 106483 CAP RADIATOR 119236 CLAMP 4 100434 MOSE RADIATOR 5 169107 HOSE RADIATOR 9 16805 CAPSCREW 3 B UNC X 1 9 17262 CAPSCREW 7 16 UNC X 5 8 10 15156 LOCKMASHER 3 B8 OOM ARAN RUM Won 1809 COOLING SYSTEM QTY RE F H NO PART NO 1234 11 15057 NUT 7 16 UNC 12 12815 COCK ORAIN 13 190519 BRACKET RADIATOR 14 15134 WASHER 3 8 15 0 03 569 3 8 UNC 16 16719 8 UNC X 3 8 He 16 15163 LOCKWASHER 8 eM 17 Z 391369 SHROUD CLAMP HOSE
95. 6 4 ELECTRICAL SCHEMATIC FOR DETROIT 6 4 b Adjust and tighten ball Joint of control cable at bail shaft end Adjust neutral start safety transmission lockout switch so that it makes contact in neutral c Move Direction Throttle Control Bail In the forward direction until control cable at servo lever has traveled 11 16 31 32 in 24 64 26 92 mm Adjust bail stops so that cable cannot be moved beyond this point d Repeat step c in reverse direction CAUTION Ensure that the amount of bail control cable travel Is limited by ball stops and not the interval Servo stops e Return Direction Throttle Control Ball to neutral vertical position DIRECTION DIESEL STOP ae DIRECTION THROTTLE CONTROL 7 CRANK ACTUATOR BAIL ARM DETENT SPRING PLUNGER FRICTION DETENT NUT 2 REO D PLATE CONTROL SHAFT HAND THROTTLE HANDLE THROTTLE P ACTUATOR ARM ML SECTION 7 TRANSMISSION f Adjust and tighten wire stop at throttle crank for 1116 In 1 59 mm gap between swivel and wire stop see figure 7 44 g Adjust ball Joint in slotted crank on bail shaft to allow full throttle when bail Is moved to either full forward or full reverse h Adjust friction control nuts and spring assembly so that Direction Throttle Control Bail will remain in any desired position 7 173 THROTTLE CONTROL LINKAGE ADJUSTMENT PROCEDURE see figure 7 44 a Adju
96. 6304 KEY IGNITION 4 15372 NIPPLE LONG B Ces 5 77328 SENDER TEMPERATURE 6 5 5 15002 NUT 10 UNF 22 169758 AMMETER 5 15916 LOCKWASHER 410 23 169779 GAUGE WATER TEMPERATURE 6 24 169759 GAUGE OIL PRESSURE 9 Ean 25 170805 GAUGE TRANSMISSION TEMP 6 157065 BOOT PROTECTOR 26 119379 METER HOUR 7 1 09 27 87415 WIRE 8 SHES 8 ime 28 184825 HARNESS WIRING INSTRUMENT 3 660 R R Haus 29 134814 CONNECTOR 9 169152 HARNESS WIRINGs ENGINE 30 126319 CONNECTOR 10 134813 CONNECTOR 31 126380 CONNEC TOR REGUL ATOR ll 152728 CONNECTOR 32 148767 HOLDER FUSE 12 126381 CONNECTOR 32 53123 FUSE 5 13 18460 CAPSCREW 1 4 UNC X 3 4 G5 33 148659 CONNECTOR 13 15054 NUT 1 4 UNC 34 121384 CONNECTOR 13 15154 LOCKMASHER 1 4 35 183575 BRACKET 13 173247 CLAMP 36 391826 BOLT 5 16 UNC X 9 14 134796 REGULATOR VOL TAGE 36 18515 WASHER 5 16 15 132853 WIRE 36 17443 NUT WING 5 16 UNC 16 168421 SWITCH TOGGLE SPRAY PUMP 37 79792 SATTERY 12 VOLT 17 163762 BREAK ER CIRCUIT 9 ode B 17 15002 10 UNF 38 169156 17 15052 NUT 10 UNC 39 111770 PROTECTOR 17 15916 LOCK WASHER 10 40 147633 PROTECTOR B B P 41 74751 HOLD DOWN BATTERY 18 128408 CLAMP 5 8 18 16378 CAPSCREW 1 4 UNC X 5 8 G5 42 169155 CABLE BATTERY 8 1 1F06 ELECTRICAL SYSTEM FOR DIESEL ENGINE REF HYSTER NAME OF PART QTY NO PART NO 1234 43 101618 CABL E GROUND LITE LII 45 MOTOR
97. 7 24 SECTION 7 TRANSMISSION FREE FLOW OIL CONTROL DISPLACEMENT HANDLE CONTROL VALVE BE ERE e uiu EA ma REVERSIBLE I VARIABLE LOW PRESSURE STATIC OIL DISPLACEMENT MOOT NAT I aT NNER A quq X FIXED DISPLACEMENT CHARGE PRESSURE HIGH PRESSURE LOW ub RELIEF VALVE RELIEF VALVES GER uU Ms BL VALVES _ CHARGE TSN NEUTRAL SWASHPLATE EER 4 a 1 SWASHPLATE VALVE CONTROL A ACUUM CYLINDER GAUGE 10 MICRON FILTER HEAT EXCHANGER HEAT EXCHANGER PASS FIGURE 7 34 SUNSTRAND TRANSMISSION IN NEUTRAL 7 25 SECTION 7 TRANSMISSION DISPLACEMENT CONTROL HANDLE h CONTROL VALVE 72 PCS CHARGE A BY PASS 7 CHECK REVERSIBLE 6 VALVES VALVE LOWPRESSURE FIXED DISPLACEMENT VARIABLE u _ MOTOR DISPLACEMENT METERED OIL HIGH PRESSURE RELIEF VALVES lt lt LOW 22 2 An AU ap CHARGE PRESSURE cup yg T 7 2 x eG TO MOTOR Q2222227 0722247 7 EE eee ae mm CASE 2 NEUTRAL ies M LAS CHARGE N O QQ 2 4 RELIEF SWASHPLATE VALVE HIGH PRESSURE OIL SERVO CONTROL VACUUM CYLINDER GAUGE 10 MICRON CHARGE PRESSURE 8 RESERVOIR a HEATEXCHANGER HiGH PRESSURE
98. 85 S sa 2D05 STEERING TRUNNION AND DRUMS 14 390104 CONE BEAR ING 14 390105 CUP BEAR ING 15 390107 SPACER 16 390108 SPACER ee ee ee GEGEN ER FOIE COT PEGS REF HYSTER NAME OF PART REF MHYSTER NAME Of PART NO PART NO 1 23 4 QTY PART NO 123 QTY 1 156220 SEAL OIL i 17 193006 NUT JAM 2 d plac a ca me aco male 17 15250 COTTER 3 16 X 3 2 2 391352 PIN KING 1 18 191412 WASHER 2 3 192427 WASHER 5 19 390106 SEAL OIL 2 4 193006 NUT JAM 3 20 16007 FITTING LUBE 2 4 15250 COTTER 3 16 X 3 3 21 390096 SHAFT AXLE 1 5 230325 CUP BEARING 3 LEO ee 5 230325 CONE BEAR ING 3 6 230389 CUP BEARING 1 22 p 391351 PIN 1 6 230390 CONE BEARING 1 23 156223 SEAL OIL 2 7 18667 CAPSCREW 1 8 UNC X 2 1 4 2 24 156224 CAP 3 T 15166 WASHER 1 2 25 44525 SEAL OIL 2 8 390084 1 26 390101 SHIM AR 26 390102 SHIM AR 9 390122 STUD BALL 1 26 390103 SHIM AR 40 19950 PIN 1 2 X 1 3 4 2 11 187238 CAPSCREM 5 8 UNF X 2 1 2 4 28 390099 SPACER 1 12 390088 DRUM STEERING 2 29 97523 CONE BEARING 2 29 91626 CUP BEARING 2 12 15316 PLUG 2 13 15320 PLUG 2 PPR A BEN Sm toe 2 2 2 2 2D06 STEERING PUMP KEY A FOR GAS ENGINE 8 FOR 4 236 DIESEL ENGINE REF HYSTER NAME OF PART REF HYSTER NAME OF PART NO PART NO 1 2 3 4 0 PART NO 123 191756 PUM P STEER ING ljos 18 17604
99. 96 169098 169099 169100 169105 169107 169109 169112 169114 169115 169116 169118 169119 169120 169122 169128 169130 169134 169135 169136 169140 169144 169150 169152 169155 169156 169240 169241 169299 169307 169308 169391 169428 169446 169693 169694 169695 169697 169698 169699 169708 169718 169719 169758 169759 169776 169779 169787 169827 169828 PAGE REF NO gt PART NO 169873 169938 169939 169940 169941 169942 169943 169944 169947 169948 1699 9 169953 170078 170079 170080 170081 170082 170306 170551 170607 170682 170686 170687 170688 170589 170690 170693 170694 170695 170750 170805 171226 171928 171974 172007 172010 172115 172116 172117 172118 172119 172120 172121 172122 172123 172124 172125 172126 172127 172128 172129 172130 172131 172264 172699 172812 172833 172851 172852 172885 PAGE 1011 1804 1804 1804 1804 1806 1804 1806 2003 2003 1806 1804 2007 1 02 1 02 1 02 1 02 1005 1 06 1 07 1008 1405 1011 1011 1011 1011 1011 1011 1011 1806 1F03 1806 1007 2406 1813 1814 1003 1E04 1 0 1 04 160 1 04 1 04 1 04 1 0 1 04 1E04 1E04 1 04 1003 1E04 1 04 1 04 203 1A08 1 08 1E03 1011 1011 1B06 REF NO PART NO 173218 173241 173255 173307 173897 173910 173994 174019 1753
100. 98 214931 214953 215007 215008 215009 215010 215011 215012 215013 215015 215017 215018 215021 215025 215026 215041 215043 215044 216590 218051 219909 219910 219911 219912 219913 219914 219915 219916 219917 219918 219920 PAGE REF NO G09 NUMERICAL INDEX PART NO 219921 219922 219923 219924 219925 219927 219928 219929 219930 219931 219932 219933 219934 219936 219937 219938 219939 219940 219941 219942 219945 219944 219945 219946 219948 219949 219950 219951 219952 219953 220501 221341 221354 221357 221565 221573 221763 221838 222665 222667 222707 222710 222719 223137 223634 223640 223641 224248 226115 226832 228811 229081 229800 229802 229805 229849 229875 229879 229880 229890 PAGE REF 229895 229896 229897 229898 229899 229931 229932 230324 230325 230389 230390 230504 230505 230506 230507 230508 230509 230510 230511 230512 230513 230514 230515 230516 230517 230518 230519 230520 230521 230522 230523 230524 230525 230526 230527 230528 230529 230530 230531 230532 230533 23053 230535 230536 230537 230538 230539 230540 230541 230542 230544 230545 230546 233155 233156 233157 233163 234718 234719 235933 PART NO 235950 236011 236012 236018 236024 236026 236066 236068 2
101. ANUAL Section CD Die ERREUR CS Iba iu iba 2 SDOCIIICaLIOI am a sa 1 3 Operations a x 4 Hyster Care 5 Troubleshoolllig uie utet a CEU DL tC C 6 F TS 7 8 P TL 9 SIEEN eee 10 ParcBrakecs 11 Water Spray System PART T SUPPLEMENTAL OPERATING MAINTENANCE AND REPAIR PARTS INSTRUCTIONS Section General ae Maintenance sert e eain E nh am Repair Supply ee cc EQUIPMENT PUBLICATIONS aucta i te Po WARRANTY GUIDEEINES 5 rere dad perd de MAINTENANCE ALLOCATION CHART MODIFICATION PROCEDURE vaga e BASIC ISSUE ITEMS EIS ierit li revu TM 5 3895 348 14 amp P 1 PRESCRIBED LOAD LIST PLL amp AUTHORIZED STOCKAGE MRNA ADDITIONAL REPAIR PARTS aaa SAMPLE FORMAT DA FORM 2765 REQUEST PART NUMBER SAMPLE FORMAT MILSTRIP REQUEST NSN SAMP
102. ARINGS Lubricate daily with GAA grease One fitting is located on each end of the guide roll shaft Apply grease into fitting until movement of old grease around seal is observed 6 STEERING TRANSMISSION HYDRAULIC RESERVOIR Cold check Check fluid level at sight gauge Add as required 7 CONTROLS AND INSTRUMENTS Check for proper indication and Engine coolant engine oil operation pressure and transmission oil temperature gauges indicate abnormal operation a Ammeter Slight charge e b Engine Coolant Temperature Gauge White warm up Green normal Red hot c Engine Oil Pressure 40 60 PSI normal operation d Transmission Oil Temperature Gauge Green Red e Hourmeter 40 Operator Crew Preventive Maintenance Checks and Services B Before D During A After W Weekly M Monthly TEM TO BE INSPECTED Item Interval Procedure Check for and have repaired Equipment is not ready no BL DTA WIM filled or adjusted as needed available if Fuel Gauge 9 Controls i e steering shifting etc Check for proper operation 8 TRANSMISSION SUCTION FILTER With engine running check reading on filter gauge Gauge indicates 10 or above 9 WATER SPRAY SYSTEM TANK a Check strainer and clean with water if required b Check water spray nozzle and clean if required 10 COCO MATS AND SCRAPER BAR Check for missing or worn mats on scraper bar One or more missing WARNING Always use extreme caut
103. B BACKUP RINGS FIGURE 7 54 FIGURE 7 55 7 39 the o rings do not slip from their grooves Torque bolts to 19 21 2 66 2 90 kg m 7 189 REPLACEMENT OF HIGH PRESSURE RELIEF VALVES 7 190 REMOVAL a Apply a wrench on HEX portion of the valve and unscrew from manifold block see figures 7 56 and 7 57 NOTE There are two relief valves in the manifold block 7 191 INSTALLATION a Prior to installation inspect o rings and back up rings for damage b Apply a lubricant to the o ring and install in the manifold block c Torque valves to 20 ft lbs 2 76 kg m 7 192 REPLACEMENT OF DISPLACEMENT CONTROL VALVE 7 193 REMOVAL a Remove the control linkage from the displacement control valve assembly b Remove the nine 9 capscrews holding the valve to the pump housing seg figure 7 58 c Lift the valve away from the housing and remove the cotter pin and washer see figure7 59 Remove pin APPLY WRENCH TO HEX PORTION OF VALVE FIGURE 7 56 SECTION 7 TRANSMISSION from link in the pump NOTE Caution must be taken to prevent these parts from falling into the pump housing A clean rag placed in the opening will help to prevent accidentally dropping parts into housing d Remove orifice and o rings from control valve see figure 7 60 Check to ensure that orifice is open 7 194 INSTALLATION a Install orifice tip down and new o rings in control valve b I
104. DRUM SCRAPERS see figure 3 4 3 16 Both Guide Rolls and the Drive roll are equipped with full width adjustable scrapers mounted ahead and behind each of the drums These scraper bars are designed to keep the large pieces of material from clinging to the rolls when moving in either forward or reverse Scrapers are spring loaded to provide positive drum contact 3 17 All bars have off the four scraper SECTION 3 OPERATION drum locking position To lock any of the four scrapers into the off the drum position 1 scraper away from the drum 2 Move the pawl into the lock position 3 Slowly move the scraper towards the drum until the pawl holds the scraper WARNING Always use extreme caution when positioning scrapers as they are under considerable spring tension and may become sharp when worn COCO MATS Seb figure 3 4 3 19 A full width COCO mat is located on each roll and is used in conjunction with the water spray system to keep the rolls clean 3 18 3 20 Both coca mat arrangements have off the drum locking positions To lock either of the two coca mats off the drum 1 Pull or lift the coca mat off of the drum 2 Engage the mat hook in the mat link 3 Slowly move the coco mat towards the drum until the mat hook holds the mat SCRAPER PAWL coco TYPICAL MAT SCRAPER BAR TYPICAL FIGURE 3 4 WATER SPRAY SYSTEM sed figure 3 1 3 22 The water spray system is
105. E 1 3 1 2 SECTION 1 INTRODUCTION 1 14 Refer to C350B Service Manual ol Section this 1 17 SAFETY PRECAUTIONS publication 1 18 When operating the unit always observe 1 15 SYSTEM DESCRIPTIONS AND REPAIRS recommended procedures given on the inside front cover of this manual 1 16 Refer to C350B Service Manual FIGURE 1 4 2 1 2 2 GENERAL TABLE Additional specification tables are SECTION 2 SPECIFICATIONS included for unit dimensions weight performance and torques Following is This section contains specification tables for each list of specification tables included in this section major system of the compactor TITLE Compactor Dimensions Performance Specifications Weight Ballast Compression Data Detroit Diesel Engine Specifications Water Spray System Specifications Hydrostatic Transmission Specifications Final Drive and Drum Assembly Specifications Steering System Specifications Brake System Specifications Torque Specifications for Standard Hardware TABLE 2 1 COMPACTOR DIMENSIONS see figure 2 1 Overall Height Overall Length Overall Width Ground Clearance 10 14 Ton C350B Wheelbase Guide Roll Width Guide Roll Diameter Drive Roll Diameter Drive Roll Width Guide Roll Maximum Oscillation Going Straight In Full Turn Guide Roll Maximum Turn INCH 77 197 65 18 15 cm DESIGN DATA C350B 196 500
106. ENANCE AND OPERATING SUPPLY LIST NOMENCLATURE Roller Motorized Steel Wheel 2 MAKE MODEL Drum Tandem 10 14 Ton CCE HYSTER C350 D MFR PART NO 3845 00 578 0372 SERIAL NO RANGE DATE TO Feb 79 MFR EE NO 4 QTY REQ COMPONENT OR QTY REQ APPLICATION NAT L STOCK NO DESCRIPTION F INITIAL OPN General GAA Grease MIL G 10924 Application 9150 00 190 0905 Anti Freeze Permanent 16 ats 50 50 solution Cooling System 6850 00 181 7933 MIL A 46153 36 APPENDIX M PREVENTIVE MAINTENANCE CHECKS AND SERVICES Maintenance Forms and Records Every mission begins and ends with the paperwork There isn t much of it but you have to keep it up The forms and records you fill out have several uses They are a permanent record of the services repairs and modifications made on your vehicle They are reports to organizational maintenance and to your commander And they are a checklist for you when you want to know what is wrong with the vehicle after its last use and whether those faults have been fixed For the information you need on forms and records see TM 38 750 Preventive Maintenance Checks and Services 1 Do your before B PREVENTIVE MAINTENANCE just before you operate the vehicle Pay attention to the CAUTIONS and WARNINGS 2 During checks and services D of PREVENTIVE MAINTENANCE will be performed while the equipment and or its component systems are in operation 3 Do your after A PREVENTIVE MAINTENANCE right after operat
107. ERATION IS ALLOWABLE WITH MINOR LEAKAGES CLASS OR Il OR COURSE CONSIDERATION MUST BE GIVEN TO THE FLUID CAPACITY IN THE ITEM SYSTEM BEING CHECKED INSPECTED WHEN IN DOUBT NOTIFY YOUR SUPERVISOR 38 Operator Crew Preventive Maintenance Checks and Services B Before D During A After W Weekly M Monthly TEM TO BE INSPECTED Item Procedure Check for and have repaired Equipment is not ready BTD A W M filled or adjusted as needed available if NOTE PERFORM WEEKLY AS WELL AS BEFORE PMCS S IF a You are the assigned operator but have not operated the equipment since the last weekly b You are operating the equipment for the first time 1 GENERAL a Visually check for loose wiring damaged piping or hoses ale b Look for evidence of fluid leakage oil fuel coolant Class 111 leaks or any fuel leakages are found 2 ENGINE CRANK CASE Check dipstick for proper level Add oil as necessary to FULL mark 3 RADIATOR Check coolant level Add coolant as required Level should be approximately 1 inch from bottom of filler neck 4 FUEL STRAINER Drain approximately X pint to remove sediment and water 39 Operator Crew Preventive Maintenance Checks and Services B Before D During A After W Weekly M Monthly UMS ITEM TO BE INSPECTED Item Interval Procedure Check for and have repaired Equipment is not ready B OTA MIM filled or adjusted as needed available if 5 GUIDE ROLL AXLE BE
108. ETER ENGINE OIL PRESSURE FUEL CAUGE VANDALISM SHIELD EMERGENCY STOP DETROIT DIESEL ONLY PARKING BRAKE STEERING WHEEL IGNITION SWITCH FRONT SPRAY SHUT OFF _ TRANSMISSION OIL TEMPERATURE FIGURE 3 1 OPERATING CONTROLS AND INDICATORS 3 1 DIESEL ENGINE HAND THROTTLE WATER SPRAY SWITCH DIESEL ENGINE STOP SECTION 3 OPERATION TABLE 3 1 OPERATING CONTROLS AND INDICATORS FIGURE 3 1 INDEX NO NOMENCLATURE TYPE FUNCTION DIRECTION Cross bar with mechan Controls direction and speed of com THROTTLE BAIL ical linkage to fuel pactor Vertical position detents and system and transmission transmission in Neutral Moving lever toward Guide Roll from Neutral causes unit to move forward Moving lever toward Drive Roll from Neutral causes unit to move in reverse direction Dis tance lever is moved from Neutral determines engine and unit speed This lever also acts as a means for dynamic braking of the unit control Indicates output current of alternator Gauge may show slight discharge RED at idle but should indicate charge GREEN when engine speed is increased ENGINE WATER TEMPERATURE Indicates temperature of water circu lating through engine Needle should point to the white or cold operating band when engine is first started After warmup period needle should register in the green operating band If needle registers in the red band stop op
109. FICATIONS FINAL DRIVE AND DRUM ASSEMBLY STEERING SYSTEM SPECIFICATIONS eee BRAKE SYSTEM 7 TORQUE SPECIFICATIONS FOR STANDARD HARDWARE SECTION 3 OPERATION GENERAL EMERGENCY ENGINE STOP DETROIT DIESEL ONLY essen RESETTING EMERGENCY ENGINE STOP DETROIT DIESEL ONLY edem spe SHIPPING THE UNIT a MISCELLANEOUS OPERATING 2 4 HYSTER CARE MAINTENANCE s AIR FILTRATION SYSTEM ua u ae aa 4 8 4 8 DIESEL CRANKGASE BREATHER dedi o o bane bone i qe nt DETROIT DIESEL BLOWER 5 ENGINE AIR BOX DRAIN Ju retreat vt cu eee tenete e aet vade o vanae teva ELECTRICAL SYS LEM etre eerte eet aaa q k oet CL t e ra OE RR C A CHECKING BATTERY ELECTROLYTE ALTERNATOR AND WATER PUMP DRIVE 6 4 10 ELECTRICAL WIRING COOLING SYS EE RADIATOR EL FAN SHROUD pe WATER PUMP SAS SRR SERA 4 13 HOSES e EE FLUSHING THE SYSTEM irte teet Leo itte ete d EL De LLL HU Eos DETROIT DIESEL FAN DRIVE 5 ENGINE LUBRICATION 5
110. ING FIXED 1 8 16376 CAPSCREW 3 8 UNC X 2 3 33 222719 PIN 2 9 18540 CAPSCREW 3 8 UNC X 3 5 34 216590 PLUG 1 10 190583 WASHER B a5 16485 O RING 1 11 190585 SHIM AR 36 15483 PLUG 1 12 190586 GASKET END 1 37 184055 PIN 1 13 190587 BEARING REAR 1 38 265788 O RING 2 14 194395 PLATE VAL VE 1 39 1 190643 SEAL SET 1 15 222710 PIN 1 40 X 15880 O RING 1 16 190591 PLATE BEAR ING 1 41 3 190657 RETATNER SEAL 1 17 267028 PILOT BEARING PLATE 1 42 226832 PIN GROOVE 1 18 4 190593 RING RETAINING 1 43 190644 SPRING SEAL 6 19 190594 RETAINER SPRING 1 44 190648 RING RETAINING 1 20 190595 GUIDE SPRING 1 21 267029 SPRING CYL INOER BLOCK 1 INCLUDED IN MANIFOLD VALVE KIT 267025 22 190597 SEAT SPRING 1 GINCLUDED IN VALVE SEAL KIT 194393 23 BLOCK CYL INDER 1 INCLUDED IN CYLINDER BLOCK KIT 267027 24 190599 PIN 1 XINCLUDED IN SEAL KIT 190641 REF NO 00 40 wwN 2802 OIL FILTER HY STER PART 215015 161146 161152 195033 237017 161161 161160 161156 161158 161159 1234 FILTER OIL HEAD amp PLUG INDICATOR SPACER BY PASS VALVE SPACER BY PASS VALVE 5 PSL LOCKNUT BY PASS VAL VE BY PASS GUIDE BY PASS CAP STEM RY PASS SCREW BY PASS SPRING BY PASS mm REF NO 10 11 12 13 14 15 16 17 20 HYSTER NAME OF PART PART NO 1234 161154 7 O RING HOUSING 161150 SEAL OtL 161155 ELEMENT 161148 HOUS ING 161149 SPRING ELEMENT 161153 GASKE
111. In This Book As Right Or Left Hand Parts Are In Accordance With The Illustration Below R H Side L H Side CAUTION Never Attempt To Clean Oil Or Adjust A Machine While It Is In Motion HOW TO USE THE ILLUSTRATED PARTS MANUAL It also includes all parts peculiar to units built in overseas plants These parts are indicated by keys symbols and footnotes This parts manual describes and illustrates assemblies subassemblies and detail parts needed for serious replacement to PAAR Lc cap 55 Lever D T 555 ONL Pares Bind orvisrow System Hrona SSE Ont ve Svsren ano Scrapers ELECTRICAL PRIM system OPERA ry 264 196 I jee 064 Wann tng NSE tons ORIVE Disco PLATE ww 2 fis Ho oo 5 77 awo OPTIONAL WUB RICAL qup oe 4 When The Part Number And Next Higher Assembly Is Not Known 1 USE Determine the function and application of the part required Turn to the illustrated index page immediately behind the front cover and select the most appropriate area Line up the black arrow containing the appropriate reference number with the black tab on the division index page with the same reference number Use the division index to determine the assembly which
112. Item used in this publication applies to a standard commercial item of commercial equipment that has been approved for a specific TOE requirements and is procured and supported under the CCE System Plan This plan permits maximum utilization of the civilian construction industry s competitive research and develop ment manufacturer s equipment publications and commercial sources for repair parts 1 4 Description The CCE Roller Steel Wheel is manufactured by Hyster Co of Kewanee IL It is powered by an in line three cylinder 3 53 series Detroit Diesel Engine The final drive consists of an internal double reduction planetary system located within the left side of the single drive drum Engine power is transferred to the final drive assembly by a closed hydrostatic transmission system The steering system is a hydrostatic operated manually controlled system with provi sions for manual steering 1 5 Operational Concept The CCE Roller Steel Wheel will be deployed worldwide as a replacement for the following 5 8 Ton Roller LIN 51068 8 12 Ton Roller LIN 511136 9 14 Ton Roller LIN 511205 and LIN 611273 It will also partially replace the 10 Ton Roller listed under LINs 511479 and 511616 The Roller is intended for use in road construction and rehabilitation airfield heliport and port construction Primary tasks are breakdown and finish rolling asphalt pavements and asphalt patch work Secondary uses are compaction of pavement base cours
113. K DRAIN COCK SECTION 4 HYSTER CARE MAINTENANCE 4 49 HOSES 4 50 Examine hoses at least twice each year for cracks hardening softening and swelling Remove the hose and check the interior section Hoses can deteriorate on the inside and appear satisfactory on the outside The Hose must be pliable and able to pass coolant without restriction 4 51 FLUSHING THE SYSTEM 4 52 Rust in the radiator or coolant indicate c that the corrosion inhibitor has lost its effectiveness This can be avoided by draining and flushing the system at least once each year For effective flushing remove the radiate hoses and the thermostat Open the engine LUWER BLOCK DRAIN SCR ACE rus 4 on 0 DETROIT 5 53 FIGURE 4 16 ENGINE COOLANT DRAIN COCKS 4 13 FLUSHING GUN FLUSHING GUN WATER 762 FIGURE 4 18 REVERSE FLUSHING RADIATOR drain cock seg figure 4 16 and allow the block to drain Close the drain cock and reverse flush the block as shown in figure 4 17 Reverse flush the radiator as shown in figure 4 18 SECTION 4 HYSTER CARE MAINTENANCE FAN n PULLEY 3 4 INCH 2 CM DEFLECTION THIS POINT FAN BRACKET MOUNTING BLOCK FIGURE 4 19 DETROIT DIESEL FAN BELT ADJUSTMENTS NOTE Make sure that the thermostat is removed Flushing as shown in figure 4 17 will close the thermostat and prevent complete flushing of the block After flushing the sys
114. L mL emis D mM Dama ean DESCRIPTION Dt rede Uu Due DO Ru e E UG CHECKS AND ADJUSTMENTS cccecseseccesecesescescessescessescecescercescsacsecerssacresacsasrsrsrsesserserserserserseres SPRAY MANIFOLDS ccceccecsessessescescescessessescscccescescescerseasercersssersaserssseasessersersessessersersersersens WATER PRESSURE cscsecssseecescescceceeecsececcecceecaecacacsaesacsaecaecaecaeeaecaeeaeeaecacersesserecseeseessereessereess es CHECKING MOTOR BRUSHES 2 REMOVAL OF PUMP AND MOTOR ASSEMBLY 0 40 0 6 6060 INSTALLATION OF PUMP AND MOTOR ASSEMBLY 2 0 200 60 6 CLEANING THE WATER TANK c cecceseccececocescescescessercescescescercercescercssessrcersessrsrsersersessesserserserseres vi DELETED PAGE 1 1 1 GENERAL 1 2 This manual contains Operation and Maintenance Instructions for the C350B Steel Wheel Roller figure 1 3 and 1 4 Operating instructions must be carefully reviewed and understood before attempting to operate a unit The individual assigned to operate the unit should see that it is kept in good condition to ensure prolonged efficiency 1 3 UNIT NAMEPLATE 1 4 The unit nameplate is located at the front of the operator s compartment as shown in figure 1 4 Make sure the nameplat
115. LE FORMAT MILSTRIP REQUEST NON NSN SAMPLE FORMAT MILSTRIP REQUEST NON NSN MANUAL MAINTENANCE 8 OPERATING SUPPLY PREVENTIVE MAINTENANCE CHECKS 8 SERVICES OPERATOR CREW PMOS eene ettet ena enata Xd RA RR AREA RA RARE ANE ORGANIZATIONAL PMCS HYSTER TECHNICAL PUBLICATION CORRECTION O HYSTER TECHNICAL PUBLICATION CORRECTION PART PARTS MANUAL VOLUME 2 Engine Operators Service and Parts Manual PART ENGINE OPERATORS MANUAL Section 1 DV OSCHIPUOM e 4 2 mec ET 13 3 Engine Equipment uu et e Rote 31 4 Operating Instr CtlOhi 47 5 Lubrication and Preventive Maintenance eene 55 6 Engine Tune Up 75 7 Trouble SNOOtiNG uu ul uuu nu unan a s Okan tu Ba Qan Qan 113 8 ijr dss aS a M 119 9 Built In Parts BOOK iet ete ree aar ra EL 123 10 Owner ASSISTANCE 147 INDEX ALPHABETICAL 3 149 PART l ENGINE SERVICE MANUAL Section 1 Engine Less Major Assemblies enn 1 1 2 Fuel System and Governors
116. LY OF STEERING PUMP a Clean pump exterior Remove woodruff key and capscrews Separate rear cover from body Remove and discard gasket Remove front cover Remove and discard front cover gasket Lift out W shaped gasket seal and neoprene spacer sed figure 9 83 Drive out shaft seal GASKET SHAFT WES SEAL FRONT COVER E W SHAPED SEAL FIGURE 9 83 MATCH MATCH YARS MARKS IVA 4 FIGURE 9 84 9 24 SECTION 9 STEERING b Mark relative position of front and rear bearings and body see figure 9 84 Do not scratch use blue for marking of all pump parts Push on rear of gear shafts until front bearings are free of the housing see figure 9 85 Remove bearings Mark relative position of gears then extract gears Match mark and remove rear bearings 9 58 CLEANING AND INSPECTION FIGURE 9 85 FIGURE 9 86 a Clean all parts thoroughly in cleaning solvent b Check gears and shafts for nicks burrs cracks or chipping Discard defective components c Examine gear chamber of body for contact between gears and body especially the intake cavity of the body Although wear of more than 1 64 of an inch 0 397 mm is abnormal it is not critical if the bearings are not defective The intake cavity is shown in figure 9 86 d Inspect the body and bearing for irregularities of the bore caused by bearing attempting to turn or signs of working s
117. N THRUST WASHER LUBE FITTING FIGURE 9 101 b Inspect all seals Replace any seals that are cut worn or otherwise have a doubtful remaining service life c Inspect all bearings for cracks nicks galling brinelling etc Replace all parts that are defective or have a doubtful remaining service life d Check bearing surfaces for evidence of bearings turning on the shaft If bearing Inner race is turning check concentricity of the shaft Repair or replace if found to be eccentric or badly worn Slight imperfections of the shaft may be removed with fine sandpaper Check the roller bearing surfaces of the shaft for nicks galling and cracks Repair or replace shaft if any of these are found or if a definite step can be felt between the worn and unworn surfaces when checked with fingernail e Clean the shaft cavity of the drums with solvent and dry thoroughly 9 95 REASSEMBLY OF AXLE SHAFT ASSEMBLY a Lubricate all bearing cup bores four then install bearing cups one inner and outer cup per drum into the drums Be sure cups are firmly seated a figure 9 102 b Install inside bearing cones and grease seals into inside hubs on both drums see figure 9 103 c Insert center spacer on shaft and install locking pins sed figure 9 104 d Install shim s in original location see step e paragraph 9 101 Insert shaft assembly Into one drum then insert the other drum into the other side of the shaft assembly
118. NER e a Check filter element and clean as required 500 b Change filter element T BLOWER SCREEN e Clean 43 ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES Q QUARTERLY S SEMIANNUALLY A ANNUALLY B BIENNIALLY H HOURS MI MILES INTERVAL ITEM TO BE INSPECTED _ ITEM NO I PROCEDURE CHECK FOR AND HAVE REPAIRED FILLED OR ADJUSTED AS NEEDED PERFORM ALL OPERATOR PMCS FIRST 8 1000 BATTERY Check specific gravity of electrolyte in each cell 9 WATER SPRAY SYSTEM Inspect and clean if required the tank strainer and nozzles 10 1000 STEERING TRANSMISSION HYDRAULIC RESERVOIR Drain fluid change filters and refill Change both the return filter and suction filter 11 GAGES AND CONTROLS Check operation 12 FINAL DRIVE a Check fluid level add as required 1000 b Drain fluid flush and refill 44 APPENDIX N HYSTER Technical Publication Correction TITLE C350B Parts Manual NUMBER 599352 CONTRACT NUMBER DSA 700 74 C 9024 Make the following corrections to the publication listed above 1 Cross out page 1D05 Air Filters as it does not apply to this roller 2 Include attached page 1E04 in your manual 45 AIR FILTER FOR 3 53 DIESEL ENGINE FIRST USED ON SERIAL NO 889 3300 AND 1485 1546 sma P A REF HYSTER NAME OF PART REF HYSTER NAME OF PART M 1234 QTY NO PART NO 1234 QTY 1 391134 PLATE A
119. ORQUE TORQUE TORQUE Fue um m we um v m ow SAE GRADE 8 CARBON STEEL CAPSCREWS AND PLACEBOLTS NOTE This table lists torque values for standard hardware and is intended as a guide for average applications involving typical stresses and machined surfaces Values are based on the physical limitations of clean plated and lubricated hardware In all cases when an individual torque value is specified it should take priority over values given in this table Replace original equipment with hardware of equal grade GRADE 5 GRADE 8 PLACEBOLT SOCKET HEAD 12 POINT CAPSCREW CAPSCREW FIGURE 2 2 TYPES OF HARDWARE 2 14 SECTION 3 OPERATION 3 1 GENERAL 3 3 The individual assigned to operate the compactor 3 2 This section contains instructions necessary for should always maintain it in good mechanical condition to operation of the C350B Steel Wheel Roller ensure prolonged efficiency Report any mechanical These instructions must be carefully reviewed and failures immediately for correction Even minor failures or understood before attempting to operate the unit Also damage may eventually result in major failures if new operators must be thoroughly trained by a skilled uncorrected operator before attempting to operate the unit unassisted NOTE Follow all operating instructions in the order given on the operating instructions decal se figure 3 3 DIRECTION THROTTLE BAIL AMMETER WATER TEMPERATURE HOUR M
120. PART NO 391369 391373 391462 391471 391486 391487 391488 391489 391490 391491 391492 391493 391494 391495 391497 391520 391569 391570 391612 391614 391649 391727 391729 39173 391750 391826 392015 392016 392018 392092 392189 392954 392971 393059 393078 393079 393080 393081 393082 393083 393084 393085 393086 393087 393089 393091 393092 393093 393094 393156 393254 393305 393307 393322 39346T 393474 393529 393530 393531 393532 PAGE REF NO PART NO 393970 980735 981878 982143 982161 982197 982198 982211 982222 982226 982235 982302 982352 983249 983271 983283 983288 983331 983340 983346 983348 983484 983553 983561 983563 983586 983593 983791 983820 983825 983827 983956 983993 984003 984206 984212 984214 984217 984218 984219 984224 984231 984236 984237 984248 984250 984251 984252 984253 984254 984256 984257 984261 984262 984268 984270 984271 984273 984274 984275 PAGE 2A08 1 02 1 05 1812 2006 181 181 1812 1 03 1C03 1 01 1 0 1012 1 01 1 04 1 04 1813 2006 1012 1EO1 1 01 1 1 03 1005 1Co5 1 01 1 02 1814 1 02 1E02 1 01 1813 1012 1013 1013 1013 1013 1013 1013 1013 1014 1013 101 1013 1013 101 101 101 101 1013 1013 1013 1013 1013 1013 1013 1013 1013 1013 1013 NO 43
121. Port S is for relief flow and is connected to the outlet fitting in the hydraulic tank 9 65 OPERATION see figure 9 92 9 66 low pump speed with input flow equal or less than set controlled flow flow is directed to the controlled flow CF port The pressure compensating pistons prevent or block any flow to the excess flow port Controlled flow in this situation may be used up to the full integral relief valve pressure however the rate of controlled flow will decrease if the input flow decreases 9 67 When input flow is increased the pressure compensated piston in maintaining a fixed pressure drop across the orifice moves further away from its stop position to allow fluid to flow from the input port to the excess flow EF port in maintaining the set controlled flow 9 68 The pilot operated relief valve is factory set to 1500 50 PSI 105 5 3 5 kg cm and cannot be adjusted This valve relieves excessive pressures due to shock loads or other causes 9 69 REMOVAL OF FLOW DIVIDER see figure 9 1 a Remove all hydraulic lines from the flow divider and cap all openings b Unscrew mounting capscrews and remove flow divider from mounting bracket 9 70 DISASSEMBLY OF FLOW DIVIDER see figure CAUTION The piston end cap is spring loaded a Remove end cap spring and piston If further b Remove relief valve assembly SECTION 9 STEERING disasssembly of the relief valve is required follow thes
122. RIMARY COMES W ENGINE 2T 14274 ELBOW 1F02 ELECTRICAL SYSTEM ALTERNATOR 1 09 DISTRIBUTOR o 4 Eoo pi m EE eee pn ih pa PUE Apron eae egets ELECTRICAL 5 5 51 o 1 05 HORN 2 cecccccccceccccecccceeccececcccecccccee STARTING MOTOR 1 1F05 ELECTRICAL SYSTEM FOR DIESEL ENGINE 58 47 58 GREEN 16GA YELLOW HGA gt CQ a w n 14 ime 5 A wom 8 i jw 2 2 85 u nr 31 a 5 Jr Wu EIN e Ee DOM ar 46 4 BLUE 166A arom sox WHITE caf J 0O ORANGE 166A ORANGE 160A a 24 me RED 28 4s 16 42 A BROWN 166A 32 49 LT BROWN 14GA BLACK 126A 5 LI m EL EET 21 TTEEESST I F AM 4 5 ECCO 8 11 am 39 Lm CC p a 38 3 35 60 19 11 30 18 28 22 23 28 4 27 5 26 B FOR 3 53 DIESEL ENGINE REF A HYSTER NAME OF PART QTY REF HYSTER NAME OF PART NO PART NO 1 2 3 4 8 NO PART NO 12 3 4 1 169776 SENDER PRESSURE 18 15154 LOCKWASHER 1 4 2 15002 10 UNF 18 15054 NUT 1 4 UNC 2 15916 LOCKWASHER 10 19 136516 CLAMP gE Gesn 19 16597 CAPSCREW 3 8 UNC X 3 4 G5 3 55983 SWITCH PRESSURE 19 15156 LOCKWASHER 3 8 4 16186 TEE 20 186305 SWITCH IGNITION AND START 4 16151 ELBOW 20 18
123. RIVE 1 23 190597 SEAT SPRING 1 50 190625 BEARING 1 24 190598 SPRING RETAINER 9 51 190626 GASKET 1 25 190599 PIN 1 52 190627 PIN 2 26 190601 GU IDE RETA INER 1 53 190628 COVER FRONT 1 REF 2804 FIRST USED ON SERIAL NO 889 3401 AND A146C 1700 HYSTER PART NO 190583 190629 190630 14591 15483 190633 39347 190635 190636 190583 190637 190638 190639 190640 190642 190643 190645 190644 190646 NAME OF PART 1234 WASHER CAPSCREW O RING PLUG PLUG HOUSING O RING PIN CAP SCREW WASHER TRUNNION SHIM O RING BEARING O RING SEAL PIN SPRING SEAL O RING gt o N 20 GENE REF NO HYSTER PART NO 190647 190648 190649 190653 190650 190651 39347 190652 221763 190654 190655 15923 190658 190575 18473 185903 NAME OF PART 1234 RETAINER SEAL RING RETAINING VALVE CONTROL VALVE GASKET PIN O RING ORIFICE WASHER COTTER SPACER HANDLE SEE 2A10 WASHER NUT WASHER CAPSCREW GASKET INCLUDED IN SEAL 190641 o n mn 2805 FINAL DRIVE FOR C3508 Em 18 CE n FIRE ss 8 e MSS ee E DE ZZA CSRS S REF HYSTER NAME OF PART REF HYSTER NAME OF PART NO PART NO 123 QTY NO PART NO 1235 QTY 1 178149 DRUM DRIVE 1 6 155370 CUP BEARING 2 dem de
124. S FOR WATER SPRAY SYSTEM eene 5 1 TROUBLE ANALYSIS FOR SUNDSTRAND HYDROSTATIC TRANSMISSION TROUBLE ANALYSIS FOR FINAL DRIVE ASSEMBLY TROUBLE ANALYSIS FOR STEERING SYSTEM 2 TROUBLE ANALYSIS FOR BRAKE SYSTEM etes SECTION 6 ELECTRICAL GENERAL rats ALL A LA AA MM MM A E A ELECTRICAL SCHEMATIC FOR DETROIT 6 4 INSTRUMENT PANEL DETAIL FOR DETROIT ENGINE 6 5 ROUTING DIAGRAM FOR DETROIT DIESEL ENGINE 220250509 0 6 6 SUNDSTRAND HYDROSTATIC 6 5 0 tnnt nna GENERAL HYDRAULIC SYSTEM estat annus cat aUud co ert acta a eruca nuca Na oc RAN HYDRAULIC OllL2uu sy OS UTERE 7 23 HYDRAULIC SYSTEM COMPONENTS sss GENERAL CHARGE PUMP CIRCUIT a E ants NEUTRAL CHARGE PUMP RELIEF VALVE 4 4 0020 0 SUCTION FILTER MC RETE COOLING uu uu a ieee aaa aa aaa ay Suma aqha cde esc ced EE OIL COOLER BY PASS VALVE brune SHUTTLE VALVE e eate rE E E os ML OTRA eT hahay CONTROL FUNCTION I MAKEUP a anan aa au aqu R Qa aqha aqhay Rana Baba aaye HYDROSTATIC PUMP ASSEMBLY rn oa III II 7 27 VARIABLE DISPLACEMENT HYDROSTATIC n
125. SSEMBLY FUNCTION REMARKS FUEL SYSTEM Fuel Injector Test Replace Fuel Pump Replace Repair Air Cleaner Service Replace Repair Air Cleaner Element Replace Blower Air Intake Service Replace Repair Fuel Tank Service Replace Repair Lines amp Fittings Replace Governor Engine Speed Test Adjust Replace Repair The subcolumns are as follows C operator crew F direct support D depot O organizational H general support 15 Section Il MAINTENANCE ALLOCATION CHART ROLLER MOTORIZED STEEL WHEEL 2 DRUM TANDEM 10 14 TON CCE 1 2 3 4 6 GROUP COMPONENT MAINTENANCE MAINTENANCE Category NUMBER ASSEMBLY FUNCTION REMARKS Fuel Filters Service Fuel Filter Element Replace Throttle Control Linkage Adjust Replace EXHAUST SYSTEM Muffler amp Exhaust Pipes Replace COOLING SYSTEM Radiator Service Replace Repair Thermostat Replace Hoses amp Clamps Replace Water Pump Replace Repair Pan Assembly Replace Repair Fan Belts Inspect Adjust Replace ELECTRICAL SYSTEM Alternator Test Replace Repair The subcolumns are as follows C operator crew F direct support D depot O organizational H general support 16 Section Il MAINTENANCE ALLOCATION CHART ROLLER MOTORIZED STEEL WHEEL 2 DRUM TANDEM 10 14 TON CCE 1 2 3 4 6 GROUP COMPONENT MAINTENANCE MAINTENANCE Category NUMBER ASSEMBLY FUNCTION REMARKS Alternator Drive Belt Inspect Adjust Replace Star
126. STARTING COMES WITH 45 ENGINE needa SHE FE 47 132131 CL AMP 48 181898 WIRE 50 391750 HARNESS WIRING 1 51 148658 CONNECTOR 1 52 SWITCH MICROe SEE 2803 REF 48 1 REF HYSTER NAME OF PART QTY NO PART NO 123 B 53 393091 WIRE 54 393092 WIRE 55 PUMP SPRAY PAGE 83 REF 33 56 215017 PLATE NAME 57 20 223 BOOT n 2 58 132972 CLAMP 2 56 54 60 156133 NUT 3 8 UNC 4 1F08 STARTING MOTOR REF HYSTER NAME OF REF HYSTER NO PART NO 1234 Ta NO PART NO 123 50 166541 HOUSING DRIVE END 57 156336 SPRING 1 50 112812 BUSHING 58 50 COLLAR 50 137699 HOUSING DRIVE END B 166479 LOCKMIRE 1 50 5585 BUSHING 9 123675 PLATE CENTER BEARING 1 51 236078 STUD SHIFT LEVER 59 SHI SEAL OIL 1 52 97497 WASHER THRUST 1 59 131172 BUSHING 1 2 137698 WASHER THRUST 3s 59 131173 GASKET 1 53 97498 RING RETAINING 1 59 55978 WASHER lt CENTER BEARING 1 53 236081 RING RETAI se 60 151840 GROMMET FRELO FRAME 85 54 97499 1 60 167010 GROMMET F IELD ERAME 1 54 236082 62 151837 INSULATION FIELD TEQIL x 5 5894 1 63 16598 CAPSCREW 3 8 UNC X 7 8 2 56 156283 1 63 16828 3 8 UNC X 1 1 4 6 1 9 6 15156 LOCKMASHER 3 8 3 BUSHING DILLESS ae HORN 17 2 2 LP 4 21 20 n C 19 i 18 T CC 0 20 21 q 25
127. STER NAME OF PART REF HYSTER NAME OF PART 0 PART NO 123 4 QTY NO PART NO 1234 QTY 1 15373 1 2 21 192335 HOSE 1 2 184313 U BOLT 28 15329 PLUG DRAIN 1 22 15154 LOCKWASHER 1 4 8 29 18466 CAPSCREW 1 4 UNC X 1 1 4 G5 4 4 199400 NOZ 21 E SPRAY 10 29 15054 NUT 1 4 UNC 5 184317 CONNECTOR 2 29 15154 LOCKWASHER 1 4 4 6 69240 L BOW 1 30 184322 BLOCK SUPPORT 2 6 14546 ELBOW 1 31 184324 VALVE 1 7 116486 HOSE 1 32 16116 BUSHING 1 8 16457 ELBOW 1 33 184325 PUMP AND MOTOR 1 11 185321 PLATE 1 33 196281 MOTOR 1 12 169708 HOSE 1 33 197861 CAP BRUSH 2 13 169693 VAL VE 1 33 197862 BRUSH AND SPRING 2 14 153685 HOSE 2 34 196431 SLINGER 1 15 184320 TUBE 1 35 196284 SEAL 1 16 115983 GROMMET 1 36 196283 IMPELLER 1 17 14546 EL BOW 1 37 196286 GASKET 1 18 390016 PIPE MANIFOLD 1 38 196285 SCREW AND WASHER 8 19 184327 PLATE 2 39 249292 COVER 1 20 199398 PIPE MANIFOLD 1 40 249291 800Y PUMP 1 id 1 15329 PLUG DRAIN 1 21 14652 TEE 1 2 14678 CONNECTOR 1 22 136516 CLAMP HOSE 1 43 15056 NUT 3 8 UNC 1 23 18535 CAPSCREW 3 8 UNC X 5 8 G5 4 43 15156 LOCKWASHER 3 8 1 23 15156 LOCKWASHER 37 8 4 24 17306 ELBOW 1 USES 25 17309 EL BOW 2 25252222 4 26 199401 FIL TER SUMP 1 1A08 DECALS AND PAINTING INSTRUCTIONS Lm 4 QU tit tovs KERE DOWN MERE SO m tF Y s o nd REF HYSTER NAME OF PART REF HYSTER NAME OF PART NO PART NO 123 QTY NO PART ND 123 4 QTY 1 393321 PLATE CDOVER 1 5 15155 WASHER 5 1
128. T CENTER POST 161151 WASHER BACK UP 161147 POST CENTER 237011 POST CENTER HEAVY DUTY INCLUDED IN SEAL AND ELEMENT KIT 237016 2803 HYDRAULIC PUMP FIRST USED ON SERIAL NO B89C 3401 AND A146C 1700 REF HYSTER NAME OF PART REF HYSTER NAME OF PART NO PART NO 1234 QTY NO PART NU 1234 ary 185902 PUMP HYDRAULTC 1 27 190602 RETATNER SLIPPER 1 1 190573 PUMP CHARGE 1 28 190603 PISTON 9 1 190576 PUMP 1 29 190604 PLATE THRUST 1 2 18478 CAPSCREW 1 4 UNC X 3 65 4 30 190605 CAPSCREW 4 3 221763 WASHER 4 31 190606 RETAINER SLEEVE 2 4 190577 GASKET 1 32 190607 SLEEVE SERVO 1 5 190578 VAL VE CHECK 2 32 218051 SLEEVE 2 6 190580 O RING 1 33 39673 O RING 1 7 190581 CAPSCREW 34 39671 O RING 1 8 190582 CAPSCREW 5 35 190611 PISTON SERVD 2 9 190583 WASHER 8 35 190616 PISTON 2 10 190584 CAP END 1 36 190612 CAPSCREW 1 11 190585 SHIM AR 37 190613 WASHER 1 12 190586 GASKET END CAP 1 38 190614 GUIOE SPRING 1 13 190587 BEARING 1 39 190615 SPRING 1 14 190588 PIN 1 40 190617 PIN 2 15 190589 PLATE VALVE 1 4 190618 RING RET AINING 16 190590 CYLINDER BLOCK 1 42 190619 LINK 1 16 190600 BLOCK 1 43 190620 PLATE SWASH 1 17 190591 PLATE BEAR ING 1244 190617 2 18 190592 PILOT 1 45 190618 RING RETAINING 4 19 190593 RING RETAINING 1 46 190621 PIN 1 20 190594 RETAINER SPRING 1 47 190622 RING RETAINING 2 21 190595 GUIDE SPR ING 1 48 190623 LINK 1 22 190596 SPRING CYLINDER BLOCK 1 49 190624 SHAFT D
129. TION 8 FINAL DRIVE C Assembly of Outer Planetary Assembly Place the outer planetary assembly on a protective surface with the large splined hub upward Note that the outer planetary pinions do not have a longer hub as do the inner planetary pinions The outer planetary pinions are symmetrical and can be installed correctly with either side towards the splined hub sed figure 8 22 d Install the snap ring bearing cups and bearing cones in each pinion gear Place thrust washer between pinion gear and planetary carrier on the capscrew side of the pinion gear sed figure 8 23 e Align the gear thrust washer and planetary carrier and insert the riding pin Install the spacer lockplate and capscrew Rotate the planetary pinion gear to insure proper seating of the bearings and thrust washer Torque the capscrew per specification back off one flat and lock Then install the other two pinion gears in the same manner see figure 8 24 FIGURE 8 22 SECTION 8 FINAL DRIVE f Place the planetary anchor flange on a protective surface with the oil breather side up Press the bearing into the flange and install the snap ring Press the oil seal into the flange until the seal bottoms on the shoulder provided see figure 8 25 Install dust protector onto anchor flange and tighten dust protector mounting bolts g Assembly of drive drum hub Press the bearing into the drum hub seg figure 8 26 mae FIGURE 8 24
130. TM 5 3895 348 14 amp P 1 TECHNICAL MANUAL OPERATOR S ORGANIZATIONAL DIRECT SUPPORT GENERAL SUPPORT AND DEPOT MAINTENANCE MANUAL INCLUDING REPAIR PARTS INFORMATION AND SUPPLEMENTAL OPERATING MAINTENANCE AND REPAIR PARTS INSTRUCTIONS ROLLER MOTORIZED STEEL WHEEL2 DRUM TANDEM 10 14 TON CCE HYSTER MODEL C350B D NSN 3895 00 578 0372 HEADQUARTERS DEPARTMENT OF THE ARMY 27 MARCH 1981 WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING Never shut down the engine when attempting to stop the unit This will reduce or eliminate all dynamic braking capabilities Always use extreme caution when positioning scrapers as they are under considerable spring tension and may become sharp when worn Always support ballast securely when removing or installing ballast mounting capscrews In order to check the high pressure relief valve it is necessary to bring the unit to stall CAUTION must be taken to ensure the safety of personnel when attempting to stall the unit Changing the quantity of shims in the relief valves is not recommended When adjusting the Displacement Control Valve the drive drum must be safely blocked off the ground Any movement of the Control Valve Spool causes the unit to shift out of neutral and the drum will turn CAUTION personnel to stand clear of the drive drum The brake assembly will be removed prior to drive drum removal Blo
131. TR CLEANER 1 6 391051 HOSE 1 2 16598 CAPSCREW 3 8 UNC X 7 8 5 7 115696 CLAMP 1 2 17428 NUT 3 8 UNC 5 8 169096 1 3 182645 FILTER AIR SEE 1008 1 9 168846 UNOICATOR RESTRICTION 1 4 2 1 5 1 138718 BANO MOUNTING 10 170306 GASK T 78286 Ct KEY B FOR 3 53 DIESEL ENGINE ONLY REF HYSTER NAME OF PART PART NO 123 n lt amp 156958 CLAMP REF NAME OF PART NO PART NO 123 182645 FIL TER ATR 169299 BODY 156954 ELEMENT cor O RING 141266 262292 156961 46 APPENDIX O HESTER TECHNICAL PUBLICATION CORRECTION TITLE C350B Service Manual NIMBER 7109M CONTRACT NUMBER DSA 700 74 C 9024 Make the following corrections to the publication listed above 1 Section 2 Table 2 11 page 2 16 entitled BRAYR SYSTEM SPECIFICATIONS Torque specification on BRAKR SEART NUT reads 100 ft lbs 13 8 g m and should read 26 ft lbs 3 6 kg m maximum Please note change manual 2 Figure 4 14 ang figure 6 4 page 6 4 nave been revised to include the horn circuit The revised figures are attached please include in the manual 3 Figure 7 40 page 7 32 Bhows two 2 arrows pointing to control pressure port The top upper most arrow is incorrect Cross out the upper most arrow 4 is incorrect Cross out the entire figure Case pressure must be checked by tying into the case drain line on top of the hydros
132. TTER 3 32 X 3 4 1 17 54872 RIVET 1 45 141 ROD END 1 18 54864 BRACKET PIVOT 2 46 15026 NUT JAM 3 8 1 19 54865 SPACER 1 47 213276 HUB 1 20 54873 SPACER 2 LOLS ly 21 210615 SPACER 2 t rri etii 22 210616 FITTING 1 pp E a 23 210617 SPACER 1 48 139773 SWITCH MICRO 1 24 4860 TUBE ADJUSTING 1 49 165786 COVER 1 25 156243 PLATE SUPPORT RH 1 50 16743 LOCKWASHER 6 2 26 15055 NUT 5 16 UNC 4 51 12425 NUT 46 UNF 2 27 15155 LOCKWASHER 5 16 4 52 15155 LOCKWASHER 3 16 2 28 191342 CABLE PARKING BRAKE 1 53 17484 CAPSCREW 5 16 UNF X 3 8 GS 2 28 128408 CLAMP 1 5 18815 SCREW 86 UNF X 1 1 4 2 28 15155 LOCKMASHER 5 16 1 28 15055 NUT 5 16 UNC 1 TONNE TIT 2D02 STEERING SYSTEM KEY gt D mc EE AER ACA C FOR 3 53 OLESEL ENGINE 2D03 STEERING SYSTEM REF HYSTER NAME OF PART PART 0 1234 1 ss SOCKET ROO END SEE 2007 1 REF 17 2 17306 ELBOW 3 CYLINDER STEERENG SEE 2007 3 REF 1 1 4 96522 HOSE HYDRAUL IC 1 5 73470 HOSE HYORAUL IC 1 6 16458 ELBOW 2 14761 NUT 1 7 1551584 HOSE HYDRAUL IC 2 8 16541 CONNECTOR 4 8 16484 O RING 1 9 seses CONTROL STEERING 2004 1 10 139150 CAPSCREM 3 8 UNC X L 1 2 2 11 155387 WHEEL STEERING 1 13 181916 COVER DUST 2 TT TFET SET 15 158406 HOSE TO OIL COOLER HH alga eee UHR avt 19 15924 LOCKWASHER 1 2 4 19 15156 LOCKWASHER 3 8 2 REF HYSTER NAME OF PART QTY NO PART NO
133. Technical Manual B End Item Identification C Noun Description D Drawing or Specification No Reference Identification 32 MANDATORY ENTRY FOR CCE Identification of reference specified in cc 70 APPENDIX K SAMPLE FORMAT MILSTRIP REQUISITION FOR NON NSN MANUAL DOCUMENT NUMBER MANUFACTURER S CODE UNIT PART NUMBER QUANTITY PART NUMBER 55 AE ERE DATE E negum 1 oare 1 SERIAL TIONER REJECT CODE FOR USE BY SUPPLEMENTARY ADORESS 46 47 s0 s1 les 64 Jes 66167 ee 6 7 71 74178176 77 ves o IDENTIFICATION DATA 1 MANUFACTURER S CODE amp PART NO When they exceed Card Columns 8 thru 22 3 MANUFACTURER S CATALOG IDENTIFICATION AND DATE 4 TECHNICAL ORDER NUMBER 5 TECHNICAL MANUAL NUMBER 6 NAME OF ITEM REQUESTED DESCRIP N OF ITEM RE 55205 COLOR END ITEM APPLICATION AND SOURCE OF SUPPLY Kapu ipp S assia MODEL NUMBER P 5 SERIAL NUMBER 2 MANUFACTURER S NAME FOLD Ling Ling 9 Clear Text Name and Address DD sare 77 1348 6 24 NON NSN REQUISITION MANUAL 33 INSTRUCTIONS This form will only be used in those cases where the manufacturer s code and part number exceed the spaces allocated in card columns S 22 of the requisition CARD MATUDATORY ENTRY COLUMN DESCRIPTION DATA FOR CCE 1 3 Document
134. USTMENT ener TRANSMISSION REPAIR a HYDROSTATIC PUMP REMOVAL III cdi atra alta REMOVAL OF HYDROSTATIC 9 REPLACEMENT OF CHARGE REPLACEMENT OF CHECK VALVES 99 9 REPLACEMENT OF ROTARY BY PASS VALVE AND MOTOR MANIFOLD errs ivr sss REPLACEMENT OF HIGH PRESSURE RELIEF VALVES I I II REPLACEMENT OF DISPLACEMENT CONTROL VALVE JII I I I REPLACEMENT OF MOTOR OR PUMP SHAFT SEAL II I enn REMOVAL OF DRIVE REMOVAL OF MOTOR CARRIER eene 7 44 DISASSEMBLY OF MOTOR CARRIER cete teet tnn 7 44 REASSEMBLY OF MOTOR CARRIER 7 46 INSTALLATION OF MOTOR CARRIER 02000000004000 INSTALLATION OF DRIVE DRUM 20000000000 INSTALLATION OF HYDROSTATIC MOTOR ccscscssessssssssesscsecssecsesssasecsesucetscsesssatsessatecsenseases INSTALLATION OF HYDROSTATIC PUMP 7 51 CLEANING THE HYDRAULIC SYSTEM ettet teet teet SUNDSTRAND TRANSMISSION START UP PROCEDURE BY PASS c i ti iM M MEE IE BY PASS CONTROL ADJUSTMENT ettet teet teet
135. WATER SPRAY SYSTEM Once the motor is electrically energized it rotates the centrifugal pump This causes the water to gravity feed from the tank into the pump the pump then pressurizes the water to about 10 PSI 0 7 kglcm Water then flows through the lines to the spray manifolds Each manifold distributes the water to the drum s 11 6 The non corrosive sump filter normally requires no maintenance because of the self cleaning action of the water washing back and forth in the tank The filter should be cleaned when the tank needs cleaning because of excessive accumulation of foreign material sed figure 11 2 11 7 CHECKS AND ADJUSTMENTS 11 8 SPRAY MANIFOLDS 11 9 The water spray angle is adjusted by rotating the spray manifold Check to see that the spray pattern completely covers the drum s Adjust the spray pattern so that spray DRIVE ROLL PIPE FIGURE 11 1 FIGURE 11 2 strikes drum at upper edge of coco mat Adjust as follows a Loosen the manifold mounting U bolts b Rotate the manifold to give desired spray pattern c Re tighten the U bolts when desired pattern adjustment is completed MOTOR BRUSH 2 REQ D MOTOR ASSEMBLY SEAL IMPELLER SECTION 11 WATER SPRAY SYSTEM 11 10 WATER PRESSURE 11 11 Water pressure and flow can be varied by turning the spray control valve located in the operator s compartment directly below the steering wheel If greater pre
136. accordance with DA Form 12 25B Organizational maintenance requirements for Roller Vibratory Selfpropelled U S GOVERNMENT PRINTING OFFICE 1996 409 304 RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS SOMETHING WRONG WITH PUBLICATION FROM PRINT YOUR UNIT S COMPLETE ADDRESS DOWN THE DOPE ABOUT IT ON THIS FORM CAREFULLY TEAR IT QUT FOLD IT AND DROP IT IN THE MAIL pa GO C SENT IET ao IN THIS SPACE TELL WHAT IS WRONG I AND WHAT SHOULD BE DONE ABOUT IT PRINTED NAME GRADE OR TITLE AND TELEPHONE NUMBER SIGN HERE DA Pd ro 2028 2 PREVIOUS EDITIONS P S IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR JUL 79 ARE OBSOLETE RECOMMENDATION MAKE A CARBON COPY OF THIS AND GIVE IT TO YOUR HEADQUARTERS THE METRIC SYSTEM AND EQUIVALENTS LINEAR MEASURE 1Centimeter 10 Millimeters 0 01 Meters 0 3937 Inches 1 Meter 00 Centimeters 1000 Millimeters 39 37 Inches 1 Kilometer 1000 Meters 0621 Miles SQUARE MEASURE 154 Centimeter 100 Sq Millimeters 0 155 Sq Inches 154 Meter 10 000 Sq Centimeters 10 76 Sq Feet 154 Kilometer 1 000 000 Sq Meters 0 386 Sq Miles WEIGHTS CUBIC MEASURE 1Gram 0 001 Kilograms 1000 Milligrams 0 035 Ounces 1Cu Centimeter 1000 Cu Millimeters 0 06 Cu Inches Kilogram 1000 Grams 22Lb 1Cu Meter 1 000 000 Cu Centimeters 25 31 Cu Feet 1 Metric 1000 Kilograms 1 Megagram 11 Short Tons TEMPERATURE F 32
137. ace Repair FRAME Frame Assembly Repair BODY HOOD amp COWLING Hood amp Cowling Replace Repair Seat Assembly Replace Repair Tool Box Replace Repair EARTH MOVING EQUIPMENT COMPONENTS Roll Scrapers Service Replace Repair Roll Mat Replace The subcolumns are as follows C operator crew F direct support D depot O organizational H general support 21 Section Il MAINTENANCE ALLOCATION CHART ROLLER MOTORIZED STEEL WHEEL 2 DRUM TANDEM 10 14 TON CCE 1 2 3 4 6 GROUP COMPONENT MAINTENANCE MAINTENANCE Category NUMBER ASSEMBLY FUNCTION REMARKS Water Spray System Tank Service Spray Pump amp Motor Replace Repair Water Tank Inlet Screen Service Replace Water Tank Sump Filter Service Replace Spray Manifolds amp Nozzles Service Replace Repair Spray Pipes Valves amp Hoses Replace Repair The subcolumns are as follows C operator crew F direct support D depot O organizational H general support 22 MAINTENANCE ALLOCATION CHART FOR Roller Motorized Steel Wheel Model c350B D SECTION III TOOL AND TEST EQUIPMENT REQUIREMENTS TOOL OR TEST EQUIPMENT REFERENCE CODE MAINTENANCE CATEGORY NATIOHAL NATO NOMENCLATURE Unless otherwise noted functions can be accomplished contained in the following Shop Equip Contact Maint TRK MTD SC 4940 97 C1IE 05 Shop Equip Org Repair Light RK MTD SC 4940 97 CL D4 Tool Kit Automotive Maint Org M
138. ain cock The fuel will drain more freely if the retaining nut at the inlet outlet head is loosened slightly b Support the bowl then unscrew the retaining nut and remove the bowl and element C Remove and discard the element and gasket Clean the bowl with fuel oil and dry thoroughly with a clean lint free cloth and compressed air d Place a new filter element that has been thoroughly soaked in clean fuel oil over the stud and push the element down onto the seat Close the drain cock and fill the bowl approximately two thirds full of clean fuel oil 4 7 REMOVE ER RETAIN REMOVE AND CLEAN FILTER ELEMENT AND INTAKE HOUSING SECTION 4 HYSTER CARE MAINTENANCE FIGURE 4 7 AIR CLEANER MAINTENANCE e Install a new gasket in the inlet outlet head Place the bowl with element into position under the inlet outlet head and start the retaining nut into the bowl stud f Tighten the retaining nut only enough to prevent fuel leakage Remove the plug in the inlet outlet head and fill the bowl with clean fuel oil 4 19 AIR FILTRATION SYSTEM 4 20 AIR CLEANER FILTERS S sed figure 4 7 4 21 The Detroit Diesel restriction indicator should be checked every eight hours of operation or daily 4 22 The air cleaner element is a reusable element that can be cleaned periodically The element should be replaced however after ten cleanings or when the specified change interval occurs Remove and clean the element
139. aint Common 1 SC 4910 95 CL A74 Tool Kit Automotive Maint Org Maint Common 2 SC 4910 95 CL A72 Tool Kit Light Weight 5180 90 CL W 26 Shop Equip Auto Maint and Repair Org Maint Supp 1 SC 4910 95 CL A73 Shop Equip Welding Field Maint SC 3470 95 CL A08 Tool Set Veh Full Tracket Sugg 2 SC 4940 95 CL A08 Shop Equip Gen Purp Repair Semitrlr MTD SC 4940 97 C ED 3 Tool Kit Automotive Fuel and Elec Sys Repair SC 4910 95 CL A50 Tool Kit Master Mechanic and Equip Maint and Repair SC 51S0 90 CLEO5 23 TOOL STOCK NUMBER all maintenance with the tools common two sets 49 40 00 294 9518 1 940 294 9516 4910 00 754 0654 4910 00 754 0650 SC 51t0 00 177 7033 4910 00 754 0653 3470 00 357 7268 49400 00 754 073 4914000 287 4894 5180 00 754 0655 5180 00 699 5273 NUMBER T10138 T13152 W32593 W32730 W33004 W32867 T16714 W65747 T10549 W32456 W45060 MAINTENANCE ALLOCATION CHART FOR Roller Motorized Steel Wheel Model C350B D SECTION III TOOL AND TEST EQUIPMENT REQUIREMENTS TOOL OR TEST EQUIPMENT REFERENCE MAINTENANCE NATIONAL NATO TOOL CODE CATEGORY NOMENCLATURE STOCK NUMBER NUMBER Shop Set Fuel and Elec 4910 00 754 0714 T30414 Sys Field Maint Basic SC 4910 95 CL AO1 Shop Set Fuel and Elec 4910 00 390 7775 T30688 Sys Field Maint Basic Sup 2 SC 4910 95 CL A65 Shop Equip Machine Shop 3470 00 754 0708 T15644 Field Maint B
140. aintenance Commander 2 3 Modifications Modifications will be accomplished by the end item manufacturer after TARCOM approves the field campaign or modification plan See Appendix D 2 4 Equipment Improvement Recommendations EIR Equipment Improvement Recommendations will be submitted in accordance with TM 38 750 2 5 Equipment Readiness Reporting Readiness Reporting will be accomplished as required by the current TM 38 750 2 6 Maintenance Expenditure Limits The average life expectancy for the Roller is 15 years PERCENT OF REPAIR YEAR 5096 1982 4596 1985 40 1987 35 1989 30 1991 20 1993 100 1994 2 7 Shipment and Storage a Shipment and Storage Refer to TB 740 97 2 for procedures covering preservation of equipment for shipment and storage b Administrative Storage Refer to TM 74D0 90 1 for instructions covering administrative storage of equipment 2 8 Destruction to Prevent Enemy Use Refer to TM 750 244 3 for procedures covering destruction of equipment to prevent enemy use 2 9 Fire Protection a A hand operated fire extinguisher may be installed at the discretion of the using unit b Approved hand portable five extinguishers are listed in TB 5 4200 200 10 2 10 Basic Issue Items List BILL See Appendix E for a list of items which accompany the end item or are required for operation and or operator s maintenance 2 11 Maintenance and Operating Supply List See Appendix L for a list of maintenance an
141. all out of the pinion gear as soon as they are free to do so Keep each cone with its respective cup by tying them in position in the pinion gears Remove the other two pinion gears from the carrier using the same procedure Keep each gear and its associated parts separate Do not mix component parts Inspect each bearing cup and cone including those not removed from the pinion gears and replace if rollers or cups are worn pitted or damaged in any way Remove parts needing replacement see figure 8 16 V Remove bearing cups from planetary pinion with a small soft punch and hammer NOTE A snap ring separates and locates the two cups in each pinion gear Remove the lower cup only i e the pinion must be turned over once to remove both cups see figure 8 17 w Remove the snap ring with a screwdriver or a small pry bar and inspect for chipping or wear Replace if necessary see figure 8 18 X Place the outer planetary assembly on a protective surface with the large splined hub upward Follow steps q through w of the inner planetary disassembly procedure BEARING CONE FIGURE 8 16 SECTION 8 FINAL DRIVE 8 7 CLEANING AND INSPECTION 8 8 All gears including both sun gears carrier pins plates and capscrews should be cleaned in solvent Inspect each gear for galling nicking chipping and cracking especially at the root of each tooth 8 9 All bearings should be washed in fresh solvent Agitate i
142. aph 3 29 for a complete explanation of the by pass valve and its function 7 215 BY PASS CONTROL ADJUSTMENT a Adjust wire stop on control cable for 1 8 114 in 3 2 6 4 mm free play see figure DETROIT ENGINES BY PASS VALVE LEVER REF BATTERY BRACKET STOP FOR 1 8 In 3 175 mm TO 1 4 In 6 35 mm FIGURE 7 105 7 53 SECTION 8 FINAL DRIVE FIGURE 8 1 8 1 8 1 GENERAL 8 2 This section contains a description of the final drive operation and overhaul instructions for components of the drive drum assembly Overhaul instructions include removal dis assemly inspection reassembly and installa tion of all components of the final drive assembly Design specifications are given in Section 2 Troubleshooting instructions are given in Section 5 8 4 C350B FINAL DRIVE DESCRIPTION see figure 8 2 8 5 The final drive consists of an internal double reduction planetary system located within the left side of the single drive drum see figure 8 1 Torque is transferred from the hydraulic motor across the drum to the planetary system by the drive shaft A A sun gear B Is splined to this shaft and drives the smaller of the two planetary gear sets C in the opposite direction This gear set C in turn attempts to turn the ring gear D bolted directly to the drive drum in the same direction gear set C is traveling but does not possess the mechanical advantage to do so
143. apter Grease Gun Coupling Flex 26 APPENDIX F INITIAL RECOMMENDATION PRESCRIBED LOAD LIST PLL AUTHORIZED STOCKAGE LIST ASL END ITEM Roller Motorized Steel Wheel 2 Drum Tandem 10 14 Ton CCE HYSTER N A 3895 00 578 0372 TO Feb 79 FOR NO OF END ITEMS U M SMR CODE NATIONAL STOCK PART NUMBER FSCM RRRA NUMBER 1 5 1 5 6 20 21 50 2940 00 019 8087 5574978 Element Engine Oil Filter 2910 00 792 8985 5774961 Element Primary Fuel Filter 2910 00 890 2436 5573261 Element Secondary Fuel Filter 3030 00 899 4888 154382 V Belt Alternator 2940 00 755 6584 180595 Element Hydraulic Oil Filter 2940 00 368 8338 156954 Element Air Cleaner 3030 00 982 1212 5126447 V Belt Matched Fan 2540 01 042 5750 157321 Cocoa Mat PAGE OF 27 NSN 4120 01 013 1355 472D 01 013 1354 2340 00 019 8087 2910 00 792 8985 2910 00 890 2436 5930 00 220 6716 6620 00 933 3594 5925 01 010 1084 5920 00 925 2639 3030 00 899 4888 2940 00 755 6584 4330 00 355 7750 5330 01 016 7837 2530 00 158 1312 5330 01 016 7838 4320 00 237 3947 6240 00 733 2984 6240 00 155 7859 5920 00 131 9915 5920 00 925 2640 5330 01 013 7673 2940 00 368 8338 4320 01 032 7972 4320 01 032 7973 4320 01 032 7974 3030 00 982 1212 2540 01 042 5750 5330 01 043 1803 6140 00 91 7 2141 P 4 100434 169107 5574978 5774961 5573261 169776 77328 163762 53123 154382 180595 237014 243868 189585 223641 158913 156776 MS15571 8 F02832V20A 53124
144. art subassembly module component or assembly end item or system 11 j Overhaul That maintenance effort service action necessary to restore an item to a completely serviceable operational condition as prescribed by maintenance standards i e DM IR in appropriate technical publications Overhaul is normally the highest degree of maintenance performed by the Any Overhaul does not normally return an item to like new condition k Rebuild Consists of those services actions necessary for the restoration of unserviceable equipment to a like new condition in accordance with original manufacturing standards Rebuild is the highest degree of materiel maintenance applied to Army equipment The rebuild operation includes the act of returning to zero those age measurements hours miles etc considered in classifying Army equipments components 3 Column entries Columns used in the Maintenance allocation chart are explained below Column Group Number Column lists group numbers the purpose of which is to identify components assemblies subassemblies and modules with the next higher assembly b Column 2 Component Assembly Column 2 contains the noun names of components assemblies subassemblies and modules for which maintenance is authorized c Column 3 Maintenance Functions Column 3 lists the functions to be performed on the item listed in Column 2 d Column 4 Maintenance Category Column 4 specifies by the listing of
145. as follows NOTE Clean the exterior of the air cleaner body before disassembly a Loosen the retainer bar securing the element Then remove the retainer bar from the housing b Remove the element from the housing c Tap the element lightly against a smooth surface while keeping it parallel to the surface to avoid damage to the end cap d Blow out the element in the opposite direction of normal air flow using compressed air Do not exceed 30 PSI 2 1 kg cm2 air pressure against the element e Carefully inspect the dry element for damaged paper pleats by placing a light inside of the element Replace element if it is damaged or after ten cleanings f Clean the intake housing with a lint free cloth moistened with cleaning solvent before installing element g On Detroit Diesel units reset the restriction indicator by pushing the reset button at the end of the indicator body after reassembly h Check rubber dust unloading valve for cracks clogging or deterioration SECTION 4 HYSTER CARE MAINTENANCE 4 25 DIESEL CRANKCASE BREATHER figure 4 9 4 26 Remove the crankcase breather from the engine each 1 000 hours of operation and wash the breather in clean fuel oil Dry thoroughly with compressed air Also clean the breather cap mounted on the valve rocker arm cover in clean fuel oil every time the engine oil is changed 4 27 DETROIT DIESEL BLOWER SCREEN sed figure 4 10 4 28 Inspect the blower scre
146. asic SC 3470 95 CL Ao2 Measuring and Lay Out Tool 5280 00 511 1950 W44512 Set Mach SC 5280 95 CL A02 Tool Kit Body and Fender 5180 00 754 0643 W33689 Repair Wrench Set Socket 3 4 49400 754 0743 W65747 Drive Hex Type Wrench Torque 3 4 Drive 5120 00 542 5577 Y84966 500 Ib Cap Multimeter 6625 00 999 7465 80242 APPENDIX D CCE MANUFACTURER FIELD CAMPAIGNS AND MODIFICATION PROCEDURES APPROVAL OF FIELD CAMPAIGN OR MODIFICATION PLAK REPORT OF APPLIED MODIFICATION REPORT OF DEFICIENCY REPORT OF DEFICIENCY THEATER MATERIEL MANAGEMENT CENTER FIELO CAMPAIGN OR MODIFICATION PLAN REPAIR OR REPLACE wama FLOW OF REPORTING FIELD CAMPAIGN OR MODIFICATION PLAN 25 NOMENCLATURE MANUFACTURER SERIAL NUMBER RANGE 1 2 MFR PART NO MVR FED CODE NATIONAL STOCK NUMBER 7520 00 559 9618 7510 00 889 3494 4210 00 889 2221 4930 00 277 9525 4930 00 204 2550 4930 00 288 1511 APPENDIX E BASIC ISSUE ITEMS LIST 3 4 S QUANITITY FURNISHED W EQUIP DESCRIPTION UNIT OF ISSUE DESCRIPTION USABLE ON CODE REF No amp IFR CODE NOTE The following items are overpacked with the roller Case Cotton Duck MIL B 11743 81349 Log Book Binder MIL B 43064 NOTE The following items are authorized but not issued with the roller Extinguisher Fire Dry Chemical Grease Gun Hand Adapter Grease Gun Coupling Rigid Ad
147. aulic tank It serves as the suction filter for the transmission inlet oil It is a 10 micron filter There is no by pass valve on the suction filter 7 103 COOLING CIRCUIT 7 104 The cooling circuit maintains a flow of oil through the transmission for cooling purposes Excess oil from the low charge pressure relief valve enters the motor housing Flow is then directed through drain lines to the pump housing The circuit is completed from the pump housing through the oil cooler to the oil tank When the hydrostatic pump is in SECTION 7 TRANSMISSION METERED OIL DISPLACEMENT CONTROL VALVE CONTROL HANDLE 2 2 REVERSIBLE ore HIGH PRESSURE OIL FIXED DISPLACEMENT VARIABLE MOTOR DISPLACEMENT Sa LOW PRESSURE OIL LOW RELI VALVE OUTPUT oN CHARGE PRESSURE SHAFT N RELIEF VALVE AC 5 A NI s 55555 SS e aw p www IN k 1 f d r 5 p 24 EN m ERAN lt Wy REST eos PITTI ZI AR TO MOTOR A pa SS i T CASE SN gt i 14 6 fW Bani FSSA Ab Ae po Ve c VALVE PUMP SWASHPLATE ic VACUUM LOW PRESSURE OIL CYLINDER TO MICRON SANSE FiLTER C D 01 CHARGE PRESSURE Sp RESERVOIR HEATEXCHANGER HIGH PRESSURE BE HEAT EXCHANGER 8Y PASS FIGURE 7 33 SUNSTRAND TRANSMISSION IN FORWARD
148. by Direction Throttle Bail This control shuts off air to engine Lever must be manually re set at the engine Refer to para graph 3 28 CAUTION The EMERGENCY STOP should be used ONLY in the event of serious engine mal functions In BRAKE ON position up lever holds park brake shoes in applied position In BRAKE OFF position down lever releases linkage that holds park brake shoes in applied position Controls oil flow to and from steering cylinder Hydrostatic steering Shuts off water supply to guide roll when water spray is required only on drive roll or down a grade Never travel across a slope Always travel up d Always set the park brake before dismounting the unit e Never shut down the engine when traveling downhill Always move the Direction Throttle Bail toward the neutral position to slow the unit f Report damage faulty X operation immediately Do not operate the unit until corrected g Make sure the operating decal is attached to the unit as shown in figure 3 3 make sure that the markings on the decal are legible 3 4 3 8 STARTING THE UNIT sed figure 3 1 a Set the park brake by moving the control lever to BRAKE ON position UP b Place the Direction Throttle Bail in Neutral detented position vertical c Pull Hand Throttle out slightly at approximately a 700 RPM setting NOTE During cold weath
149. ch of the flat surfaces of the meter section parts as it is ready for assembly in a similar way see figure 9 54 s Place the plate over this assembly so that the bolt holes in the plate align with the tapped holes in the housing see figure 9 55 Place the meter gear ring the assembly so that the bolt holes align sed figure 9 56 t Place the splined end of the drive within the meter gear star so that the slot at the control end of the drive is in alignment with the valleys between the meter gear teeth sed figure 9 57 Push the splined end of the drive FIGURE 9 53 FIGURE 9 57 9 15 SECTION 9 STEERING through the gear so that the spline extends about one half its length beyond the meter gear star and hold It in this position while installing into the unit Note the position or direction of the cross pin within the unit Enter the meter gear star into the meter gear ring and wiggle the parts slowly in position so that the drive does not become disengaged from the meter gear star Hold the plate and meter gear ring in position on the assembly while the star is being installed Rotate the meter gear star slightly to bring the cross slot of the drive into engagement with the cross pin and the splined end of the drive will drop down against the plate see figures 9 58 9 59 and 9 60 WARNING Alignment of the cross slot in the drive with valleys between the teeth of the meter gear star determines proper valve timing o
150. ck the machine safely to prevent movement When removing the drive drum take caution The drive drum is extremely heavy approximately 12 000 5440 kg without ballast CAUTION personnel to stand clear During transmission start up procedure disconnect the cable from the pump until after initial start up This will allow the pump to remain in neutral see figure 7 104 Connect the drum hub to a hoist before removal from the drive drum The outer planetary assembly will accompany the drum hub upon removal Care should be taken when handling these components When assembling the steering control unit alignment of the cross slot in the drive with the valleys between the teeth of the meter gear star determines proper valve timing of the unit There are 12 teeth on the spline and 6 pump teeth on the star Alignment is exactly right in 6 positions and exactly wrong in 6 positions If the parts slip out of position during this part of assembly repeat until you are certain correct alignment is obtained see figure 9 57 WARNING WARNING WARNING WARNING DO NOT extend the hands or arms through the center of the steering wheel during start up after the steering control unit has been reassembled If the steering control unit has been disassembled and incorrectly timed the steering wheel may suddenly become motorized or rotate abruptly with extreme force If this occurs see figure 9 2 and paragraph 9 27 step t and retime the control
151. cted Cable seized Free up or replace 6 1 GENERAL see figure 6 1 6 2 The electrical system consists of and the discharge circuit gauges lights several subsystems they are starting circuit charging circuit etc 6 1 SECTION 6 ELECTRICAL When checking for default each subsystem should be considered because of their interdependence The electrical system specifications are given in Section 2 and a troubleshooting guide is presented in Section 5 DELETED PAGES 6 2 AND 6 3 SECTION 6 ELECTRICAL gt Ey WATER SPRAY CIRCUIT BREAKER S un ECT PRE WATER TENP NDI IT SWITCH a e SENDING UN OIL PRESSURE SENDING lt TT WATER PUMP SWITCH zu r PRESSURE Ec I sa ME O NUETRAL START SAFETY SWITCH q D se vanae 199 4 PARK db Lon sake LIGHT BASH rr gt TRANSMISSION TEMP LL LLLI Ll E a LIGHTS SEE FIGURE 7 6 FOR COLOR CODE TABLE FIGURE 6 4 ELECTRICAL SCHEMATIC FOR DETROIT 6 4 SECTION 6 ELECTRICAL LIGHT SWITCH DASH LIGHT R w FF EE EE DASH LIGHT WATER SPRAY SWITCH xr AMMETER A f AD lt lt REGULATOR 9 Spi 3 4 NL 4 F E E N J HOUR METER IGNITION SWITCH lt Q OIL PRESSURE OIL TEMPERATURE wIRE GAUGE COLOR TO PARK BRAKE 12 BLUE A
152. d operating supplies required for initial operation 2 12 Special Tools and Equipment No special tools or equipment are required for operation and maintenance of the Roller 2 13 Maintenance Forms and Records Operational Maintenance and Historical records will be maintained as required by the current TM 38 750 2 14 Towing the Roller Before towing a unit that has malfunctioned ensure that the transmission by pass valve is in the open position and park brake has been released The by pass valve is located under the hood next to the batteries After towing be sure that the b pass valve has been closed CAUTION The by pass valve is not intended for towing a unit from one job site to another Tow at speeds of one 1 to 2 MPE for as short a distance as possible 2 15 Starting the Roller a Always set the park brake by moving the control lever to BRAKE ON position up b Place the Direction Throttle Bail in Neutral detented position vertical c Start engine 2 16 Safety Precautions Always observe the following safety pre cautions to prevent possible injury to personnel and damage to the equipment a TRAINED OPERATIONS ONLY b Always use slower unit speeds and added caution when operating close to a lift edge or when traveling downhill c Never travel across a slope Always travel up or down a slope d Always engage the parking brake before dismounting the unit e Never shut down the engine when traveling up or down a sl
153. d wait one 1 minute allowing the starter to cool FIGURE 3 3 OPERATING INSTRUCTIONS DECAL 3 5 NOTE If the Detroit Diesel engine fails to start after the third attempt check the EMERGENCY STOP Control has been manually reset as described in paragraph 3 28 3 9 OPERATING THE UNIT seel figure 3 1 NOTE Before operating the unit allow the engine to idle at 700 RPM for approximately two minutes to allow engine and hydraulic oil to begin to reach operating temperature 3 10 Release the park brake by pushing the control lever to the BRAKE OFF position down 3 11 SPEED AND DIRECTION CONTROL 3 12 Speed and direction of the unit are controlled by the Direction Throttle Bail Move the Direction Throttle Bail off of neutral in the desired direction forward or reverse To increase unit speed move the lever further away from the neutral position To decrease unit speed move the lever back toward the neutral position NOTE Optimum torque to the drive drum is achieved by moving the Direction Throttle Bail toward the neutral position when the engine starts to lug down Move bail until engine RPM increases to loaded RPM speed 3 13 DYNAMIC BRAKING 3 14 Slowing or stopping the unit during operation is accomplished by moving the Direction Throttle Bail toward Neutral WARNING Never shut down the engine when attempting to stop the unit This will reduce or eliminate all dynamic braking capabilities 3 15
154. delivery to the Government This warranty applies to the end item components and all supplies furnished under the contract 2 Using units may not contact their local dealer You must mail DA Form 2407 to the Maintenance Directorate TARCOM at the following address US Army Tank Automotive Material Readiness Command ATTN DRSTA MVB Warren Michigan 48090 To expedite actions you may call the information to AUTOVON 273 3349 or 273 3439 with the information from your DA 2407 section 1 block 1 through 11 blocks 16 17 18 and 20 3 General information a DA Form 2407 prepared in accordance with warranty claim actions in TM 38 750 will be used to submit warranty claim actions for end items when components parts or assemblies are defective and are covered by a manufacturer s warranty End items under warranty are identified by a decal plate and or warranty statement included in the operator s and maintenance manual for the end item All warranty actions settled or unsettled will be reported to the National Maintenance Point NMP on DA Form 2407 For warranties settled locally the DA Form 2407 will contain a statement For Information Only in block 35 b Maintenance activities in support of organizational maintenance are the responsible points of contract between the originator of warranty claims and the National Maintenance Point US Army Tank Automotive Material Readiness Command DRSTA MVB AUTOVON 273 3349 or 273 3439 Warren Michigan 48090
155. e Repair Oil Return Filter Service Replace Case Pressure Relief Valve Replace Repair Lines amp Fittings Replace Repair FI AL DRIVE Drive Drum Assembly Replace Repair Motor Carrier Assembly Replace Repair Final Drive Assembly Service Replace Repair Overhaul PARKIC BRAKE SYSTEM Brake Lever The subcolumns are as follows C operator crew F direct support D depot O organizational H general support 19 Section Il MAINTENANCE ALLOCATION CHART ROLLER MOTORIZED STEEL WHEEL 2 DRUM TANDEM 10 14 TON CCE 1 2 3 4 6 GROUP COMPONENT MAINTENANCE MAINTENANCE Category NUMBER ASSEMBLY FUNCTION REMARKS Replace Repair Cable amp Linkage Replace Repair Brake Shoe Replace Repair Brake Drum Replace Repair STEERING SYSTEM Steering Wheel Replace Guide Rolls Replace Repair Axle Shaft Bearings Service Replace Repair Yoke amp Pin Assembly Service Replace Repair Steering Control Unit Replace Repair Hydraulic Pump Replace Repair The subcolumns are as follows C operator crew F direct support D depot O organizational H general support 20 Section Il MAINTENANCE ALLOCATION CHART ROLLER MOTORIZED STEEL WHEEL 2 DRUM TANDEM 10 14 TON CCE 1 2 3 4 6 GROUP COMPONENT MAINTENANCE MAINTENANCE Category NUMBER ASSEMBLY FUNCTION REMARKS Overhaul Hoses Lines amp Fittings Replace Steering Cylinder Service Replace Repair Flow Divider Repl
156. e figure 9 87 e Examine bearings and body for scratches and pitting see figure 9 88 Use fine sand paper on surface plate to dress out any slight imperfections of bearings see figure 9 89 Do not attempt to remove deep scratches or gouges Check bearing bores for concentricity Place bearings n their respective positions in the body and check clearance between bearing flats Under no circumstances should FIGURE 9 87 SECTION 9 STEERING se clearances exceed specifications refer to Section 2 f Check milled seal and gasket recesses of the cover for any obstruction that would prevent normal seating Make sure internal threads of front cover and threads on capscrews are in good condition 9 59 REASSEMBLY OF STEERING PUMP see figure 9 91 a Apply a light coat of non hardening gasket cement to the bore in the front cover Press new shaft seal into the bore and wipe off excess cement Stake seal in three places NOTE Generously lubricate all parts with SAE 10 W oil during pump assembly b Install front bearing gears and rear bearings in their respective positions Make sure all marks previously made during disassembly are aligned EN USE A FIGURE 8 MOTION FIGURE 9 89 FIGURE 9 88 9 25 FIGURE 9 90 SECTION 9 STEERING c Position gasket spacer and W shaped gasket seal In front cover recesses d Assemble front and rear cover to the body being careful
157. e brake shoe assemblies The shoe rib and table can be wiped with a solvent dampened cloth No solvent should get on the lining b Examine drum for cracks heat checks and deep grooves The drums should not be bell mouthed of barrel shaped nor should the mounting holes be elongated If any of these conditions exist the drum should be replaced Glaze on the drum which is otherwise in good condition can be removed with coarse sandpaper c The brake shoe linings should be replaced if worn to within 1115 inch 1 69 mm or If bonding agent is failing Do not attempt to save lining soaked with oil or with deep scores d Check springs and discard them If broken rusted twisted nicked or appear fatigued 10 9 REASSEMBLY AND INSTALLATION CAUTION Use only Hyster Approved replacement parts a Install backing plate with actuator lever depression in position shown seg figure 10 2 b Install backing plate capscrews and torque to 49 ft 16 6 8 kg m Then install rollers on both actuator cranks figure 10 3 c Connect actuator lever to control cable then position actuator lever into backing plate as shown see figure 10 4 ACTUATOR LEVER DEPRESSION 10 2 FIGURE 10 4 SECTION 10 BRAKES d Next install brake hub rubber seal washer and slotted nut see figure 10 5 Tighten slotted nut to remove end play Back off one 1 flat 012 in 305 mm loose DO NOT EXCEED 26 FT LBS TORQUE
158. e steps 1 Remove the spring loaded end cap and remove the spring and pin 2 Push the piston out of the housing by inserting a small drift into the hose end of the housing Removal of piston may be difficult because the o ring has to slide past threads 9 71 CLEANING AND INSPECTION a Clean all parts thoroughly b Check bores and spools for nicks and scratches Spools must slide freely in their bores C Ports and orifices must be free of obstructions 9 72 REASSEMBLY AND INSTALLATION OF FLOW DIVIDER see figures 9 1 and 9 92 CAUTION Replace and oil all o rings a Insert the relief piston into the relief valve housing Insert the pin into the piston the short side goes into the piston and the spring Screw the end cap into relief valve housing b Screw the relief valve housing assembly into the flow divider c Install the piston spring and cap d Install the mounting capscrews e Connect the hydraulic lines 9 73 ADJUSTMENT OF FLOW DIVIDER RELIEF VALVE 9 74 The relief valve is factory set at 1500 50 PSI 105 5 3 5 kg cm Do not try to adjust or repair the relief valve but replace the whole valve 9 75 STEERING CYLINDER 9 76 DESCRIPTION figure 9 93 9 77 The steering cylinder is a double acting cylinder consisting primarily of a shell piston and rod assembly and two end plugs Hydraulic oil applied to one of the cylinder ports acts against the piston causing piston and
159. e port b Place the Direction Throttle Control Bail in neutral es HYDROSTATIC PUMP FIGURE 7 37 SECTION 7 TRANSMISSION c Start the engine and increase speed to 1500 RPM The gauge should indicate 190 to 220 PSI 13 36 to 15 47 kg cm2 above case pressure with oil at operating temperature If the pressure is not within the specified limits troubleshoot the system as specified in Table 5 2B 7 160 CHECKING LOW CHARGE PRESSURE se figure 7 38 7 161 The low charge pressure should be between 150 and 180 PSI 10 55 and 12 66 kg cm2 above case pressure with oil at operating temperature when the transmission is operating in forward or reverse The low charge pressure relief valve is located in the motor manifold as shown in figure 7 38 Check the pressure as follows a Remove the threaded plug from the Low Charge Pressure Check Port Install a 600 PSI 40 kg cm2 gauge equipped with a short section of hose Use an o ring adapter in the port Make sure that the gauge is accurately calibrated b Block the drive drum safely off the ground and start the engine c Increase engine speed to 1500 RPM Move the Direction Throttle Control Bail slightly to LOW CHARGE PR CHECK PORT HY ROSTATIC MOTOR FIGURE 7 38 7 30 the forward and reverse positions The gauge should indicate 150 to 180 PSI above case pressure 10 55 to 12 66 kg cm2 in each direction d If the pressure is not within the s
160. e remains attached to the unit at all times NOTE Make sure that nameplate information is complete If not contact a Hyster Dealer 1 5 SERIAL NUMBER DATA se figure 1 4 CAUTION The COMPLETE serial number must be identified when ordering parts or communicating service information to Hyster Company CHEER Terena vano Tues t Uu RO kus unen orm eamm m 2 mesta a unti moana LI SECTION 1 INTRODUCTION 1 6 The unit serial number is located on the unit nameplate It is also stamped on the left hand side of the gooseneck The serial number indicates the design series manufacturing plant serial number of the unit and year manufactured Example B89 C 0000 T 1 7 SYSTEM DESIGN SPECIFICATIONS 1 8 Design specifications for individual systems of the unit are listed in Section 2 Maintenance Specifications are given in Section 4 1 9 OPERATING INSTRUCTIONS 1 10 All instructions necessary for safe and efficient operation are given in Section 3 1 114 HYSTER CARE MAINTENANCE 1 12 Section 4 Contains the schedule and procedures required for proper maintenance The schedule lists recommended time intervals between maintenance checks The procedures provide detailed instructions for performing maintenance checks 1 13 TROUBLESHOOTING FIGUR
161. e shaft sheared Remove and disassemble the pump Inspect and replace worn or broken parts Air leaks at the intake Check the inlet connections to determine where air is being drawn in Tighten any loose connections Replace seols where necessary Fluid intake hose in reservoir Remove and flush or replace suction restricted hose between the pump and tank Ser vice transmission filters if necessary Gears worn or broken Replace parts as necessary Insufficient Pump Insufficient relief pressure Pressure Check relief valve in the flow divider for contamination Clean or replace Worn parts causing internal leakage of Inspect and replace as necessary pump delivery Damage to cylinder packing Refer to Steering Cylinder Troubles Pump Making Noise Pump intake partially blocked Remove and flush or replace suction line between pump and tank Check the fluid condition and if necessary drain and flush the system Refill with clean fluid Air leaks at the intake or shaft seal Oil in tank may be foamy Check the inlet connections and seal to determine where air is being drawn in Tighten any loose connections and replace if necessary Air in circuit Check all connections for tightness Dirt and sludge in the pump Disassemble the pump and clean all parts Drain the hydraulic tank Vnd flush Replace with
162. ecial Tools and Equipment Maintenance Forms and Records Towing the Roller Starting the Roller Safety Precautions REPAIR PARTS SUPPLY General Prescribed Load List Authorized Stockage List Requisitioning Repair Parts Submitting Requisitions This publication superseded USMP 5 3895 348 dated Jul 76 Page ee 2 APPENDIXES Equipment Publications Warranty Guidelines Maintenance Allocation Chart Modification Procedure Basic Issue Items List Prescribed Load List PLL amp Authorized Stockage List ASL Additional Repair Parts Sample Format DA Form 2765 Request Part Number Sample Format MILSTRIP Request NSN Sample Format MILSTRIP Request Non NSN Sample Format MILSTRIP Request Non NSN Manual Maintenance amp Operating Supply List Preventive Maintenance Checks amp Services Operator Crew PMCS Organizational PMCS HESTER Technical Publication Correction HYSTER Technical Publication Correction Page NIS STE 3 o af ko SECTION I GENERAL 1 1 Purpose To provide User and Support personnel supplemental maintenance and repair parts instructions that have special application to Commercial Construction Equipment CCE items 1 2 Scope This publication applies to Department of the Army Units Organizations and Activities that use and or support the CCE Roller Motorized Steel Wheel 10 14 Ton 1 3 CCE ltem The term CCE
163. ective or non conforming since delivery for reasons other than as a result of having been 1 improperly repaired altered or subjected to misuse negligence accident or lack of normal maintenance services or 2 operated at load factors which although consistent with the user s duty cycle requirements are in excess of Detroit Diesel Allison s published commercial ratings for the product This Guaranty shall then continue as to any such exchange supplies or parts thereof until one 1 year after the date of delivery thereof Notwithstanding the foregoing the Contractor s total liability for transportation charges shall not exceed the cost of transporting the allegedly defective or non conforming supplies or parts thereof by the usual commercial surface method of shipment from the shipping destination originally specified under this contract for the applicable CLIN to the Contractor s plant and return and the Government shall reimburse the Contractor for all transportation expense in excess of such amount upon request If the Government does not require the exchange of any supplies or parts thereof agreed to be defective or non conforming the Contractor if required by the Contracting Officer within a reasonable time after notice of the defect or non conformance shall repay such portion of the contract price for the supplies as is equitable in the circumstances and comparable to the price s at which the Contractor then offers the exchanged suppl
164. ed air then steam clean if facilities are available Apply the air or steam to the side opposite of normal air flow Be careful not to bend the radiator fins If fins are bent straighten carefully RADIATOR CAP 4 A4 The radiator cap gasket and filler neck seat must also be checked to be sure that they are providing the proper seal If the rubber face of the valve is damaged a new cap must be installed Always install a cap having a 7 PSI 0 53 kg cm2 pressure rating Always inspect the overflow pipe for restrictions A plugged or damaged pipe FIGURE 4 15 CHECKING Cooling SYSTEM may prevent the cap from venting excess pressure SHROUD 4 12 4 45 FAN SHROUD 4 46 The fan shroud directs air flow through the radiator with a minimum loss of air due to turbulence On Detroit Diesel units the four capscrews securing the shroud can be loosened so that the shroud can be moved up or down for proper positioning with respect to the fan blades DO NOT ALTER ADD TO OR REMOVE THE SHROUD Check to see that it is anchored securely and not bent from its original shape The depth that the fan penetrates into the shroud is critical and should not be altered 4 47 WATER PUMP 4 48 The water pump should be checked for leaks after each 50 hours of operation Water pump leaks may allow air to be drawn into the cooling system This can cause foaming or overheating Repair or replace the pump immediately if leakage occurs UPPER BLOC
165. en each 1 000 hours of operation If necessary clean the screen in clean fuel oil and dry thoroughly with compressed air Reinstall the screen and gasket assembly with the screen side of the assembly toward the blower 4 29 ENGINE AIR BOX DRAIN see figure 4 11 4 30 With the engine running check for flow of air from the air box drain tubes each 1 000 hours of operation If the tubes are clogged remove clean and reinstall the tubes The air box drain tubes should be cleaned periodically even though a clogged condition is not apparent 4 31 ELECTRICAL SYSTEM 4 32 CHECKING BATTERY ELECTROLYTE LEVEL 4 33 The electrolyte level in each battery cell should never be below the top of the plates If the level is low add drinking water The electrolyte level is correct when filled to the bottom of the split ring in each cell SECTION 4 HYSTER CARE MAINTENANCE 4 36 ALTERNATOR AND WATER PUMP DRIVE BELT S m FIGURE 4 10 SERVICING DETROIT DIESEL BLOWER SCREEN DETRO TUBES 4 37 Examine the belt s for cracks on the inner surface of the plys before making tension adjustments A belt that is adjusted too tight places an added load on the water pump and alternator bearings as well as the belt A belt that is too loose allows slippage premature failure of the belt and may lower the output of 4 10 SECTION 4 HYSTER CARE MAINTENANCE the charging system The drive belt s should be checked and adjus
166. engine Switch spring returns to No 3 posi tion when key is released TRANSMISSION OIL Gauge Indicates temperature of oil flowing TEMPERATURE through hydrostatic transmission and steering systems Shut down unit if gauge pointer moves to RED zone CAUTION Do not use starting fluid and cold start aid together t may damage engine components HOUR METER Gauge Indicates total hours of engine operation FUEL Gauge Indicates quantity of fuel remaining in fuel tank 3 3 SECTION 3 OPERATION TABLE 3 1 OPERATING CONTROLS AND INDICATORS CONT VANDALISM SHIELD EMERGENCY STOP Detroit Diesel only PARKING BRAKE CONTROL LEVER STEERING WHEEL Power 3 4 OPERATING CONTROLS AND INDICATORS 3 5 The controls and indicators necessary for operation of the compactor are listed and described in Table 3 1 and illustrated in figure 3 1 3 6 SAFETY PRECAUTIONS 3 7 Always observe the following safety precautions to prevent possible injury to personnel and damage to the equipment a TRAINED OPERATORS ONLY b Always use slower unit speeds and added caution when operating close to a lift edge or when traveling downhill Gate Valve FIGURE 3 1 INDEX NO NOMENCLATURE TYPE FUNCTION Hinged Panel Push Pull Lever Overcenter Lever Protects controls engine compartment and battery against vandalism Shuts down engine if engine RPM cannot be controlled
167. entes CHARGE PUMP aree eal ete eee atten i sut NEN na dad ata GHECK VALVES SD aina aq aa q nee SERVO CONTROL SYSTEM DISPLACEMENT CONTROL VALVE SERVO CONTROL CYLINDERS HYDROSTATIC MOTOR ASSEMBLY FIXED DISPLACEMENT HYDROSTATIC 9 MANIFOLD Oe umu ama ern Rana han aseo HIGH PRESSURE RELIEF 5 SHUTTLE VALVE GA SS LOW CHARGE PRESSURE RELIEF VALVE ener tna PRESSURE CHECKS erste ais a avd CHECKING NEUTRAL CHARGE PRESSURE 2 CHECKING LOW CHARGE PRESSURE o CHECKING HIGH 55 2 9 CHECKING CONTROL PRESSURE 22000 0 4 00011 0 000 000 800 III 6 5555 VACUUM CHEGN wt cel cewek oc eich ch elie PUPA IBS S RECEDIT DISPLACEMENT CONTROL VALVE NEUTRAL ADJUSTMENT ene TRANSMISSION CONTROL LINKAGE ADJUSTMENT a aa aaa THROTTLE CONTROL LINKAGE ADJ
168. er OCONUS will use the appropriate code from Appendix P paragraph P 3a 1 AR 725 50 Weapons System Designator code BD DA Message 091400Z DALO SMS June 78 will be entered in card columns 55 and 56 of all requisitions for parts to support the roller 3 Project Codes The applicable project code will be entered in card columns 57 59 of requisitions for Non NSN parts whether CONUS or OCONUS customers Project code BGW will be used by CONUS customers when requisitioning part numbered parts Supply customers OCONUS will use project code JZC for part numbered parts 3 5 Submitting Requisitions a Using Units and Organizations will submit DA Form 2765 Series requisitions to designated support units or activities in accordance with local procedures b Support units and activities will forward MILSTRIP requisitions for NSN parts through the Defense Automated Addressing System DAAS to the Managing Supply Support Activity Requisitions for part numbered part will be forwarded through DAAS to the Defense Construction Supply Center DCSC NOTE When the manufacturers part number and Federal Supply Code for Manufacturer FSCM exceed the space in card columns 8 through 22 of 02 requisitions prepare an AO5 AOE requisition DD Form 1348 6 and mail it to Commander Defense Construction Supply Center ATTN DCSC OSR Columbus OH 43215 TM 5 3895 348 14 amp P 1 APPENDIX A REFERENCES A 1 Publications Logistic Assistance
169. er conditions it may be necessary to proceed as follows OPERATING INSTRUCTIONS Starting Set pare hune 2 Move throttle bar to neutral vertical position Start engene To Protect Engine and Tiansmession Do aol operate above half throttie until Transmission temperature 5 over 100 F Operating Release brake 2 Dwechon and speed controlled by 4 al travel duecboa bad 5 moved bad moremect creases speed 3 To prevent an upgrade move bad back towards neutral poston 4 Use emergency stop identiked on dash in red onip d engine speed cannot be controlled Stopping 1 Put throttle control bail neutral vertical position 2 Set park brate 3 Tuin switch to of position Tew la cose of machine moltuscnon vehicle mey be moved ot slew speed by opening by pass veles This is dene by polling ep and locking the cobie locoted under me hood e the bydrowlic side of the orit ade when operating on slopes and faulty operation Mely do not operate machine y ope y brake belo C350B STEEL WHEEL ROLLER SECTION 3 OPERATION Detroit Diesel Engine Consult manufacturers service literature d Turn the Ignition Key fully clockwise to engage the starter CAUTION Do not crank the engine for more than THIRTY SECONDS at any or e time If the engine fails to start set the IGNITION key to off an
170. eration and correct the cause of the overheating condition ENGINE OIL PRESSURE Indicates pressure of the oil being pumped through engine Gauge may indicate high pressure when engine is first started but should drop to normal level as engine warms Stop engine immediately if no pressure is indicated while engine is running Push Pull Lever DIESEL ENGINE HAND THROTTLE HAND THROTTLE Controls engine speed independently of Direction Throttle Bail Use for cold starting conditions and to regulate initial warmup speed Toggle Switch Engages or disengages water spray system 3 2 SECTION 3 OPERATION TABLE 3 1 OPERATING CONTROLS AND INDICATORS CONT FIGURE 3 1 INDEX NO NOMENCLATURE TYPE FUNCTION Push Pull Lever DIESEL ENGINE STOP ENGINE STOP Shuts off diesel fuel flow for engine shutdown IGNITION SWITCH Four position No 1 Position Accessory Position operated Interlock Applies power to water spray switch Switch No 2 Position OFF position moves all power to electrical circuits No 3 Position ON position Applies power to all electrical circuits This position is also a lockout position Prevents accidental engagement of the starter motor when engine is running Ignition Key must be rotated back past this position to the No 2 OFF position before starter motor can be energized again No 4 Position Start position Applies power to starter motor to crank
171. erenne on DOCUMENT Mandatory Entry forCCE A0A CONUS A011 Overseas for CONUS see AR 725 50 for OCONUS Weapon System Code DD FORM 1348 1 MAR 74 EDITION OF 1 APR 71 MAY BE USED COD SINGLE LINE ITEM REQUIS SYSTEM DOCUMENT MECHANICAL 23316 APPENDIX J SAMPLE FORMAT MILSTRIP REQUISITION FOR gr pe Re emp eene parnm Lo Do ups po Well 3 NON NSN d AQ So A VARIABLE DATA ELCUENTS DEPENDING GOCUMEKY IDENTIFIER CODE 16 2 2 13 Ea ane Duane 2252 gw Card Column Description of Data 1 3 Document Identifier Code 4 6 Routing Identifier Code 7 Media Status Code 8 22 FSCM and Part Number 23 24 Unit of Issue 25 29 Quantity 30 43 Document Number 44 Demand Code 45 50 Supplementary Address 51 Signal Code 52 53 Fund Code 54 56 Distribution Code CC 54 CC 55 56 57 59 Project Code 60 61 Priority Code 62 64 Required Delivery Date 65 66 Advice Code 31 VARIABLE DATA ELEMTNTS DEPENDING ox 1 DOCUMENT IOENTIFIER CODE E Mandatory Entry for CCE AOB CONUS 02 Overseas Always S9C F for CONUS see AR 725 50 for OCONUS Weapon System Code DD FORM 348m 1 MAR 74 EDITION OF 1 APR 71 MAY BE USED CARD COLUMN 67 69 70 71 80 DESCRIPTION OF DATA Blank Identification code applicable to entry in cc 71 80 A Technical order or
172. ering control is normal NOTE f steering control fails to return to normal air may be entering the system at the suction side of the pump see Check and tighten all hose fittings securely Also check system pressure as specified i SECTION 9 STEERING 9 86 CHECKING RELIEF PRESSURE see figure 9 95 9 87 Pressure can be checked at the base of the steering cylinder fitting Use a gauge rated at 3000 PSI 200 kg cm or greater temperature should be approximately 100 F 37 C To check pump output pressure proceed as follows PRESSURE CHECK PORT FIGURE 9 95 a Remove the plug at the steering cylinder base inlet fitting b Connect pressure gauge to the cylinder fitting c Start the engine and set speed at high idle Rotate steering wheel from stop to stop As guide rolls reach stops the pressure gauge should indicate relief pressure refer to CAUTION Do not hold system over relief for longer than 20 seconds This will damage the pump NOTE If proper pressure is not obtained remove the relief valve and clean all parts thoroughly Carefully check the relief valve spool for burrs Install the valve and recheck the pressure If proper pressure cannot be 9 30 obtained replace the relief valve assembly If pressure remains low disassemble the pump and inspect all parts for damage and wear 9 88 STEERING TRUNNION ASSEMBLY 9 89 DESCRIPTION see figure 9 96 9 90 The Steering Trunn
173. es and stabilized bases and pavements 1 6 Procurement Status The procurement contract number is DSA 700 74 C 9024 and was awarded June 1974 1 7 Equipment Publications a Initially two sets of the manufacturer s commercial publications will be overpacked and shipped with each Roller reference Appendix A b Additional commercial manuals may be obtained by requisitioning from Defense Construction Supply Center DCSC Requisitions to DCSC should be prepared in the same manner as for part numbered repair parts using the Federal Supply Code for manufacturer s FSCM and manual numbers listed in Appendix A If DD Form 1348 6 is used mail it direct to Commander DCSC ATTN DCSC OSR Columbus OH 43215 c If additional assistance is required contact the address in paragraph 1 11 of this publication 1 8 Personnel and Training a MOS Requirements 1 Operator 62J20 General Construction Machine Operator 2 Organizational Maintenance 62B20 Construction Equipment Repairman 3 Direct and General Support Maintenance 62B30 Construction Equipment Repairman 63G20 Fuel and Electrical Systems Repairman 44B20 Metal Body Repairman b New Equipment Training New Equipment Training Teams NETTs are available to major field commands Requests for NETTs should be forwarded to Commander US Army Tank Automotive Materiel Readiness Command TAROOM ATTN DRSTA MLT Warren MI 48090 Training teams should be requested only when trained
174. essure is determined by external conditions such as grade and 7 23 SECTION 7 TRANSMISSION ground conditions which establish the demand on the system The pump and motor are contained in separate housings and are connected by high pressure hoses All valves required for a closed loop circuit are included in either the pump or motor assemblies A reservoir filter oil cooler and lines complete the circuit Figure 7 33 7 34 and 7 35 illustrate the system in neutral forward and reverse modes 7 95 CHARGE PUMP CIRCUIT 7 96 CHARGE PUMP 7 97 A charge pump is a part of the hydrostatic pump assembly When the engine is running the charge pump provides oil supply cooling and pressure for control functions 7 98 The charge pump draws oil from the hydraulic tank through the suction filter to supply oil under pressure to the low pressure side of the main circuit 7 99 NEUTRAL CHARGE PRESSURE RELIEF VALVE 7 100 When the transmission is in neutral charge pump pressure is controlled by the neutral charge pressure relief valve This valve is an integral part of the charge pump and has no adjustments that can be made in the field When charge pressure exceeds the range of 190 to 220 PSI 13 36 15 47 kg cm2 above case pressure the neutral charge pressure relief valve opens allowing oil to flow into the pump case oil cooler and hydraulic tank 7 101 SUCTION FILTER 7 102 A low pressure filter is mounted on the hydr
175. f the unit There are 12 teeth on the spline and 6 pump teeth on the star Alignment is exactly right in 6 positions and exactly wrong in 6 positions If the parts slip out of position during this part of assembly repeat until you are certain correct alignment is obtained see figure 9 57 u Place the spacer in position within the end of the meter gear star dure If the spacer does not drop flush with the gear surface the drive has not properly engaged the cross pin RECHECK Place the meter end cap over the assembly and install two 2 capscrews finger tight to maintain alignment of the parts sed figure 9 62 Install all seven capscrews and bring them gradually and evenly to 12 5 ft lbs 1 728 kg m sed figure 9 63 FIGURE 9 59 FIGURE 9 58 219 FIGURE 9 61 v Check the condition of the column assembly clean it and replace on the unit with two capscrews oriented as before Rotate the steering shaft while bringing the surfaces into contact to allow splines to engage sed figure 9 64 If in doubt follow the orientation as shown Tighten capscrews to 23 3 ft Ibs 3 22 kg m seg figure 9 65 9 28 INSTALLATION OF STEERING CONTROL UNIT 9 29 Install the steering control unit by reversing procedure presented in paragraph 9 19 Install hydraulic hoses per illustration figure 9 66 CAUTION Complete bleeding the system procedure paragraph 9 83 before returning unit to service SECTION 9 STEERING
176. fan shroud capscrews CAUTION Before starting the engine make sure that fan blade tips do not contact the shroud NOTE Replace the two drive belts as a matched set when one is worn Single belts of similar size shout De uses as a substitute for a matched belt set Premature belt wear can result because of belt length variations after short periods of operation 4 56 ENGINE LUBRICATION SYSTEM 4 57 ENGINE OIL see figure 4 20 4 58 Engine lubrication oil should be kept up to the FULL mark on the dipstick To accurately check the oil level stop the engine and allow approximately five minutes for the oil to drain off of engine internal parts This eliminates the possibility of overfilling The oil should generally be changed every 100 hours or two weeks or more often where adverse SECTION 4 HYSTER CARE MAINTENANCE LUBE LUBE SUNDSTRAND FIGURE 4 21 LUBRICATING THROTTLE AND TRANSMISSION LINKAGE conditions prevail Color cannot be relied upon as indicating the need for an oil change The use of an oil analysis service is the only reason for not following the change interval specified in When checking the oil level make sure that the area around the dipstick and filler cap are clean before removing them 4 59 ENGINE OIL FILTER 4 20 4 60 The Detroit Diesel oil filter should be changed each time the oil is changed Clean the outside of the filter flange to prevent dirt from entering the engine
177. for evidence of bearings turning on the shaft If bearing inner race is turning check concentricity of the shaft Repair or replace if found to be eccentric or badly worn Slight imperfections of the shaft may be removed with fine sandpaper Check the roller bearing surfaces of the shaft for nicks galling and cracks Repair or replace shaft if and of these are found or if a FIGURE 9 122 FIGURE 9 123 SECTION 9 STEERING definite step can be felt between the worn or unworn surfaces when checked with fingernail e Clean the inside of the gooseneck with solvent and dry thoroughly 9 99 REASSEMBLY AND INSTALLATION OF YOKE AND KING PIN ASSEMBLY a Install bearing cups into gooseneck housing if removed during disassembly seg figure 9 122 b Pack bearing cones with Hyster Approved multipurpose grease c Install bearing cone and oil seal into gooseneck see figure 9 122 d Insert king pin into gooseneck and fill housing with Hyster approved multipurpose grease e Install upper bearing cone washer and slotted nut seg figure 9 123 f Install bearing cups into yoke see figure 9 1 24 g Insert oscillation pin into yoke and king pin Install two locking bolts into oscillation pin and torque to 200 ft lbs 27 7 kg m See figure 9 125 h Pack bearing cones with Hyster approved multipurpose grease and install two 2 washer and slotted nut on each end of the oscillation FIGURE 9 124 9 38 p
178. ght machine oil or grease see figure 7 80 FIGURE 7 81 FIGURE 7 82 7 46 SECTION 7 TRANSMISSION b Install a new oil seal with a press Avoid use of drifts and hammers They may easily damage component parts Lubricate the oil seal lip see figure 7 81 c Install bearing on housing by heating slightly if necessary Seat the bearing cone firmly against the motor housing shoulder see figure 7 82 d Set the bearing carrier with bearing cups and oil seal on the housing mounted bearing cone see figure 7 83 e Place the bearing cone around motor housing hub and seat it into the bearing cup sed figure 7 84 FIGURE 7 84 NOTE Rotate the bearing carrier on the motor housing hub to insure proper seating of the bearing and the oil seal lip f Temporarily install the bearing retainer plate and torque the capscrews to 25 ft lbs 3 457 kg m Rotate the bearing retainer on the motor housing hub to insure proper seating of the bearings seg figure 7 85 g Remove the bearing retainer plate and place a straight edge across the end of the motor housing hub and bearing cone With a feeler gauge measure the FIGURE 7 85 FIGURE 7 86 7 47 SECTION 7 TRANSMISSION distance between the motor housing hub and the straight edge see figure 7 86 h Assemble a shimpack equaling measurement determined in step g plus 001 in 025 mm Replace the bearing retainer plate and torq
179. gine and Transmission Do not operate above half throttle until transmission temperature is over 100 F Operating Release park brake Direction and speed are controlled by bail Machine will travel in direction bail is moved Additional bail movement increases speed To prevent lugging engine on an upgrade move bail back towards neutral position Use emergency stop identified on dash in red only if engine speed cannot be controlled Stopping 1 Put throttle bail in neutral vertical position 2 Set park brake 3 Turn ignition switch to off position Do not Tow In case of machine malfunction vehicle may be moved at slow speed by opening transmission by pass valve This is done by pulling up and locking the control cable located under the hood on the hydraulic tank side of the unit FOR SAFETY TRAINED OPERATOR ONLY Use slower speed and added caution when operating close to fill edge and when traveling downhill Travel up and down the grade when operating on slopes Report damage and faulty operation immediately do not operate machine until corrected Always set park brake before getting off machine Transmission will not hold parked machine on a grade Follow the operating instructions above and in the owners and operators manual Extra copies available from your Hyster dealer DIESEL ENGINE GUARANTY CLAUSE FOR GOVERNMENT CONTRACTS Notwithstanding the provisions of Clause 5 of the General Provisions entitled Inspec
180. gures 7 481 7 49 a Install a new gasket Make sure that the new gasket is properly installed as shown in figure 7 48 If positioned wrong the relief valve port will be covered by the gasket b Line the drive tank on charge pump shaft with the slot on the main pump shaft see figure 7 49 The charge pump should assemble freely with the main pump Do not force charge pump into position Hold aluminum spacer in position with fingers to prevent its dislodging Torque the four 4 mounting bolts 10 11 ft Ibs 1 38 1 52 kg m d Install the connector to charge pump and torque to 14 20 ft lbs 1 93 2 76 kg m e Install the line from the reservoir to the connector on the charge pump DO NOT REMOVE FIGURE 7 47 7 37 RELIEF VALVE FIGURE 7 48 DRIVE TANG AND SLOT iN FIGURE 7 49 rem tW FIGURE 7 50 SD NEA SECTION 7 TRANSMISSION FIGURE 7 51 NOTE Excessive tightening may distort the charge pump and cause leakage or malfunction f Check oil level in the reservoir 7 183 REPLACEMENT OF CHECK VALVES 7 184 REMOVAL a Remove the charge pump see paragraph 7 181 b Using a drag link unscrew check valve from end cap see figures 7 50 and 7 51 NOTE There are two check valves It is advisable to replace both check valves at the same time 7 185 INSTALLATION a Prior to installation inspect o rings for damage see figure 7 52 b Apply a
181. haracteristics of an item and comparing those characteristics with prescribed standards c Service Operations required periodically to keep an item in proper operating condition i e to clean decontaminate to preserve to drain to paint or to replenish fuel lubricants hydraulic fluids or compressed air supplies d Adjust To maintain within prescribed limits by bringing into proper or exact position or by setting the operating characteristics to specified parameters e Align To adjust specified variable elements of an item to bring about optimum or desired performance f Calibrate To determine and cause corrections to be made or to be adjusted on instruments or test measuring and diagnostic equipment used in precision measurement Consists of comparisons of two instruments one of which is a certified standard of known accuracy to detect and adjust any discrepancy in the accuracy of the instrument being compared g Install The act of emplacing seating or fixing into position an item part or module component or assembly in a manner to allow the proper functioning of an equipment or system h Replace The act of substituting a serviceable like type part subassembly or module component or assembly for an unserviceable counterpart i Repair The application of maintenance services or other maintenance actions to restore serviceability to an item by correcting specific damage fault malfunction or failure in a p
182. he spool slots contact the straight pin extending through the sleeve and the spool In this position the porting holes in the sleeve and spool are aligned This permits incoming oil to flow to the metering section and opens one of the cylinder ports 9 18 Further rotation of the steering wheel causes the spool to rotate the pin which then turns the sleeve and the rotor in the metering section At this time oil is being metered by the metering section and is allowed to flow through the spool and sleeve to one side of the steering cylinder The porting arrangement also allows the oil to flow from the opposite side of the cylinder through the control section and back to the hydraulic tank The output of the metering section is directly proportional to the speed and distance that the steering wheel rotates 9 19 When rotation of the steering wheel stops the metering action in the metering section also stops The six centering springs then return the sleeve to the neutral open center position When this occurs 9 3 pressure is maintained in the cylinder to maintain guide roll position but all incoming oil from the system pump flows back to the tank To return the guide roll to the straight ahead position the steering wheel must be rotated in the opposite direction The control unit will then function as described but all parts will rotate in the opposite direction 9 20 REMOVAL OF STEERING CONTROL UNIT a Remove the horn cover
183. hen in neutral the shuttle valve directs oil flow to the cooling circuit The shuttle valve prevents loss of high pressure oil when transmission is reversed 7 111 CONTROL FUNCTION 7 112 The charge pump provides oil under pressure to control valves 7 113 MAKE UP CIRCUIT 7 114 The charge pump provides oil to the circuit to make up for internal leakage 7 115 HYDROSTATIC PUMP ASSEMBLY 7 116 The hydrostatic transmission employs a variable displacement hydraulic pump driving fixed displacement hydraulic motor to transfer engine power to the final drive 7 117 The hydrostatic pump assembly is attached to and driven by a hub assembly on the engine flywheel 7 118 VARIABLE DISPLACEMENT HYDROSTATIC PUMP see figure 7 36 FIXED SWASHPLATE CYLINDER BLOCK MOTOR FIXED DISPLACEMENT FIGURE 7 36 7 119 The variable displacement hydrostatic pump consist primarily of a drive shaft charge pressure relief valve replenishing check valves servo pistons swashplate cylinder block assembly and valve bearing plate 7 120 The pump drive shaft is splined into the center of the cylinder block The cylinder block assembly contains nine 9 cylinder pistons When the engine is running the cylinder block and pistons are always rotating 7 1 21 Movement of the Direction Throttle Control Bail causes the servo control circuit to act on the displacement control valves These valves cause one or the other of the two 2 ser
184. her parts of the unit are being disassembled and parts can be set to dry on clean paper towel The meter gear set must be disassembled and cleaned similarly 9 24 Inspect all moving surfaces to insure that they have not been scored or abraded by dirt particles or otherwise disrupted Smooth burnished surfaces are normal in many areas Slightly scored parts can be cleaned with 600 grit abrasive paper by hand rubbing only 9 25 To prepare all surfaces of the meter section for reassembly and insure that all edges of the parts are burr free place a piece of 600 grit abrasive paper face up on an extremely flat clean hard surface The surface to be used for this purpose should be as flat as FIGURE 9 30 FIGURE 9 31 9 10 SECTION 9 STEERING plate glass or better If the 600 grit paper is new it should first be rubbed down with a scrap steel part to remove grit which would produce scratches The ends of the star gear can be used for this purpose if necessary Then both sides of the ring gear both sides of the plate the 14 hole end of the housing and the flat side of the end cap should be cleaned lightly 9 26 Stroke each surface across the abrasive several times and observe the part see figures 9 30 9 31 and 9 32 Any small bright area near an edge indicates a burr which must be removed Hold the part so that contact with the abrasive is as flat as possible Do not push one edge down hard or the part will become rounded
185. ies or parts thereof for sale to the Government March 1974 TABLE OF CONTENTS INTRODUCTION GENERAL UNIT NAMEPLATE e SERIAL NUMBER DATA ssscceceicccecenecdsceseccsecetesedssesecedcanteccdecatecadesstassdscatesctucesenatnestacadseatactaceuecsteuseaers SYSTEM DESIGN SPECIFICATIONS OPERATING INSTRUCTIONS cccecceccecceccescescescescessessessssscesceaceacseceacasersessessersrsersersessersesserserseree HYSTER CARE MAINTENANCE cccecceccecceccescescescescescescescescescescrcscrseacersessseaceaseasersessersesserserees TROUBLESHOOTING n Pur Deus kan SYSTEM DESCRIPTIONS AND REPAIRS cccecceccecescescescescescescescescescscersersersacersersessessersersessereree SAFETY PRECAUTIONS c ceccessessescessescecceccescscescsssceaserssaceecsacsacsssrsescsrsersessersersersersessersesserserseses SPECIFICATIONS GENERAL Dun dd ceased e Ed tiunt COMPACTOR 2 20 yo Dada c PERFORMANCE SPECIFICATIONS 2 9 9 99 WEIGHT BALLAST COMPRESSION DATA 2 No RR 1 T 1 T 1 1 T 1 CoO co PO i DETROIT DIESEL ENGINE WATER SPRAY SYSTEM HYDROSTATIC TRANSMISSION SPECI
186. in sed figure 9 126 Tighten slotted nuts equally so that king pin remains centered on yoke Torque one slotted nut to 200 ft lbs 27 7 kg m lubed then back off to loose and retorque to 75 10 4 kg m Check torque on opposite slotted nut It should be 75 ft Ibs 10 4 kg m NOTE Check that running clearance exists on both sides of king pin Adjust if necessary by repeating step h i Install cotter keys into slotted nuts on both ends of the oscillation pin Fill dust caps half full with Hyster approved multipurpose grease and install j Install guide roll assembly refer to paragraph 9 96 k Place unit on ground so that entire weight of gooseneck rests on king pin Torque slotted nut to 200 ft Ibs 27 7 kg m lubed Back off to loose and retorque to 75 ft Ibs 10 4 kg m I Install cotter key and fill dust cap half full with Hyster approved multipurpose grease and install FIGURE 9 125 9 39 SECTION 9 STEERING FIGURE 9 126B SECTION 10 10 1 GENERAL 10 2 This section contains a description of the parking brake system and repair instruction for the brake drum assembly Repair instructions include removal inspection and installation of the park brake assembly 10 3 Design specifications are given in Section 2 Maintenance requirements are discussed in Section 4 Troubleshooting instructions are given in Section 5 10 4 DESCRIPTION 10 5 The parking brake is a mechanically o
187. ing the vehicle Pay attention to the CAUTIONS and WARNINGS 4 Do your weekly W PREVENTIVE MAINTENANCE weekly 5 Do your monthly M PREVENTIVE MAINTENANCE once a month 6 If something doesn t work troubleshoot it with the instructions in this manual or notify your supervisor 7 Always do your PREVENTIVE MAINTENANCE in the same order so it gets to be a habit Once you ve had some practice you ll spot anything wrong in a hurry 8 If anything looks wrong and you can t fix it write it on your DA Form 2404 If you find something seriously wrong report it to organizational maintenance TRGHT NOW 9 When you do your PREVENTIVE MAINTENANCE take along the tools you need to rake all the checks You always need a rag or two A Keep it clean Dirt grease oil and debris only get in the way and may cover up a serious problem Clean as you work and as needed Use dry cleaning solvent SD 2 on all metal surfaces Use soap and water when you clean rubber or plastic material WARNING Dry cleaning solvent used to clean parts is potentially dangerous to personnel and property Do not use near open flame or excessive heat Flash point of solvent is 1000F 1380F 37 B Bolts nuts and screws Check them all for obvious looseness missing bent or broken condition You can t try them all with a tool of course but look for chipped paint bare metal or rust around bolt heads If you find one you think is loose tighten it or report it
188. ion Assembly consists primarily of a king pin assembly oscillation pin assembly steering yoke axle assembly and two guide rolls The unit gooseneck frame rests on the trunnion assembly Two guide rolls are used to prevent scuffing of material during turns The oscillation pin assembly allows the steering yoke to adjust to differences in ground levels preventing bridging between the drive drum and guide rolls 9 91 REMOVAL OF GUIDE ROLLS AND STEERING AXLE ASSEMBLY 9 92 The method of removing the axle shaft assembly depends upon the availability of the equipment An overhead crane of a lift truck KING PIN ASSEMBLY Ip pg ente YOKE SECTION 9 STEERING can be used to lift the front end of the unit so the guide rolls and steering axle assembly can be removed a Remove front scraper assembly Then position guide roll rear scraper in the up position see figure 9 97 WARNING The scraper bar may be sharp b Remove the capscrews four from both steering yoke caps Then remove and tag the caps see figure 9 98 NOTE Yoke caps are matched and must be assembled to the same side of the yoke from which they were removed WARNING Be sure drive drum is securely blocked c Lift the gooseneck up until the guide roll shaft will clear the steering yoke Carefully roll the guide roll ahead Block up the front of unit frame see figure 9 99 d Lower the gooseneck until the frame is securely held by the bl
189. ion when repositioning the scraper bars as they are under considerable spring tension and may become sharp when worn 11 AIR CLEANER a Inspect air cleaner element Element missing e b Check air cleaner indicator if red clean and service element 41 Operator Crew Preventive Maintenance Checks and Services B Before D During A After W Weekly M Monthly are TEM TO BE INSPECTED Item Interval Procedure Check for and have repaired Equipment is not ready BID A WIM filled or adjusted as needed available if 12 V BELTS Check for frayed cracked or broken belts 13 BATTERY Check fluid level Fill as necessary to split ring Inspect for obvious defects such as cracked case or burnt broken or One or more missing or will loose terminal and cables not crank engine 42 ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES Q Quarterly S Semiannually A Annually B Biennially H Hours M Miles INTERVAL ITEM TO BE INSPECTED ITEM NO PROCEDURE Check for and have repaired filled or adjusted as needed 1 e ENGINE Check for leaks loose mounts and proper operation 2 100 OIL FILTER Change oil and filter 3 B00 FUEL FILTER AND STRAINER Change filter element and strainer element 4 POO V BELTS all belts Check tension 5 RADIATOR e a Check for leaks and clean exterior as required e b Check antifreeze protection 000 c Drain and flush radiator and engine 6 AIR CLEA
190. just control valve spool for neutral position Remove the 7 16 x 20 straight thread o ring plugs on either side of the control valve housing Ref 1 to reveal the servo cylinder porting holes Ref H Loosen locknut Ref G and adjust the control valve by screwing the centering spring housing Ref C in or out so that the open areas shaded areas of Ref J between the spool 7 33 lands and sides of the porting holes are equal Tighten locknut Ref G recheck the open areas and reinstall the two 7 16 x 20 plugs 7 172 TRANSMISSION CONTROL LINKAGE ADJUSTMENT seg figure 7 43 a Place Direction Throttle Control Bail in neutral vertical position Adjust control cable at pump so that jam nut on end of cable has full thread engagement and no more Tighten jam nut securely Loosen jam nut on engine flywheel housing and adjust cable so that the Swivel on the servo pump control arm is centered in the bracket Tighten jam nut securely Measure distance between swivel bracket and external cable end These must be a minimum of 13 32 in 27 69 mm Refer to figure 7 43 SECTION 7 TRANSMISSION DIRECTIONAL CONTROL BAIL FRICTION CONTROL BAIL STOP NEUTRAL START SAFETY SWITCH 1 ADJUST TRAVEL PERKINS amp DETROIT HERE DIESEL ENGINES 1 09 27 7 mm WHEN CABLE I IN MID TRAVEL NEUTRAL FIGURE 7 43 7 34 b Adjust and tighten ball joint of control cable at bail shaft end Adjust neutral start safety
191. kg cm STEERING CYLINDER Type Stroke Double Acting 18 1 8 Inches 45 7 0 3 2 12 SECTION 2 SPECIFICATIONS TABLE 2 10 STEERING SYSTEM SPECIFICATIONS CONT DESIGN DATA ENGLISH METRIC STEERING WHEEL TURNS 2 1 4 Clockwise Stop to Stop 3 Seconds Clockwise and 3 5 Seconds Counterclockwise STEERING HANDPUMP Type Open Center Rotary Actuated Displacement 7 4 Cubic Inches per Revolution 121 3 cc per Revolution Port Size 3 4 16 UNF Ports 19 05 mm 16 UNF Ports GUIDE ROLL STEERING ANGLE Full Turn 45 Each Side CLEARANCE BETWEEN GUIDE ROLL DRUMS 0 010 0 030 In 0 25 0 76 mm TRUNNION TORQUE Steering Axle Nuts 200 then 45 ft Ibs 27 6 then 6 2 kg m Oscillation Pin Nut 200 then 75 ft lbs 27 6 then 10 4 kg m King Pin Nut 200 then 75 ft lbs 27 6 then 10 4 kg m Trunnion Cepscrews 200 ft Ibs 27 6 kg m TABLE 2 11 BRAKE SYSTEM SPECIFICATIONS BRAKE DRUM DIAMETER 10 0 In BRAKE LINING THICKNESS 0 25 In LINING TYPE Segmented Riveted BRAKE LEVER ADJUSTMENT 80 Lbs Min Pull 36 3 kg Min Pull BACKING PLATE CAPSCREWS 49 ft Ibs 6 8 kg m BRAKE HUB TO BRAKE DRUM CAPSCREWS 49 ft lbs 6 8 kg m BRAKE SHAFT NUT 100 ft Ibs 13 8 kg m 2 13 SECTION 2 SPECIFICATIONS TABLE 2 12 TORQUE SPECIFICATIONS FOR STANDARD HARDWARE SAE GRADE 5 CARBON STEEL CAPSCREWS FOOT POUNDS 0 5 KILOGRAM METERS EUROPEAN TORQUE T
192. ks Instructions listed in the procedures subsection are given by systems and are not necessarily in the order listed in Table 4 1 4 3 Hyster Care Maintenance is planned maintenance program that includes periodic inspection and lubrication Hyster Care maintenance should be SECTION 4 HYSTER CARE MAINTENANCE correlated closely with the operating hours recorded on the hourmeter located on the instrument panel 4 4 HYSTER CARE MAINTENANCE SCHEDULE 4 5 Table 4 1 lists the recommended maintenance checks It is outlined in two schedules the hourly schedule and the periodic schedule If the unit is operated more than eight hours per day the hourly schedule should be followed If the unit is operated less than eight hours per day the periodic schedule should be followed 4 6 Maintenance checks given Table 4 1 are listed in the same sequence as listed on the maintenance decal starting with the eight hour checks The first and last columns of the table DETROIT DIESEL LY PLUG 17 1 2 INCHES ABOVE GROUND FIGURE 4 1 MAINTENANCE CHECKPOINTS SECTION 4 TABLE 4 1 HYSTER CARE MAINTENANCE SCHEDULE HYSTER CARE MAINTENANCE FIGURE SCHEDULE HOUR PERIOD ITEM ITEM 8 50 100 1200 300 500 000 QUANTITY TYPE NO day wk 2wks mo 6wks 3mo yr ENGINE OIL 4 56 DETROIT DIESEL 3 53 X C NOTE Refer to engine manufac turer s maintenance manual for
193. l properly Pressure surges may be observed on pressure gauge this is normal while running at 750 RPM the charge pressure must be at least 100 PSI 7 0 kg cm2 above case pressure If it is not shut down and troubleshoot see Section 5 i Increase speed to 1000 RPM charge pressure should be 190 220 PSI 13 4 15 5 kg cm2 above pump case pressure j Shut down the engine and reconnect the push pull cable to the pump linkage k Check oil level in reservoir Fill if necessary Restart engine and run at 1500 to 1800 RPM Charge pressure should be 190 220 PSI 13 4 15 5 kg cm above pump case pressure m Move Direction Throttle Control Bail slowly to the forward and then to the reverse position Charge pressure will drop to 160 180 PSI 11 2 12 7 kg cm2 above pump case ADJUST WIRE FREE PLAY SECTION 7 TRANSMISSION pressure Repeat cycle for five minutes CAUTION Should the charge pressure drop below 100 PSI 7 0 kg cm2 above pump case pressure at any time discontinue start up until trouble has been determined n Run engine at maximum RPM with the pump in neutral Observe the reading of the suction filter vacuum gauge located on the filter This gauge should be reading NORMAL o Shut down engine remove all gauges and replace all lines and plugs Check reservoir oil level and tighten oil fill cap p Machine is now ready for operation 7 213 BY PASS VALVE 7 214 Refer to Section 3 paragr
194. l spool almost to neutral where it ports just enough oil to the servo cylinder to keep the swashplate at the proper angle 7 140 When the Direction Throttle Bail is released the displacement control spool is returned to neutral by a spring This allows oil from both servo cylinders to flow into the case through the small underlaps Both servo cylinders are thus exhausted and one of the servo springs mechanically forces the swash plate to neutral 7 141 HYDROSTATIC MOTOR ASSEMBLY see figure 7 36 7 142 The fixed displacement motor is an axial piston motor that converts fluid power received from the variable displacement pump into rotary mechanical power 7 143 The fixed displacement motor is attached to the unit final drive mechanism at the right hand side of the drive drum as viewed from the rear of the unit The ports of the variable displacement pump are connected to the motor through high pressure hoses 7 144 MOTOR 7 145 The fixed displacement hydrostatic motor output is coupled to a final drive by a shaft extending through the center of the drive drum 7 146 The hydrostatic motor converts high pressure hydraulic power into rotary mechanical power The motor shaft can rotate in either direction The action of the hydrostatic pump reversing the direction of oil in the FIXED DISPLACEMENT HYDROSTATIC 7 29 SECTION 7 TRANSMISSION main circuit reverses the direction of the motor output shaft 7 147 The moto
195. lete De ol BG Bol OT er rrr n 7 16823 CAPSCREM 5 8 UNF X 1 1 2 G5 8 2 Qf 390453 CARRIER MOTDR 7 15160 LOCKWASHER 5 8 8 3 MOTOR HYORAULIC SEE 2 11 2 12 8 94086 O RING 1 29 56998 BOLT 1 2 UNC X 1 1 4 G8 6 5 150194 SEAL OTL 1 1 4 198214 PIN 2 1 6 155369 CONE BEARING 2 10 P 333053 SHAFT DRIVE 1 2806 FINAL DRIVE FOR C3508 REF HYSTER NAME OF PART REF 5 NAME OF PART NO PART NO 1234 QTY 0 PART 0 123 QTY 11 167458 WASHER 2 39 15320 PLUG 1 11 T8826 BEARING THRUST 2 40 156197 WASHER 3 12 156201 SNAP RING 2 41 156194 CUP BEARING 6 13 167459 GEAR SUN 1 41 156195 CONE BEAR ING 5 14 156174 CARRIER PL ANETARY 1 2 156193 SNAP RING 3 15 154029 GEAR RING 1 43 154023 GEAR PLANETARY PINION 3 16 15316 PLUG 1 44 156196 PIN 3 1T 97577 BOLT 1 2 UNF X 1 3 4 68 16 45 156183 PIN 3 18 154028 HUB 1 46 154026 GEAR PLANETARY PINION 3 19 156187 CARRIER PLANETAR Y 1 47 156161 CUP BEARTNG 6 4T 156182 CONE BEARTNG 6 20 7 391462 PLATE 1 48 156180 SNAP RING 3 7 49 180397 PIN GROOVE 3 21 390494 FLANGE 1 50 156185 PLATE LOCK 3 22 390460 SHIM 005 AR 51 156186 PLATE 3 22 390461 SHIM 020 AR 52 16820 CAPSCREW 1 2 UNF X 1 G5 3 22 390462 SHIM 062 AR 53 156184 WASHER THRUST 3 54 167457 GEAR SUN 1 23 16049 FITTING LUBE l 55 34507 SNAP RING 1 24 156200 SEAL OFL 1 56 183543 COUPLING 1 25 44326 BEARING BALL 1 57 161246 PLATE 1 26 44307 BEAR ING BALL 1 58 161244 SHIM 005 AR 27 12921 SNAP RING 1 58 1612
196. light coat of oil c Install check valves and torque to 80 90 ft lbs 11 06 12 44 kg m d Install charge pump see paragraph 7 182 CAUTION The valves must assemble below the face of the end cap 7 186 REPLACEMENT OF BY PASS VALVE AND MOTOR MANIFOLD 7 38 SECTION 7 TRANSMISSION 7 187 REMOVAL a Prior to removal of the manifold assembly remove all dirt and clean the area where manifold assembly is attached to the end cap b Place drain pan under manifold to catch oil Remove by pass valve linkage c Remove the four 4 corner bolts holding the manifold to motor end cap seg figure 7 53 d Grasp manifold to prevent it from dropping and remove the remaining two 2 mounting bolts see figure 7 54 There is no gasket between the manifold and the end cap Sealing is obtained by o rings and back up rings 7 188 INSTALLATION a Use new o rings and back up rings b The two grooves side by side on manifold assembly sed figure 7 55 require an o ring and a back up ring one of each per groove The o ring goes into the groove first Then install the back up ring on top of the o ring The flat side of the back up ring faces away from the o ring c The groove positioned by itself see figure 7 55 requires only an o ring FIGURE 7 53 d Place the manifold against the motor end cap Install the bolts while making certain that Q RING ONLY A O RING B AND BACKUP RING O RING A
197. lso the chemical structure of the oil deteriorates after prolonged use 4 68 Drain the oil by removing the drain plug at the bottom of the tank Fill the tank through the filler neck shown in figure 4 22 CAUTION Make absolutely sure that the oil level can be seen in the sight guage before starting the engine and operating the steering or hydrostatic transmission systems 4 69 TRANSMISSION HYDRAULIC FILTERS 4 70 The suction filter should be checked every 100 hours of operation or at two week intervals by noting the reading on the vacuum gauge Change the filter element if the reading exceeds 9 inches of mercury with oil temperature at 100 F and engine at high idle Always replace the suction filter element at least once a year or 1 000 hours whichever occurs first NOTE Removal of hydraulic lines or hoses is not required for replacement of the element in the suction filter assembly a Unscrew the bowl center post fitting at the bottom of the bowl b Remove and discard the element Inspect filter head o ring and bowl gasket Replace if necessary c Wipe the bottom section of the filter head using a clean lint free cloth Install a new o ring in the filter head if required Use a light film of grease to hold the o ring in place if necessary CAUTION Do not use lint type cloth to clean hydraulic components Lint deposits can affect the operation of the system d Install a new element in the filter bowl CAUTION
198. lter in the suction line and locate point or points where air is being drawn into the system Tighten fittings where air leaks exist Free up or replace charge pressure relief valve Refer to Section 7 for placement procedure Replace with new or overhauled pump and motor Refer to Section 7 Air in system b Charge pressure relief valve in the motor manifold stuck open c Internal damage to pump or motor Defective charge check valves Check operation in both directions to determine which check valve is defective Defective high pressure relief valves at motor manifold Refer to Section 7 for pressure check procedures Examine both relief valves Clean and replace if defective Do not attempt to shim valves Internal damage to pump or motor Indicated by a Low zero or rapidly fluctuating charge pressure b Operating pressure in forward or reverse is less than high pressure relief setting Charge pressure lower than normal may drop to zero when high pressure is reached Noisy pump or motor NOTE Indications a b and may be corrected by minor repair cedures Refer to Section 7 for hydrostatic system checks and adjustments before remov ing pump or motor If internal failure is certain replace with a new or overhauled pump or motor Pieces or flakes of brass in tank or
199. moval from the drive drum The outer planetary assembly will accompany the drum hub upon removal Care should be taken when handling these components g Remove the inner planetary assembly see figure 8 4 h Remove the brake shaft snap ring Then pull the inner sun gear small thrust washers and needle thrust bearing from inner planetary assembly to prevent their loss or damage sed figure 8 5 i Inspect ring gear for wear damage cracked teeth or any other signs of impending failure Use the puller holes provided to remove ring gear if replacement or repair is necessary see figure 8 6 j Seal off drive shaft hole and steam clean planetary gear case in the drive drum make sure pockets and corners are cleaned thoroughly FIGURE 8 4 8 3 SECTION 8 FINAL DRIVE k Remove the planetary anchor flange oil seal for replacement Remove snap ring dust protector and bearing if it is worn or damaged seelfigure 8 7 1 Inspect the interlocked sun gear for excessive wear on both of its thrust surfaces one located at each end and twisted or cracked splines or any other signs of impending failure Remove if necessary by removing snap ring from inside of the carrier and lift out the gear figure 8 8 SECTION 8 FINAL DRIVE m Press outer planetary assembly out of the drive drum hub using an arbor press sed figure 8 9 CAUTION The drum hub must be supported in three equally spaced points when
200. n spool to rotate the spool for distribution of oil 9 11 The control section consists of a spool and sleeve assembly six centering springs and a manual steering check valve mounted in a cast housing The housing also contains an inlet port a dump port and two steering cylinder ports The spool is fitted into the center of the sleeve and is held in place in the sleeve by a straight pin and the set of six centering springs The pin extends through the sleeve and two radial slots in the spool The pin is a tight fit in the sleeve and a loose fit in the spool The centering springs extend through the spool and out each side of the sleeve so that they return the spool to the center position The spool contains a series of porting holes that align with similar holes in the sleeve when the spool is rotated off of the center position 9 12 A shaft with a radial slot at one end and splines at the opposite end connects the control section to the metering section The slotted end of the shaft mates with the straight pin extending through the spool The splined end fits into the center of the rotor set closest to the control section The control section is also attached to the metering section through a porting plate 9 13 The metering section consists of a rotor set metering element which is connected to the control section spool The rotor set consists of a matched rotor and stator 9 14 The stator has seven concave configurations serving a
201. n the rod f Remove tape and install jam nut specification Torque per g Compress wear ring and piston ring with fingers and insert into the cylinder shell h Push the rod and the retainer into the shell until the snap ring can be installed easily Install snap ring i Pull sharply on the rod until the retainer bottoms against the snap ring j Install the nut on the retainer Torque per specification k Install rod end ball joint Lubricated the five rod end ball joint internal parts which include the spring seat spring both ball stud seats and threaded plug refer to Section 4 9 82 INSTALLATION OF STEERING CYLINDER see figure 9 94 a Install the spring seat spring and one ball stud seat in the shell end of the cylinder and position the cylinder on the gooseneck mounted ball stud b Install the remaining ball stud seat and threaded plug Tighten plug until the cylinder will hold its position horizontal to the floor without assistance C Tighten plug until the cotter pin can be installed Install cotter pin d Connect hydraulic hoses to the cylinder e Position the rod end ball stud joint on the trunnion arm mounted ball stud Install the remaining ball stud seat the threaded plug f Tighten plug until all the spring movement in the ball joint is taken up Tighten plug until the cotter pin can be installed Install the cotter pin 9 29 g Fold boots over the ball joints and secure their p
202. n the solvent do not use a brush as some of the bristles may break off and lodge in the bearing Blow FIGURE 8 18 bearing completely dry do not spin with compressed air Oil bearing with light oil and rotate several times by hand Discard bearing if rotation is not free of binding and clicking Compare bearing looseness with a new one Discard the bearing if there is a considerable difference The bearing cages must be tight and the bearings free of defects Wrap bearings in clean paper if they are not to be installed immediately 8 10 Discard all seals snap rings and thrust washers that are worn or scored 8 11 REASSEMBLY AND INSTALLATION OF FINAL DRIVE ASSEMBLY a Install the snap ring bearing cups and bearing cones in each pinion gear seg figure 8 20 b Matching the marks on the pinion gear and planetary carrier install one pinion gear into the planetary carrier long hub on pinion gear away from interlocked sun gear Place thrust washer between pinion gear and planetary carrier on the capscrew side of the pinion gear Align the gear thrust washer and planetary carrier and insert the riding pin Install the spacer lockplate and capscrew Rotate the planetary pinion gear to insure proper seating of the bearings and thrust washer Torque the capscrews per specification back off one flat and lock Then install the other two pinion gears in the same manner sed figure 8 21 SNAP RING SEC
203. nd Feet 0738 Kilopescals Pounds per Square Inch 0 145 Kilometers per Liter Miles per Gallon 2354 Kilometers per Hour Miles per Hour 0 621 PIN 048458 000 This fine document Was brought to you by me Liberated Manuals free army and government manuals Why do I do it I am tired of sleazy CD ROM sellers who take publicly available information slap watermarks and other junk on it and sell it Those masters of search engine manipulation make sure that their sites that sell free information come up first in search engines They did not create it They did not even scan it Why should they get your money Why are not letting you give those free manuals to your friends I am setting this document FREE This document was made by the US Government and is NOT protected by Copyright Feel free to share republish sell and so on I am not asking you for donations fees or handouts If you can please provide a link to liberatedmanuals com so that free manuals come up first in search engines A HREFzhttp www liberatedmanuals com Free Military and Government Manuals lt A gt Sincerely Igor Chudov http igor chudov com
204. nded for towing a unit from one jobsite to another Tow at speeds of one 1 to two 2 M PH 1 61 3 22 km in for as short a distance as possible 3 8 FIGURE 3 6 SUNDSTRAND TRANSMISSI SECTION 3 OPERATION E ON BY PASS VALVE ON DIESEL UNITS 3 31 SHIPPING THE UNIT 3 32 When shipping the roller the four tie down eyes should be used One eye is located at each end of the rear scraper bar mount and under each operator mounting step in front The drive roll should be blocked front and rear and on both sides The guide rolls must be blocked on both sides CAUTION Do not block the guide rolls front and rear as it will shock load the trunnion king pin and bearings 3 33 MISCELLANEOUS OPERATING POINTS a Using the hood as an arm rest will ensure smooth control b No more than two people are allowed on the machine when operating Do use steering wheel or direc tion throttle bail as machine mounting assists d Always look in the direction of travel 4 1 GENERAL 4 2 This section contains instructions necessary for proper Hyster Care Maintenance for the C350B Steel Wheel Roller Hyster Care Maintenance is divided into two subsections Hyster Care Maintenance Schedule and Hyster Care Maintenance Procedures The maintenance schedule lists the recommended time intervals between maintenance checks The procedures subsection provides detailed instructions for performing the maintenance chec
205. ne and disconnect the gauge Install all plugs and tighten all fittings securely 7 164 CHECKING CONTROL PRESSURE se figure 7 40 7 165 The control pressure can be checked at the transmission pump as follows a Remove the threaded plugs from the two check ports and install a 600 PSI 40 kg cm2 gauge equipped with a short hose in each port Make sure that the gauges are accurately calibrated b Place the Direction Throttle Control Bail neutral Block the drive drum safely off the ground c Start the engine and set speed at approximately 1500 RPM with the transmission in neutral Shift the Direction Throttle Control Bail to the forward position and observe the gauge The pressure should be 45 PSI 3 2 kg cm2 initially then gradually reach charge pressure Shift the Control Bail to the reverse position The gauge should indicate 45 PSI 3 2 kg cm2 initially then gradually reach charge pressure d If the pressures in both the forward and reverse directions is not as specified the control valve assembly may be dirty or defective If the pressure is abnormal in one direction only the associated servo piston may be leaking in 5 5 7 HYDROSTATIC PUMP FIGURE 7 40 7 32 SECTION 7 TRANSMISSION 7 166 CHECKING CASE PRESSURE see figure 7 167 Case pressure should not be greater than 40 PSI 2 8 kglcm2 Attach adequate gauge to either pump or motor case as shown in figure 7 11 7 168
206. ng yoke clears the axle shaft spacers Then carefully roll the guide rolls until yoke is directly over the axle shaft see figure 9 111 c Position the spacer slits so they line up with the slits between the caps and the steering yoke Remove the frame blocking and lower the gooseneck until the axle shaft carries the weight see figure 9 112 d Install each cap on the original side it was removed FIGURE 9 108 from Be sure groove larger D is to the outside see figure 9 113 FIGURE 9 109 FIGURE 9 111 POSITION SPLIT SPACER PARALLEL FIGURE 9 110 FIGURE 9 112 9 35 SECTION 9 STEERING e Torque the capscrews to specification see figure 9 114 f Install the front scraper bar Lubricate the axle shaft assembly refer to Section 4 See figure 9 115 9 97 REMOVAL AND DISASSEMBLY OF YOKE AND KING PIN ASSEMBLY NOTE Remove axle shaft assembly from unit by following procedures outlined in paragraph 9 91 Then proceed as follows a Remove scraper bar and coco mat assembly water spray manifold and disconnect steering cylinder ball joint assembly seg figure 9 116 DISCONNECT BALL JOINT 42 FIGURE 9 116 RS FIGURE 9 115 FIGURE 9 117 9 36 b Support yoke with a hoist or lift truck Then remove king pin dust cover cotter pin jam nut and thrust washer sed figure 9 117 WARNING Be sure unit is securely blocked Lower yoke assembly onto the floor then remo
207. ngine malfunction If the engine continues to run after the ENGINE STOP has been pulled out or if the engine overspends the shut down device will prevent damage to the engine by cutting off the air supply and thus stop the engine 3 26 The shut down devicd figure 3 5 consists of an air shut off valve mounted in the engine air inlet housing The shut off valve is retained in the open position by a latch A cable connected to the EMERGENCY STOP SECTION 3 OPERATION control is used to remotely trip the latch shut off valve closing the 3 27 RESETTING EMERGENCY ENGINE STOP Detroit Diesel Only sed figure 3 5 3 28 The emergency engine stop must be manually reset before the engine can be restarted To reset the emergency stop push the cam pin handle located on the engine air inlet housing downward This will open the shut off valve Then push the EMERGENCY STOP Control lever against the instrument panel S JA CAM PIN HANDLE PUSH DOWNWARD TO RESET FIGURE 3 5 3 29 MOVING THE UNIT see figure 3 6 3 30 Before moving a malfunctioning unit the transmission by pass valve MUST be opened f the valve is not opened the drive drum will have restricted movement Rotate the slotted cam 90 degrees clockwise On units equipped with a Sundstrand Transmission pull up and lock the control cable located under the hood on the hydraulic tank side of the unit CAUTION The by pass valve is not inte
208. ning the hole in carrier with capscrews seg figure 7 74 removal procedure WARNING Support the motor carrier with hoist and sling arrangement c Using the puller holes provided pull the carrier and lift from unit SECTION 7 TRANSMISSION FIGURE 7 73 7 200 DISASSEMBLY OF MOTOR CARRIER a Remove o ring on outside of bearing carrier for replacement Remove bearing lock plate and shims Check flatness of lock plate with a straight edge Replace if deformed sed figure 7 75 b Lift off bearing carrier upper bearing and seal from motor housing Tag the bearing cone with its respective cup seg figure 7 76 c Inspect the bearings cups and cones Remove bearing from the carrier and replace if the rollers or cups are worn pitted or damaged in any way seg figure 7 77 FIGURE 7 74 7 44 SECTION 7 TRANSMISSION FIGURE 7 75 FIGURE 7 79 FIGURE 7 80 7 45 d Remove oil seal for replacement CAUTION The o ring and oil seal in the motor side of the drive drum play a critical part in preventing premature failure of drum support bearing and the planetary system These seals should be replaced during overhaul seg figure 7 78 e Replace o ring if required by inspection in step c sed figure 7 79 7 201 REASSEMBLY OF MOTOR CARRIER a If new bearing cups are to be installed press them firmly against the bearing carrier shoulders Lubricate the bearings and cups with li
209. nstall new gasket on control valve dry c Install pin in control valve links and pump links d Place washer in pin install the cotter pin and spread NOTE Caution must be taken during installation of these parts to prevent them from falling into the unit Lightly coating the parts with petroleum NOT grease is advised e Install valve to motor and torque the nine 9 bolts to 10 11 ft Ibs 1 38 1 52 kg m 7 195 REPLACEMENT OF MOTOR OR PUMP SHAFT SEAL FIGURE 7 57 7 40 SECTION 7 TRANSMISSION mrs ex 4 9 CAPSCREWS FIGURE 7 58 FIGURE 7 60 FIGURE 7 59 FIGURE 7 61 7 196 REMOVAL seg figure 7 63 a Disconnect hoses and remove pump or motor from unit e With fingers or two screwdrivers remove bronze rotating part of the seal from drive shaft see figure 7 64 b Insert Tru Arc 77 pliers in snap ring holes compress the ring and roll it out see figure 7 61 7 61 CAUTION Use care not to damage bronze rotating ring or shaft splines c Remove the aluminum seal retainer with screwdriver see figure 7 62 f 7 63 and account for all the parts shown d Remove the steel stationary seal This seal will 7 197 INSTALLATION usually come out with the retainer 7 41 SECTION 7 TRANSMISSION FIGURE 7 63 CAUTION Always replace both stationary and rotating parts of the seal DO NOT mix old and new parts a Wash and clean
210. o daily preventive maintenance checks and services b Organizational Maintenance Organizational maintenance consists of scheduled preventive maintenance services minor repairs and adjustments c Direct Support Maintenance Direct support maintenance consists of repairs on site or in a direct support unit s shops Repairs are accomplished with a minimum of tools and test equipment the assemblies and end items thus repaired are returned to their users d General Support Maintenance General support maintenance overhauls selected assemblies and repairs items designated by the area support command for return to stock e Depot Maintenance Depot Maintenance overhauls end items and selected major assemblies when they are required to satisfy overall Army requirements Overhaul of the end item may also be performed by contract with the manufacturer 2 2 Maintenance Allocation Chart Maintenance will be performed as necessary by the category indicated in the Maintenance Allocation Chart MAC Appendix C to retain or restore serviceability All authorized maintenance within the capability of a using organization will be accomplished before referring the item to support maintenance Higher categories will perform the maintenance functions of lower categories when required or directed by the appropriate Commanders Using and support units may exceed their authorized scope and functions in the MAC when approval is granted by the next higher support m
211. o pull it into the brake applied position Twist the end of the brake lever clockwise lever in brake off position to increase force required to apply the brake LUBE _ FITTING ADJUSTING THREADS ADJUSTING KNOB FIGURE 4 26 PARKING BRAKE LEVER MAINTENANCE 4 87 FINAL DRIVE ASSEMBLY see figure 4 27 4 88 CHECKING LUBRICANT LEVEL 4 89 Model C350B has fill and check plug as described ir paragraph 4 90 4 90 On model C350B the small pipe plug located on the left hand side of the drive drum communicates with the final drive compartment The correct lubricant level of the final drive compartment can be checked by rotating the plug to its high extreme Then slowly rotate the drive drum until the bottom of the FILL AN T i 17 IN 44 5CM CHECK PLUG h f DRIVE ROLL POSITION FOR CHECKING LUBE LEVEL FIGURE 4 27 SERVICING C350B FINAL DRIVE ASSEMBLY 4 20 SECTION 4 HYSTER CARE MAINTENANCE plug is 171 2 inches 44 5 cm from the ground Remove the plug If no lubricant is present at the filler hole turn the drum until the hole is again at its high extreme and add two quarts 1 9 Itr of specified lubricant Refer to for lubricant type Recheck lubricant level Replace and tighten the plug 4 92 FLUSHING THE FINAL DRIVE MECHANISM 4 93 Each 1 000 hours of operation or yearly the final drive mechanism should be flushed to remove the old lubricant and accumulated foreign material
212. o the return manifold Clogged filters or suction line Service suction or return filters Clean or replace line from tank to charge pump Internal leakage usually accompanied by loss of acceleration and power a High pressure relief valves stuck partially open Refer to Section 7 for pressure check procedures If the operating pressure is 200 PSI 14 kg cm or more lower in in one direction switch the high pres sure valves If the lower pressure read ing switches to the opposite side of the circuit do not attempt to shim valve Replace the volve System Operating Hot Cont b Internal parts of pump or motor or both worn Refer to Section 7 for pressure check procedures Replace defective pump or motor NOTE If either unit is considerably worn or damaged carefully check and clean other unit pump or motor System Noisy Air in system a Low oil level Check oil level at sight gauge on side of tank Replenish with approved oil listed in Section 4 Locate and fix leaks causing loss of oil Refer to manufacturer s warranty policy 5 6 SECTION 5 TROUBLESHOOTING TABLE 5 2B TROUBLE ANALYSIS FOR SUNDSTRAND HYDROSTATIC TRANSMISSION CONT TROUBLE PROBABLE CAUSE CORRECTIVE ACTION System Noisy Cont Acceleration and b Line or filter leaks considerable amount of foam in the tank Hosing or tubing not properly in
213. o use a depth micrometer and measure the depth from the outside of the flange through the puller bolt holes to the machined face of the frame Total the three measurements taken and record them Remove the anchor flange by using three puller capscrews figure 7 97 With micrometer measure the thickness of the flange next to the puller holes Total the three measurements taken and subtract from the depth measurement Divide your answer by three to obtain the shim thickness needed For the C350B assemble a shim pack equal to the final answer plus 003 in 076 mm or minus 002 in 051 mm FIGURE 7 97 FIGURE 7 98 7 50 SECTION 7 TRANSMISSION j Insert a shim pack equal or as close as possible with available shims to the measured distance in step i Be sure marks are aligned as in step g C350B only sed figure 7 98 CAUTION The mating surface of the frame shims and planetary anchor flange must be cleaned with solvent and dried with compressed air Any lubricant on these surfaces could cause the planetary anchor flange to work back and forth k Install the four planetary to anchor flange capscrews and torque to 120 ft lbs 16 6 kg m C350B only Insert all of the frame to anchor flange capscrews and torque to 200 ft Ibs 27 7 kg m see figure 7 99 I Pump the brake shaft support bearing full Pump the brake shaft support bearing full 200 FT LBS 27 660 kg m 7 120
214. ocks Then lift the axle OSCILLATION PIN ASSEMBLY STEERING AXLE ASSEMBLY FIGURE 9 96 9 31 shaft assembly away from the unit seg figure 9 100 9 93 DISASSEMBLY OF AXLE SHAFT ASSEMBLY seg figure 9 101 NOTE Remove axle shaft assembly from unit by following procedure outlined in paragraph 9 91 Then position axle shaft assembly on a hard level surface a Remove cotter pin slotted nut and thrust washer from one side b Remove split spacers and solid spacer reassembly into same position Tag for c Slightly lift the drum with components removed and slide the drum off of the axle SS POSITION UP I FIGURE 9 98 SECTION 9 STEERING d Perform steps a and b on the remaining drum then pull the axle shaft from the drum e Remove seals bearings shim s and center spacer from axle shaft CAUTION Tag bearings and shim s for reassembly into same position f Clean and inspect components paragraph 9 94 9 94 CLEANING AND INSPECTION a Clean all parts in solvent or other suitable cleaning agent Dry thoroughly with compressed air or clean lint free cloth If parts are not to be assembled immediately coat all machined surfaces with clean oil and cover ROLL DRUM FORWARD SE AND AWAY FIGURE 9 100 9 32 INNER BEARING N CENTER SPACER TO SHAFT LOCKING PINS SECTION 9 STEERING OUTER SOLID SPACER OUTER BEARING SPLIT
215. ol of swashplate angle displacement is accomplished in the hydrostatic pump by use of a powered servo system 7 133 DISPLACEMENT CONTROL VALVE 7 134 The Displacement Control valve assembly is a closed center four way valve with the servo pressure ports exhausted at the center neutral position The valve is operated through internal linkage connections with both the swashplate and the external control Direction Throttle Control Bail 7 135 To put the pump in stroke the control handle moves the displacement control spool through a torsion spring Once the swashplate angle is set a feed back link returns the displacement spool almost to neutral where it ports just enough oil to the servo cylinder to keep the swashplate at the proper angle 7 136 When the Direction Throttle Control Bail is released the displacement control spool tends to be returned to neutral by a spring 7 137 SERVO CONTROL CYLINDERS 7 138 The hydrostatic pump is equipped with two 2 servo cylinders They are controlled by low pressure oil directed from the displacement control valve 7 139 When the pump is stroked oil under charge pressure is ported to the servo cylinder The piston moves the swashplate against the opposite servo spring Both servo springs are constrained so that they can only force the swashplate toward neutral When the swash plate has moved to the angle set by the control handle the feed back link returns the displacement contro
216. om neutral and bring the unit to stall Observe the pressure gauge With the transmission stalled the gauge should indicate 5500 PSI 386 7 kg cm2 If not stop the engine and remove the two 2 high pressure relief valves It will be necessary to disconnect the two 2 high pressure hoses f Reverse the relief valves in the manifold ports and recheck at the REVERSE check port If the pressure is normal replace the relief valve originally removed from the reverse side of the manifold If the pressure remains abnormal troubleshoot the transmission as specified in Table 5 2B WARNING Changing the quantity of shims in the relief valves is not recommended g If pressure reading at Reverse port was normal then connect the gauge to the FORWARD check port sed figure 7 39 h Start the engine again and increase speed to 1500 RPM i Slowly move the Direction Throttle C6ntrol Bail in the Forward direction from neutral and bring the unit to stall Observe the pressure gauge With the transmission stalled the gauge should indicate 5500 PSI 386 7 kg cm2 If not stop the engine and remove the two 2 high pressure relief valves j Reverse the relief valves in the manifold ports and recheck the pressure at the FORWARD port If the pressure is normal replace the relief valve originally removed from the forward side of the manifold If the pressure remains abnormal troubleshoot the system as specified in Table 5 2B k Stop the engi
217. on 8 Inspect for jammed linkage or material jammed against brake drum SECTION 5 TROUBLESHOOTING TABLE 5 3 TROUBLE ANALYSIS FOR FINAL DRIVE ASSEMBLY CONT TROUBLE PROBABLE CAUSE CORRECTIVE ACTION Noisy Final Drive Dry or defective bearings Remove final drive assembly from axle housing Disassemble as needed to check for damaged parts Replace as needed refer to Section 8 Assemble and fill with proper lubricqnt refer to Section 4 Incorrect bearing adjustment Adjust the motor carrier bearing preload Refer to Section 8 Worn or broken planetary gear teeth Replace parts as needed Check for use of proper lubricant refer to Section 4 Install gears as specified in Section 8 Incorrect or lack of lubricant Fill with correct lubricant as specified in Section 4 Losing Lubricant Worn brake shaft seal Replace seal Lubricate before installation Defective motor housing gasket Replace gasket Fill final drive as specified in Section 4 Incorrect lubricant Drain lubricant Refill as specified in Section 4 Over filling Drain to correct level Refer to Section 4 for filling instructions Operating on side slope Operate the unit up or down the grade DELETED PAGE 5 9 SECTION 5 TROUBLESHOOTING TABLE 5 4 TROUBLE ANALYSIS FOR STEERING SYSTEM CONT TROUBLE CORRECTIVE ACTION GEAR PUMP Detroit Diesel Only Pumping Not De livering Fluid PROBABLE CAUSE Driv
218. ope Always move the Direction Throttle Bail toward the neutral position to slow the unit SECTION III REPAIR PARTS SUPPLY 3 1 General a The basic policies are procedures in AR 710 2 AR 725 50 and DA Cir 700 27 are generally applicable to repair parts management for CCE items b Manufacturer s parts manuals are furnished with CCE items instead of Department of the Army Repair Parts and Special Tool List RPSTL c National Stock Number NSNs are initially assigned only to PLL ASL parts and major assemblies i e engines transmissions etc Additional NSNs are assigned by the supply support activities as demands warrant d Proper use of project codes and weapon systems designator codes on parts requisitions is essential e Automated Processing AUTODIN of Federal Supply Code Manufacturer FSCM part number requisitions without edit for matching NSNs and exception data is authorized f Repair parts are available from commercial sources and may be purchased locally in accordance with AR 710 2 and AR 734 110 g Initial Prescribed Load List PLL and Authorized Stock List ASL will be distributed by US Army Tank Automotive Materiel Readiness Command TARCOM ATTN DRSTA FH 3 2 Prescribed Load List PLL The PLL distributed by TARCOM is an estimated 15 days supply recommended for initial stockage at organizational maintenance Management of PLL items will be governed by the provisions of AR 710 2 and local command procedu
219. osition with the metal ribbons 9 83 BLEEDING THE SYSTEM 9 84 Air may become trapped in the system if any hoses or components are removed An aerated system Is indicated by jerky or spongy operation when the steering wheel is turned 9 85 All hydraulic hoses leading to and from the cylinder enter at the top of the cylinder Therefore the system can be bled without disconnecting the hoses Bleed the system as follows a Fill the hydraulic tank with the specified oil refer to Section 4 b Start the engine and allow to idle at 500 to 600 RPM for approximately one minute This allows large air bubbles in the system to escape WARNING Do not extend the hands or arm through the center of the steering wheel If the steering control unit has been disassembled and incorrectly timed the wheel may suddenly become motorized or rotate abruptly with extreme force If this occurs see figure 9 2 and paragraph 9 27 step t and retime the control unit as shown c Increase engine speed to approximately 1 000 RPM and rotate the steering wheel as fast as possible in either direction This should produce enough compression of oil to force the air out of the lines d Continue to rotate the wheel in the same direction until the guide roll reaches its limit Quickly reverse the steering wheel rotation to pressurize the opposite end of the steering cylinder e Continue to rotate the wheel left and right from stop to stop until ste
220. otation of the control spool and sleeve parts with column shaft sed figure 9 14 amp e Place clean wooden block across vise throat to FIGURE 9 7 support spool parts and clamp unit 28 24 24 23 22 86 7 9 101 12 13 1 CAPSCREW 16 SPRINGeCENTERING 2 17 SPRING 3 SPACER 18 BALL STEEL 1 4 4 PLATE 19 SEAT CHECK s DRIVE 20 PLUG SEAL amp CAPSCREW 21 O RING 7 HOUSING 22 STEERING COLUMN 8 SEAL OIL TUBE AND FLANGE 9 SEAL QUAD RING 23 SHAFT 10 BUSHING CAP LOCATER 24 SNAP RING 11 O RING 25 BEARING 12 HOUSING VALVE 26 RING RETAINING 13 SLEEVE AND SPOOL 27 CAPSCREW 3 8 UNC X 3 4 14 PIN CENTERING 28 NUT 13 16 NEF tS DISC PIN 29 GEAR SET FIGURE 9 8 9 5 SECTION 9 STEERING FIGURE 9 9A FIGURE 9 11 FIGURE 9 9B FIGURE 9 12 FIGURE 9 10 FIGURE 9 13 FIGURE 9 16 SECTION 9 STEERING across port face with control end up Remove and set aside four 4 capscrews see figure 9 1 5 f Hold spool assembly down against block in vise and lift off end cap seelfigure 9 16 g Inspect mating surfaces for obvious leakage path wear seal condition see figure 9 17 h Remove cap locator bushing see figure 9 18 i Place housing on solid surface with port face down so that it can be held securely and remove spool sleeve assembly from the 14 hole end of housing see figure 9 19 j Be extremely careful to prevent these parts from binding as they are very closely fitted
221. parts give the unit serial number part number name of part and quantity required For any further information on parts service or ordering consult your local Hyster dealer FIRE PRECAUTION To avoid fires operators should be instructed to refuel compactors in well lighted areas outside of buildings Repairs and adjustments should be made on only those compactors which have been taken to a garage or maintenance shop STORAGE OF COMPACTOR Lubricate the compactor according to lubrication recommendations if it is to be left standing for any length of time This will protect against rusting The engine should be run once a week until it is thoroughly warm This will circulate the oil and prevent rusting from condensation in addition to keeping the battery charged If freezing weather is expected before the engine will be started again see that the cooling system is adequately protected against freezing Drain all water ballast from drums or use calcium chloride solution If the engine is to be stored or left standing longer than a normal day fill the fuel tank with clean fuel to keep out moisture laden air This will prevent condensation and rust from forming inside the tank OPERATION AND MAINTENANCE TIPS The following tips will help increase compactor life and contribute to the reduction of expensive downtime 1 Check lubricating and hydraulic oils and engine coolant at the beginning of each work shift Use only recommended oils
222. pecified limits replace the low charge pressure relief valve If this fails to correct the pressure troubleshoot the system as specified in Table 5 2B WARNING Changing the quantity of shims in the relief valve is not recommended 7 162 CHECKING HIGH PRESSURE RELIEF see figure 7 39 CAUTION Transmission should NOT be stalled at high pressure relief for periods longer than 15 seconds 7 163 The pressure in the high pressure lines should be 5500 PSI 386 7 kg cm2 when the transmission is in a stalled condition Two 2 high pressure relief valves are located in the motor manifold as shown in figure 7 39 Two 2 check ports are located at the side of the manifold for checking the setting of the relief valves Check the high pressure valves as follows WARNING In order to check the high pressure relief valves it is necessary to bring the unit to stall CAUTION must be taken to ensure the safety of personnel when attempting to stall the unit HIGH PRESSURE CHECK PORTS NN NKG a a D FIGURE 7 39 7 31 SECTION 7 TRANSMISSION FIGURE 7 39 a Movement of the unit must be safely restricted b Remove the cover from the right hand side of the frame at the drive drum c Connect a 10 000 PSI 700 kg cm2 gauge to the REVERSE check port d Start the engine and set Park Brake Increase engine speed to 1500 RPM e Slowly move the Direction Throttle Control Bail in the Reverse direction fr
223. perated friction brake mechanism that prevents the final drive from rotating The braking mechanism is mounted on CONTROL CARLE BACKING ACTUATOR SF ACER BRAKE SHOES RETURN SPRINGS SECTION 10 BRAKES the left hand side of the final drive housing It is operated by a handlever mounted to the gooseneck A flexible teflon coated steel cable connects the braking mechanism to the handlever When the handlever is pulled the cable retracts operating an actuator lever which forces the brake shoe type lining against the Inside of the brake drum The brake drum is splined to the final drive shaft 10 6 REMOVAL AND DISASSEMBLY see 10 7 Block guide roll and drive drums prior to removal of the brake drum assembly to prevent movement of the unit Set the parking brake handlever to the brake applied position Remove parking brake access cover located on the rear of the left hand frame channel RUBBER WASHER WASHER FIGURE 10 1 a Remove the brake drum capscrews then release the parking brake control lever Remove the brake drum b Remove the brake shaft cotter pin then remove slotted nut Remove hub and spacer c Disconnect and remove the brake return springs Remove brake shoes d Lift out the brake shoe actuator lever and disconnect the control cable e Remove backing plate capscrews then remove the backing plate 10 8 CLEANING AND INSPECTION a Use solvent to clean all metal parts except th
224. personnel are not available in the command to operate and or maintain the Roller 1 9 Logistics Assistance a Tank Automotive Command Field Maintenance Technicians stationed at CONUS and OCONUS installations will be fully qualified and available to furnish on site training and or assistance concurrent with receipt of the Roller b Assistance can be obtained by contacting the Logistics Assistance Office listed in Appendix B or AR 700 4 1 10 Warranty The CCE Roller contractor warrants the products furnished under this contract according to the terms and conditions described in the equipment publications and Appendix B of this publication All warranties furnished to the Roller contractor by subcontractors of assemblies or components utilized in the manufacture of the end item will be extended to the Government See Appendix B for warranty guide lines 1 11 Reporting You can improve this publication by recommending improvements using DA Form 2028 Recommended Changes to Publications and Blank Forms and mail direct to Commander US Army Tank Automotive Materiel Readiness Command ATTN DRSTA MVB Warren MI 48090 SECTION II MAINTENANCE 2 1 Maintenance Concept The CCE Roller will not require any new or special maintenance considerations All maintenance functions can be accomplished within the current maintenance concepts established for construction equipment a Operator Crew Maintenance Operator and crew maintenance is limited t
225. planetary gear see figure 8 35 Install inner planetary into ring gear see figure 8 36 r Apply a large amount of lubriplate Insert thrust washer first and then assemble needle bearing into outer planetary seg figure 8 37 5 Lift the outer planetary assembly into the ring pinions with gear meshing the planetary E amp 5 ode URE 8 36 FIG SECTION 8 FINAL DRIVE the ring gear and push this assembly into the drum until it bottoms against the thrust washers sed figure 8 38 NOTE Check to see that the two planetary carriers do not touch Also check that the thrust needle bearings not fallen out of place Planetaries must be removed if these conditions are a problem t Paint outer face of ring gear with Locktite Plastic Gasket or equivalent Apply Lubriplate to machine boss of outer planetary see figure 8 39 Position drum hub loosely against drive wheel Use three place bolts equally spaced to initially pull hub against ring gear sed figure 8 40 CAUTION Do not align puller holes of the drum with those of the ring gear Remove puller bolts and install the 16 drum hub capscrews Torque in a circular pattern to specification see figure 8 41 W Manufacture a puller per illustration in figure 8 42 X Assemble special puller onto splined APPLY PLASTIC SEALER HERE SECTION 8 FINAL DRIVE gear Tighten capscrews until splined gear is flush with bearing
226. presented in Section 5 7 88 HYDRAULIC SYSTEM see figure 7 32 7 89 The closed loop hydraulic system consists of two subsystems the hydrostatic transmission subsystem and the steering subsystem The two subsystems share hydraulic oil and hydraulic tank These components are presented in this section Refer to the steering section for the remaining coverage of the steering hydraulic components 7 90 HYDRAULIC OIL cu Specifications for hydraulic oil are given in 7 92 HYDRAULIC SYSTEM COMPONENTS see figures 7 33 7 34 and 7 35 7 93 GENERAL 7 94 The hydrostatic transmission offers infinite control of speed and direction Control of the variable displacement axial piston pump and the fixed displacement motor is the key to controlling the unit When the variable pump swash plate is tilted by movement of the Direction Throttle Control Bail a positive stroke to the pistons is created This at any given input speed produces a flow from the pump This flow is transferred through high pressure lines to the motor The ratio of the volume of flow from the pump to the displacement of the motor will determine the speed of the motor output shaft Movement of the Direction Throttle Control Bail to the opposite side of neutral causes the flow from the pump to reverse and the motor output shaft turns in opposite direction Speed of the output shaft is controlled by adjusting the displacement flow of the transmission Load working pr
227. r shaft and cylinder block assembly rotate together The direction of rotation depends on the direction of the high pressure oil entering the motor from the hydrostatic pump High pressure oil enters one of the motor main ports to push the cylinder pistons out of their cylinder and firmly against the motor swashplate This action causes each piston slipper which is protected by a thin film of oil to slide down the face of the thrustplate rotating the entire cylinder block assembly The cylinder block is splined to and rotates the motor output shaft As the cylinder block rotates and the filled cylinders pass the other main port return oil flows to the hydrostatic pump at low pressure The speed at which the cylinder block rotates is determined by the volume of pump output oil 7 148 MANIFOLD 7 149 The manifold is connected across the high pressure and low pressure sides of the main circuit It includes 1 two high pressure relief valves 2 a shuttle valve 3 a low charge pressure relief valve 7 150 HIGH PRESSURE RELIEF VALVES 7 151 Two high pressure relief valves are part of the manifold They serve to prevent abnormal pressure surges in either of the two branch lines of the main circuit They accomplish this by dumping oil from the high pressure line to the low pressure line Situations such as rapid acceleration abrupt braking and sudden application of load will activate the relief valves 7 152 SHUTTLE VALVE 7 15
228. raulic Motor 386 7 14 kg cm 3 2 kg cm2 approximately 2 8 kg cm Normally 0 7 kg cm 25 4 HG Maximum 68 8 cc per Revolution at 18 Swashplate Angle 386 7 kg cm 2 8 kg cm 9 kg cm2 Above Case Pressure 37 9 LPM 12 3 cc Per Per Revolution 34 1 LPM Max at High Idle 9 525 mm 16 Thread Four Bolt Split flange Boss 22 225 mm 14 UNF 2B Boss 22 225 mm 14 UNF 2B O ring Boss SECTION 2 SPECIFICATIONS TABLE 2 8 SUNDSTRAND HYDROSTATIC TRANSMISSION SPECIFICATIONS CONT DESIGN DATA ENGLISH METRIC Fixed Displacement Axial Piston 4 26 Cubic Inches at 189 Pump 69 8 cc at 18 Pump Swashplate Angle Swashplate Angle 150 180 PSI 10 5 12 7 kg cm HYDRAULIC MOTOR Type Displacement Charge Pressure Relief Valve setting Main Relief Valve Setting 5500 PSI Above Charge Pressure 386 7 kg cm 2 Above Charge Pressure Port Sizes Main Line Inlet Outlet 3 8 16 Thread Four Bolt 9 525 mm 16 Thread Four Bolt Ports 2 Split flange Boss Split flange Boss Case Drain Port 7 8 14 UNF 2B O ring Boss 22 225 mm 14UNF 2B O ring Boss TABLE 2 9 FINAL DRIVE AND DRUM ASSEMBLY SPECIFICATIONS DESIGN DATA ITEM C3508 60 1 1 FINAL DRIYE GEAR RATIO LUBRICATION Type Quontity SAE 90 Multi purpose Gear Oil 4 Quarts 3 8 Itrs GEAR TOOTH DATA Inner Sun Gear 17
229. res Selection of PLL parts for shipment to CONUS OCONUS units is based upon the receiving Command s recommendation after their review of the TAROOM prepared list Organizations and activities in CONUS OCONUS will establish PLL stocks through normal requisitioning process 3 3 Authorized Stockage List ASL The ASL distributed by TARCOM is an estimated 45 days supply of repair parts for support units and activities The ASL parts will be shipped according to the recommendations of the receiving commands after they have reviewed the initial list distributed by TARCOM Support units and activities in CONUS OOONUS will establish ASL stocks through normal requisitioning process 3 4 Requisitioning Repair Parts a Using Units Organizations Requisitions DA Form 2765 Series will be prepared according to AR 710 2 and local command directives All requisitions will have the Weapons System Designator code BD Interim Change 5 1 AR 710 2 per DA Message DALO SMS 091400Z Jun 78 entered in the 2nd and 3rd positions of block 18 Units in CONUS will use project code BGW in block 19 Units OCONUS will enter in block 19 project code JZC Appendix H b Support Units and Activities 1 General All MILSTRIP requisitions DD Form 1348 Series prepared for repair parts support of CCE items will include distribution and project codes see Appendixes l J and K 2 Distribution Code Supply customers in CONUS will use code F in card column 54 Custom
230. s oil cavities It also contains the same number of convex configurations each one being diametrically opposite a cavity The rotor contains six lobes that are formed to mate with the stator cavities Each lobe has a diametrically opposite lobe therefore when one rotor is in a cavity of the stator its opposite lobe is at the crest of the stator convex SECTION 9 STEERING configuration opposite the cavity Due to the interaction between the rotor and stator there are 42 overlapping fluid discharging actions in one revolution of the rotor OPERATION sef figure 9 2 9 16 Rotation of the steering wheel actuates three main components in the steering control unit 1 The control section spool 9 15 2 The control section sleeve 3 The metering element rotor in the metering section When the steering wheel is stationary the control section spool and sleeve are held in the center position by the six centering springs During this condition oil is received from the system hydraulic pump and is routed back to the tank 9 17 As the steering wheel is turned and the spool just begins to rotate the spring set tends to rotate the sleeve to maintain the center relationship between the spool and sleeve However the force required to turn the rotor set is greater than the spring pressure and the6springs start to flex This flexing action permits the spool to move within the sleeve approximately 1 8 inch until the ends of t
231. sed figure 4 25 The suction shut off valve should be open when draining the pump so all water from the suction side is removed Water in the pressure side of the system should be blown out with compressed air Cap or tape the nozzles and coat the tank fill cap threads with grease 4 107 DRUM BALIAST 4 108 If water ballast is being used in the guide rolls and drive drum this water should be drained before storing Rotate each drum until the ballast plug largest plug is at its low extreme when draining Replace the drain plugs for storage 4 109 STEERING CYLINDER 4 110 After the roller has been positioned for storage turn the steering wheel to provide minimum steering cylinder rod exposure This will prevent rusting of the sliding contact surface of the rod Coat the cylinder rods and control valve spools with a heavy grease 4 111 FUEL SYSTEM 4 112 Diesel fuel will leave a waxy substance that plugs the system f the unit is placed in storage for any appreciable length of time all fuel should be drained from the tank and the engine run until the fuel in the system is used SECTION 4 HYSTER CARE MAINTENANCE 4 113 ENGINE COOLING SYSTEM 4 114 When storing the unit the engine cooling system should be protected against freezing This can be done by either draining the system or adding one of the various anti freeze mixtures To drain the system open the stop cocks on the bottom of the radiator and the side of
232. ssure is desired on the drive drum the front guide roll spray can be restricted by turning the shut off valve located under the unit steering wheel 11 12 CHECKING MOTOR BRUSHES see figure 11 3 WARNING Be sure ignition key switch and water spray switch are in the OFF position before inspecting brushes 11 13 To inspect the brushes unscrew the brush retainers Blow out any brush dust with compressed air Check for at least 3 8 inch 9 5 mm of brush length at the shortest point 11 14 Examine the commutator for burns pits or wear The space between the segments should be clean and free of deposits Replace motor if commutator is damaged 11 15 REMOVAL OF PUMP AND MOTOR ASSEMBLY a Turn the shut off valve located at the pump under the unit seelfigure 11 4 b Disconnect electrical wiring pressure and suction lines seg figure 11 4 BRUSH RETAINER CENTRI FUGAL PUMP ASSEMBLY amp END HOUSING FIGURE 11 3 11 2 SECTION 11 WATER SPRAY SYSTEM c Remove four 4 mounting plate capscrews and lower unit to floor WARNING Support mounting plate during capscrew removal DO NOT allow subassembly to fall 11 16 REPAIR 11 17 Determine if pump or motor has failed Separate pump or motor and replace failed unit Refer to CHECK MOTOR BRUSHES paragraph 11 12 NOTE The pump impellar is pressed on the armature shaft 11 18 INSTALLATION OF PUMP AND MOTOR ASSEMBLY 11 19 Install p
233. st transmission control linkage per procedure outlined in paragraph 7 172 Sundstrand UPPER e whit e ADJUSTMENT MJ THROTTLE X BRACKET LINK ou Y gt HAND THROTTLE THROTTLE CONTROL CABLE ENGINE i FORWARD STOP NN STOP CABLE 225 SCREW V a MAIN REVERSE THROTTLE STOP CABLE SCREW DETROIT DIESEL HAND UNITS ONLY THROTTLE FIGURE 7 44 7 35 50 WELDS 4 1 3 FIGURE 8 42 51 FRAME AND BODY POWER UNIT FUEL SYSTEM A01 ILLUSTRATED INDEX PARTS WATER SPRAY SYSTEM ELECTRICAL 5 eere TRANSMISSION AND POWER BRAKES AND 0 STEERING AND LINKAGE eee OPTIONAL een NUMERICAL INDEX 1404 1B02 1D02 1F02 2A04 2C02 2D02 2E02 G02 999999959 A02 ALPHABETICAL INDEX 8 1 09 BRAKE AND 2C03 een 1E04 FUEL SYSTEM 3 53 DIESEL 1E03 CONTROL LINKAGE eene 2A09 HORNO ais 1F08 COOLING 1B09 HYDRAULIC MOTOR 2A11 HYDRAULIC PUMP 2A
234. stock push the retainer into the cylinder shell until the snap ring can be easily removed from the shell d Remove snap ring e Pull sharply on rod to remove retainer piston and rod f Clamp rod in a vise between two pieces of clean soft wood Remove piston jam nut g Tape rod threads and remove piston h Remove the wear ring from piston if damaged scored or chipped i Remove the teflon piston ring and o ring j Remove the inner o ring from the piston k Remove retainer from the cylinder rod and remove the outer and inner o rings and back up rings l Remove wiper seal from the end of the retainer 9 80 CLEANING AND INSPECTION a Wash all parts in solvent and inspect for nicks burrs and scratches Dress parts with fine sandpaper or India stone if necessary b Check all contact surfaces for any abnormalities and piston rings for wear Replace if necessary 9 81 REASSEMBLY OF STEERING CYLINDER see NOTE All o rings and wipers should be replaced on reassembly a Install outer and inner o rings and backup rings and wiper seal in the retainer b Lubricate the rod and the entire retainer with Hyster Approved Packing Lubrication Carefully install the retainer on the rod SECTION 9 STEERING c Install inner o ring in the piston d Install the wear ring piston ring on the piston outer o ring and teflon e Lubricate the piston with Hyster Approved Packing Lubricant and install the piston o
235. sulated Air in system Deceleration Sluggish Unit Will Not Move Low charge pressure Control orifice plug partially blocked Internal wear or damage Engine lugs down Check suction filter and suction line between tank and charge pumps for leaks allowing air to enter into system Re place defective hose and or tighten fitting Make sure hose or tubing is not touching any metal that can amplify natural hydraulic system hum Refer to System Noisy air in system Refer to System Will Not Operate In Either Direction Low or zero charge pressure Refer to Section 4 Replace suction filter more often Refer to Unit Will Not Operate In Either Direction Internal damage to pump or motor Refer to engine manufacturer s service manual Refer to manufacturer s warranty policy TABLE 5 3 TROUBLE ALALYSIS FOR FINAL DRIVE ASSEMBLY TROUBLE PROBABLE CAUSE CORRECTIVE ACTION Control linkage to transmission Transmission bypass valve open Broken drive shaft Planetary gears jammed Parking brake not releasing Adjust Refer to Section 7 Close valve control Refer to Section 3 Replace defective part Determine cause of failure and correct before placing unit back in service Check entire drive train for possible damage Remove final drive from unit for complete teardown and inspection Check ali parts for damage Replace as needed Check alignment of components Refer to Secti
236. tatic pump 5 Figure 7 44 page 7 35 s incorrect Cross out entire figure The revised figure is attached please include in the manual 6 Section 7Jparagraph 7 172 7 33 reads a dimension of 13 32 Please correct copy to read 1 3 32 7 paragraph c eads a dimension of 11 16 Please correct copy to read 1 1 16 8 igure 8 42 page 8 12 15 incorrect Cross out entire figure The revised figure is attached please include in the manual 47 ALTERNATOR wr WATER TEMP SENDING UNIT SICH 0 PRESSURE NE TRANSMISSION 010 db Wr WIREGAUGE LIGHTS A B lt 2 LIGHT DAS alsia CIRCUIT BREAKER gem R PUMP SWITCH ane 0 NUETRAL START SAFETY SWITCH Ge PARK T BRAKE D 9 65 FIGURE 4 14 ELECTRICAL SYSTEM SCHEMATIC WITH DIESEL ENGINE 48 SECTION 6 ELECTRICAL GRC WATER SPRAY FO CIRCUIT ALTERNATOR TRANS SE WATER TEMP PESE SEONG UNIT ee EN a T PUMP SWITCH LL TN af 4 i 299 v ei j rH m E dec i TRATISEISSION TEMP AA 4 ION A SAFETY SWI D 2m UNIT 432r j ww Dr RART 1 p j BATTERY Al BRAKE LIGHT Dash db m Se es BATTERY z Dotted C Ld LIGHTS HORN D SEE FIGURE 6 6 COLOR CODE TABLE FIGURE
237. ted after each 50 hours of operation or weekly The alternator belt s should deflect 1 4 inch 6 35 mm with six pounds 2 7 kg of force CAUTION Detroit Diesel Only Replace both alternator drive belts when one or both needs replacing 4 38 ELECTRICAL WIRING sed figure 4 14 4 39 Periodically inspect all wiring for Proper routing loose terminal connections cracks wear faulty insulation brittleness and that they are free from oil and grease Electrical components should be connected per the schematic drawing when components are replaced CAUTION Do not use a wire smaller than the original factory installed wires 4 40 COOLING SYSTEM sed figure 4 15 4 11 SECTION 4 HYSTER CARE MAINTENANCE CIRCUIT BREAKER ALTERNATOR MISSION PRESSURE SENDING UN SWITCH Eia Re D OIL PRESSURE WATER PUMP SENDING m SWITCH aw ur NUETRAL START SAFETY SWITCH le PARK mn 4 LIGHT 1 DASH SWITCH ud LIGHTS 9 54 0 4 E FLD BAT 011 REGULATOR WHITE BLUE BLUE GREEN BROWN BLACK YELLOW ORANGE WHITE LIGHTS A B BROWN BROWN GREEN WHITE c da m30zzrz 4 41 RADIATOR 4 A2 The radiator should be filled to one inch 2 54 cm below the filler neck 4 43 The radiator core must be serviced if it becomes clogged at any point where light cannot be seen through the core Blow out thoroughly with compress
238. tem add coolant as specified in Table 4 1 4 53 DETROIT DIESEL FAN DRIVE BELTS see fig 4 54 Examine the belt for cracks on the inner SECTION 4 HYSTER CARE MAINTENANCE puoi FILTER DETROIT 3 53 FIGURE 4 20 CHECKING AND CHANGING ENGINE OIL AND FILTER 4 15 plys before making tension adjustments The fan drive belts should be checked and adjusted after each 50 hours of operation or weekly 4 55 New drive belts will stretch after the first few hours of operation After the first eight hours of operation check the belts again and retighten if necessary Adjust the belt tension so that a firm push with the thumb at a point midway between the longest span deflects the belts approximately 3 4 inch 2 cm Adjust the belt tension as follows a Loosen the four capscrews 2 on each side of engine securing the fan bracket to its mounting blocks Also loosen the four capscrews securing the fan shroud to the radiator b If the belts are too tight push the fan bracket downward to loosen the belts If the belts are too loose use a pry bar between the stud welded on the inside of mounting bracket and the mounting block to move the bracket upward CAUTION When adjusting the fan pulley always adjust the fan shroud the same distance in either direction The fan must always be centered in the shroud c When the correct adjustment is obtained tighten the four fan bracket capscrews securely Tighten the four
239. ter completion of servives make certain that you know exactly what repairs were performed and or parts replaced This is required for overall problem trend evaluation by the NMP and must be identified upon completion of warranty servives f Telephone the NMP at TARCOM AUTOVON 273 3349 273 3439 and or 273 3387 if 1 Your equipment requires repairs and you cannot obtain these servives using the procedures listed above 2 The length of time required for repairs may seriously hamper your mission or if the dealer s overall response to your requirements are not satisfactory 3 You have any questions regarding warranty procedures either in general or about a specific job Do not wait until your problems become critical g Do not attempt to conduct negotiations regarding a breech of warranty This is a function of the Contracting Officer through the NMP at TARCOM 10 APPENDIX C MAINTENANCE ALLOCATION CHART FOR Roller Motorized Steel Wheel Model C35B D Section INTRODUCTION 1 General This Maintenance Allocation Chart designates responsibility for performance of Maintenance functions to specific Maintenance categories 2 Maintenance functions a Inspect To determine the serviceability of an item by comparing its physical mechanical and or electrical characteristics with established standards through examination b Test To verify serviceability and detect incipient failures by measuring the mechanical or electrical c
240. that the W gasket seal retains its position in the recess of the front cover Tighten capscrews to specified torque CAUTION The pump rotation is identified by arrow stamped on the pump body When assembling the pump the front cover drive end of the pump should be located on the arrow end 9 60 INSTALLATION a Tighten the mounting bolts securely b Make certain all hydraulic fittings are tightened 1 CAPSCREW 8 FRONT COVER 2 LOCKWASHER 9 KEY c Bleed the system as specified in paragraph 9 3 FRONT BEARING 10 DRIVE GEAR ae 4 GASKET 11 DRIV 5 SPACER 12 SEAR CAUTION Check for abnormal hot spots If any 6 GASKET SEAL 13 REAR COVER particular area is hot disassemble and 7 SHAFT SEAL 14 REAR BEARING inspect 9 61 FLOW DIVIDER DETROIT DIESEL FIGURE 9 91 9 62 DESCRIPTION sef figure 9 92 RELIEF VALVE ASSEMBLY PILOT VALVE ALLEN SCREW PISTON SPRING HOUSING a PISTON FLOW DIVIDER ASSEMBLY FIGURE 9 92 9 26 9 63 The flow divider is mounted on the front right hand side of the engine compartment Four hoses are routed to and from the flow divider The unit consists of a body pressure compensated piston and pilot operated relief valve 9 64 Port P is for the pump supply hose Port CF is for controlled flow and is connected to the steering control unit at the gooseneck Port EF is for excess flow and is connected to the inlet fitting of the pump
241. the mounting plate and shaft seal carefully to insure that they are clean and in good condition Insure that the mounting plate seal grooves are clean and smooth Each of these seals are slightly larger than its seal grooves so that they will be adequately retained in service Push each gently into place and smooth down into seal groove with finger tip see figure 9 50 o Thin oil seal at exterior of mounting is a dirt exclusion seal and does not generally need replacement If this is replaced it should be pressed into counterbore so that the lip is directed away from the unit p Place the mounting plate sub assembly over spool shaft and slide down into place over cap locator bushing smoothly so that seals will not be disrupted in assembly eb TUIS EE Be certain that the mounting plate rests fairly flush against the end of housing assembly so that the cap locator bushing is not cocked and install four mounting plate capscrews Tighten these evenly and gradually to a torque setting of 21 ft Ibs 2 9 kg m see figure 9 14 FIGURE 9 51 SECTION 9 STEERING SECTION 9 STEERING FIGURE 9 52 q Reposition in vise and clamp across the edges of the mounting plate lightly Check to insure that the spool and sleeve are flush or slightly below the 14 hole surface of the control housing seg figure 9 53 r Clean the upper surface of the housing by wiping with the back of a clean hand or the butt of the thumb Clean ea
242. the proper oM as specified in Section 4 Replace the transmission oil filters 5 10 SECTION 5 TROUBLESHOOTING TABLE 5 4 TROUBLE ANALYSIS FOR STEERING SYSTEM CONT TROUBLE No Response When Steering Wheel Turned Slowly Slow Or Hard Steering Steering Wheel Does Not Center Continuous Steering Wheel Rotation No Response PROBABLE CAUSE CORRECTIVE ACTION STEERING CONTROL UNIT Handpump Dirt in hydraulic system Cil level too low Cil level low Clogged line Dirt in hydraulic system Worn sleeve and spool Worn metering gear Malfunction of double vane hydraulic pump Manual steering check bail off its seat Broken centering springs Broken centering springs Burr on sleeve and spool Dirty fluid Pump failure 5 11 Drain and flush complete hydraulic system Change transmission suction and return filters Refill system with specified hydraulic fluid Refer to Section 4 Fill to sight gauge on tank Refer to Section 4 for specified hydraulic fluid Fill to sight gauge on tank Refer to Section 4 for specified hydraulic fluid Check lines Clean and replace as required Drain and flush complete hydraulic system Change transmission suction and return filters Refill system with specified hydraulic fluid Refer to Section 4 Replace sleeve spool and housing as a unit Replace both sets of metering gears Refer to troubleshooting Gear
243. ther see figures 9 37 and 9 38 Test for free rotation Spool should rotate smoothly in sleeve with finger tip force applied at splined end FIGURE 9 37 SECTION 9 STEERING FIGURE 9 41 FIGURE 9 40 FIGURE 9 43 9 12 FIGURE 9 44 FIGURE 9 45 FIGURE 9 46 9 13 STEERIBGTION 9 STEERING e Bring spring slots in both parts in line and stand on end of bench Position pairs of centering springs or 2 sets of 3 each on bench so that extended edge is down and arched center is together Enter one end of one spring set into slot just far enough to edge on opposite side se figure 9 39 f Enter second spring set from opposite side from installed spring set Work the spring set around until spring set enters slot on opposite side The two spring sets will now have tension between them at their arches sed figure 9 40 g Center the spring set so that they push down evenly and flush with the upper surface of the spool and sleeve seg figure 9 41 h Install cross pin through spool assembly see figure i Push into place until cross pin is flush or slightly below the sleeve diameter at both ends sed figure 9 43 j Position the housing on a solid surface with the port face down Start the spool assembly so that the splined end of the spool enters the 14 hole end of the housing first sedie a k Be extremely careful that the parts do not cock out of position while entering Push parts gently into place
244. ting Motor Test Replace Repair Instrument Panel Accessories Replace Repair Miscellaneous Electrical Items Switches Circuit Breakers etc Replace Head Light Assembly Replace Repair Read Light Lamp Units Replace Sending Unites Warning Switches Replace Horn Assembly Replace Battery Inspect Test Service Replace Battery Cables Replace Repair The subcolumns are as follows C operator crew F direct support D depot O organizational H general support 17 Section Il MAINTENANCE ALLOCATION CHART ROLLER MOTORIZED STEEL WHEEL 2 DRUM TANDEM 10 14 TON CCE 1 2 3 4 6 GROUP COMPONENT MAINTENANCE MAINTENANCE Category NUMBER ASSEMBLY FUNCTION REMARKS Wiring Harness Replace Repair TRANSMISSION SYSTEM Hydraulic Tank Service Replace Repair Suction Filter Service Replace Hydrostatic Pump Replace Repair Overhaul Servo Control Valve Replace Repair Direction Throttle Control Assy Service Adjust Replace Repair Hydrostatic Motor Replace Repair Overhaul Transmission By Pass Valve Replace The subcolumns are as follows C operator crew F direct support D depot O organizational H general support 18 Section Il MAINTENANCE ALLOCATION CHART ROLLER MOTORIZED STEEL WHEEL 2 DRUM TANDEM 10 14 TON CCE 1 2 3 4 6 GROUP COMPONENT MAINTENANCE MAINTENANCE Category NUMBER ASSEMBLY FUNCTION REMARKS Repair Hydraulic Oil Cooler Service Replac
245. tion the Contractor guarantees that at the time of delivery thereof the supplies provided for under this contract will be free from defects in material or workmanship and will conform to the requirements set forth in the contract Notice of any alleged defect or non conformance shall be given by the Government to the Contractor within one 1 year following delivery of the allegedly defective or non conforming item The Contractor shall be afforded the opportunity to examine the allegedly defective or non conforming supplies or parts thereof at the site at which the suspected malfunction is experienced or if field examination cannot be accomplished such allegedly defective or non conforming supplies or parts thereof shall be returned freight collect via cheapest transportation to the Contractor s plant The Contractor shall with all possible speed exchange such supplies or parts thereof with supplies or parts of like kind and ship such supplies or parts thereof freight prepaid to the location from which the defective or non conforming supplies or parts thereof were returned or if such location is not within CONUS to the port of embarkation or other location within the original 48 States or the District of Columbia prescribed by the Contracting Officer provided examination of such supplies or parts thereof discloses to the Contractor s satisfaction that the material received a was defective or non conforming when delivered or b has become def
246. to mount plate f Pull pump straight back and tilt shaft end of pump up enough to lift pump from unit FIGURE 7 45 g Plug or cap all ports to prevent contamination 7 179 REMOVAL OF HYDROSTATIC MOTOR see figure 7 46 a Remove hydrostatic motor inspection plate on the right hand side of the frame b Disconnect high pressure lines Plug or cap ports on hoses Remove the by pass valve linkage c Support the hydrostatic motor and remove the four 4 motor mounting bolts d Carefully pull the motor far enough out of the motor carrier to remove the case drain line Plug or cap all hoses and ports to prevent contamination of the hydrostatic system 7 180 REPLACEMENT OF CHARGE PUMP 7 181 REMOVAL see figure 7 47 a Remove the line connecting the charge pump to the reservoir and plug to prevent draining of the reservoir Remove the connector fitting b Remove the four 4 capscrews NOTE Do not remove the capscrews at the top and bottom of the charge pump sed figure 7 47 2 MOUNTING BOLTS FIGURE 7 46 SECTION 7 TRANSMISSION c Pull charge pump away from the main pump Use caution not to drop aluminum spacer CAUTION Do not use sharp tools to pry charge pump from main pump A scratch on the sealing surface may cause leakage If charge pump does not pull loose tap LIGHTLY on the side of the charge pump with a plastic hammer to break paint or gasket seal 7 182 INSTALLATION sed fi
247. to organizational maintenance if you can t tighten it C Welds Look for loose or chipped paint rust or gaps where parts are welded together If you find a bad weld report it to organizational maintenance D Electric wires and connectors Look for cracked or broken insulation bare wires and loose or broken connectors Tighten loose connectors and make sure the wires are in good shape E Hoses and fluid lines Look for wear damage and leaks and make sure clamps and fittings are tight Wet spots show leaks of course But a stain around a fitting or connector can mean a leak If a leak comes from a loose fitting or connector tighten it If something is broken or worn out report it to organizational maintenance 10 It is necessary for you to know how fluid leakage affects the status of your vehicle The following are definitions of the types classes of leakage an operator or crew member needs to know to be able to determine the status of his her vehicle Learn then be familiar with them and REMEMBER WHEN IN DOUBT NOTIFY YOUR SUPERVISOR Leakage Definitions for Crew Operator PMCS Class Seepage of fluid as indicated by wetness or discoloration not great enough to form drops Class 11 Leakage of fluid great enough to form drops but not enough to cause drops to drip from item being checked inspected Class III Leakage of fluid great enough to form drops that fall from the item being checked inspected CAUTION EQUIPMENT OP
248. transmission lockout switch so that it makes contact in neutral c Move Direction Throttle Control Ball in the forward direction until control cable at servo lever has traveled 11 16 31 32 In 24 64 26 92 mm Adjust ball stops so that cable cannot be moved beyond this point d Repeat step c In reverse direction CAUTION Ensure that the amount of ball control cable travel is limited by bail stops and not the interval servo stops e Return Direction Throttle Control Bail to neutral vertical position f Adjust and tighten wire stop at throttle crank for SECTION 7 TRANSMISSION 1 16 in 1 59 mm gap between swivel and wire stop see figure 7 44 g Adjust ball joint in slotted crank on bail shaft to allow full throttle when bail is moved to either full forward or full reverse h Adjust friction control nuts and spring assembly so that Direction Throttle Control Bail will remain in any desired position 7 173 THROTTLE CONTROL LINKAGE ADJUSTMENT PROCEDURE see figure 7 44 a Adjust transmission control linkage procedure outlined in paragraph 7 172 DIESEL STOP DIRECTION CONTROL THROTTLE DIRECTION THROTTLE BAIL TRANSMISSION CRANK ACTUATOR ARM HAND THROTTLE HANDLE THROTTLE ACTUATO ve f ARM a PE 2 K UPPER BB A ADJUSTMENT THROTTLE 2 FRICTION CY tink lt PLUNGER THROTTLE CABLE
249. ue capscrews to 105 ft lbs 14 521 kg m seg figure 7 87 i Install the o ring well lubricated on the bearing carrier Seat against the mounting flange see figure 7 88 FIGURE 7 87 FIGURE 7 88 7 202 INSTALLATION OF MOTOR CARRIER a Lift motor housing with hoist and pilot the bearing carrier into the drum CAUTION Care should be taken when installing the motor housing in the drum as not to damage the o ring b Align the capscrew mounting holes of the bearing carrier flange with those of the drum flange This can be done through the access hole in the back surface of the motor housing Coat capscrews with John Crane number 2 seal Insert capscrews and torque per specifications se figure 7 89 Torque C350B cap screws to 130 ft Ibs 17 98 kg m 7 203 INSTALLATION OF DRIVE DRUM FIGURE 7 90 7 48 SECTION 7 TRANSMISSION a Position the drum directly behind the unit and lift or roll the drum into the frame until the drum is aligned with the large holes in the frame see figure 7 90 b Rotate the motor housing in the drum until the access hole in the back wall of the housing is at its highest extreme Position motor housing pilot flange so it will fit into the frame see figure 7 91 c Align the frame to motor housing capscrew holes and insert the capscrews Tighten the capscrews in an alternate pattern back and forth across the motor housing Turn these capscrews only 1 4 to
250. ump and motor assembly by reversing procedure presented in paragraph 11 15 11 20 CLEANING THE WATER TANK a Drain the water tank for periodic cleaning by removing the drain plug located under the unit see figure 11 5 An access plate Is located at the front of the unit frame SHUT OFF VALVE FIGURE 11 5 NO MATTER HOW YOU SAY IT La Prudence Paye La Seguridad Paga Betriebssicherheit Macht Sich Bezahlt Passaa Olla Huolellinen Veiligheid Voor Alles S kerhet F rst Essere Sicuro Paga Seguran a Paga Sikkerhet F rst Pinter Be Awas amem ae Rar aah PART Il SUPPLEMENTAL OPERATING MAINTENANCE AND REPAIR PARTS INSTRUCTIONS STEEL WHEEL ROLLER C350B CONTRACT NO DSA 700 74 C 9024 Section Section 11 Section III SUPPLEMENTAL OPERATING MAINTENANCE AND REPAIR PARTS INSTRUCTIONS FOR ROLLER MOTORIZED STEEL WREEL 2 DRUM TANDEM 10 14 TON MODEL C350BD TABLE OF CONTENTS GENERAL Paragraph Purpose Scope CCE Item Description Operational Concept Procurement Status Equipment Publications Personnel and Training Logistics Assistance Warranty Reporting MAINTENANCE Maintenance Concept Maintenance Allocation Chart Modifications Equipment Improvement Recommendations Equipment Readiness Reporting Maintenance Expenditure Limits Shipment and Storage Destruction to Prevent Enemy Use Fire Protection Basic Issue Items List Maintenance and Operating Supply List Sp
251. val procedure presented in Section 10 paragraph 10 d Drain the final drive lubricant refer to Section 4 e Remove the flange anchor capscrews Before removing the hub capscrews pull the anchor flange using the puller holes provided and appropriate capscrews At the same time pry between the right side frame and drum moving the motor housing out of the side frame pilot see figure 7 71 f Remove the hub 12 point capscrews C350B only from the anchor flange and remove the flange from the drive drum Then remove the brakeshaft outer snap ring C350B only Push brakeshaft in so that it will clear the frame for drum removal sed figure 7 72 FIGURE 7 70 0 Carefully lift the drive drum from the unit alternate procedure is to remove the scraper beam at the rear of the unit and roll the drive 7 43 HUB CAPSCREWS 4 REQ D FLANGE ANCHOR CAPSCREWS ME 16 REO D FIGURE 7 71 SNAP RING REMOVED FIGURE 7 72 drum out of the rear of the unit taking care not to damage machined surfaces see figure 7 73 CAUTION Care must be taken not to damage machined surfaces WARNING The drive drum is extremely heavy approximately 12 000 lbs 5 440 kg without ballast Caution personnel in area to stand clear 7 199 REMOVAL OF MOTOR CARRIER a Complete the drive drum presented in paragraph 7 198 b Remove the motor carrier to drum mounting capscrews by turning the carrier and alig
252. ve both king pin bearings and the seal Tag bearings for reassembly with Its respective cup Inspect bearings and replace both king pin bearing assemblies if any one of the bearing components is damaged see figure 9 118 d Remove oscillation pin dust covers cotter keys jam nuts and thrust washers then remove locking bolt seg figure 9 119 e Remove oscillation pin and bearings Tag SECTION 9 STEERING bearings for reassembly with its respective cup Inspect bearings and replace both bearings if any one of the bearing components is damaged see figure 9 120 NOTE Mark king pin and oscillation pin so they may be installed at the same attitude with respect to the yoke f Lift out the king pin Remove the oscillation pin seals and bearing cups Thoroughly clean the bores and inspect for damage seg figure 9 121 9 98 CLEANING AND INSPECTION a Clean all parts in solvent or other suitable cleaning agent Dry thoroughly with compressed air or clean lint free cloth If parts are not FIGURE 9 120 FIGURE 9 119 FIGURE 9 121 9 37 to be assembled immediately coat all machined surfaces with clean oil and cover b Inspect all seals Replace all seals that are cut worn or otherwise have a doubtful remaining service life c Inspect all bearings for cracks nicks galling brinelling etc Replace all parts that are defective or have a doubtful remaining service life d Check bearing surfaces
253. ve system or the steering circuit the entire 7 51 SECTION 7 TRANSMISSION hydraulic system should be disassembled and cleaned 7 209 Removal and disassembly of the following list of components is required when any system component fails Inspect each component for damage and rebuild or replace as required a Steering pump b Steering cylinder c Steering control unit NOTE Matching of mating parts is critical d Cooler by pass valve e Hydraulic tank f Transmission displacement control valve g Transmission servo cylinders h All hoses NOTE Replace the oil filter with a Hyster approved 10 micron filter only It is recommended after overhaul that the oil filter be replaced at 50 hours after start up before returning to normal maintenance cycle 7 210 Refill the hydraulic system with oil specifications sed Section 2 7 211 Precharge the hydraulic system as follows per a Disconnect the case drain hose at the pump b Fill pump and motor cases with specified oil see Section 2 c Loosen the end of the suction hose at the charge pump If hydraulic oil is not present pressurize the tank to a maximum of 10 PSI 0 7 d Retighten hose fittings when oil appears e Complete the transmission start up procedure NOTE Partial cleaning of the system is ineffective Any contamination left in the system may cause a repeat failure CAUTION Oil MUST be at the charge pump before engine
254. vo pistons to move the pump swashplate 7 122 The pump swashplate can tilt either side of center When the swashplate in exactly centered the transmission is in neutral 7 123 Each cylinder piston has a slipper plate at one end The slipper retainer keeps all nine 9 slippers in contact with the thrust plate which contacts the swashplate When the swashplate is centered the cylinder pistons do not stroke in the cylinders When the swashplate is tilted the cylinder pistons stroke The degree of tilt determines the volume displacement of oil pumped by each cylinder piston 7 124 The valve bearing plate contains elon gated ports that are in contact with the cylinder block The opposite side of the valve bearing plate mates with the pump end cap Two ports in the end cap are connected through high pressure lines to a hydrostatic motor 7 125 When the swashplate is tilted each cylinder piston moves back and forth in its cylinder with each revolution of the cylinder block When a piston rotates past the inlet ports in the valve bearing plate it moves out of the block and draws low pressure oil into the cylinder This is the intake stroke of the piston Further rotation of the cylinder block moves the filled cylinders toward the outlet ports in the valve bearing plate They are forced into the cylinder block by the tilt of the swashplate The oil under high pressure ports to the outlet port in the end cap through the valve bearing plate
255. would normally contain the part required Proceed then to locate the part on the assembly breakdown page When The Part Number Is Not Known And Next Higher Assembly Is Known 3 Determine the assembly the required part Is used on Turn to the alphabetical index immediately following the Illustrated index 4 Locate the assembly the required part is used on and turn to the page indicated for that assembly Proceed then to locate the part on the assembly breakdown page When The Part Number Is Known 5 Use the numerical Index to find the part number Turn to the page listed and locate the part as indicated by the reference number GENERAL The assembly breakdowns include part numbers description quantities required keys and footnotes to help in selecting the correct parts 6 Keys are used to show effective serial numbers two or more similar assemblies RH and LH assembly parts etc Select the appropriate key A B C or D and the corresponding quantity column to find the required part Indent numbers are used to indicate assemblies and sub parts of assemblies Number 1 Is the major assembly Part descriptions which are indented under 2 3 or 4 are sub parts of that major assembly shown above Quantities shown are for one assembly Note that three assemblies are shown but the quantities of the sub parts are indicated as one and two This means one and two per assembly ORDERING PARTS When ordering replacement

TM 5-3895-348-14&P-1 27 MARCH 1981

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TM 5-3895-348-14&amp;P-1 27 MARCH 1981

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TM 5-3895-348-14&P-1 27 MARCH 1981