Operations, Service, and Parts Manual€¦ · Operations, Service, and Parts Manual Manual No. 1012791-01 LeeBoy Model 400 & 400T Rollers 400 400 T This manual applies to Serial Number

Operations, Service, and Parts Manual

Manual No. 1012791-01

LeeBoy Model 400 & 400T Rollers

400

400 T

This manual applies to Serial Number 400-41197

and above

LeeBoy Model 400 & 400T Rollersii

Safety

Information and Specifications

Component Location

Operation

Maintenance

Schematics

Illustrated Parts List (IPL)

1

2

3

4

5

6

7

Thumb Index

LeeBoy Model 400 & 400T Rollersiv

DISCLAIMER AND COPYRIGHT

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

©2015 VT LeeBoy, Inc.LeeBoy reserves all copyright and other rights in this manual and the manual’s content. No part of this manual may be reproduced or used in any way without the written permission of LeeBoy, except as necessary to operate LeeBoy equipment.

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

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

TABLE OF CONTENTS

LeeBoy Model 400 & 400T Rollers v

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ix

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

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

Pre-Operation Hazard . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Safety Label Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Safety Decals Care . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Machine Specific Precautions . . . . . . . . . . . . . . . . . . . . . . . 1-8

Hot Material Precautions . . . . . . . . . . . . . . . . . . . . . . . 1-8

Hydraulic Systems Precautions . . . . . . . . . . . . . . . . . . . 1-8

Refueling Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Battery Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Tire Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . 1-10

Parking Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Storage Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . 1-11

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

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

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

Record of Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Specifications Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

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

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

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

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

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


vi

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

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

Location of Operation Panels and Controls . . . . . . . . . . . . . . . . . 3-4

Hydraulic Levers (400T ONLY) . . . . . . . . . . . . . . . . . . . . . . . 3-6

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

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

Operating Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

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

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

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

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

Adjusting Operator Seat . . . . . . . . . . . . . . . . . . . . . . . 4-5

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

Pre-Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Engine Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Engine Warm-Up . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Cold Weather Engine Warm-Up . . . . . . . . . . . . . . . . . . . 4-6

Directional Control . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Vibratory Compactor . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Water Spray System . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Principles of Compaction . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Rolling Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Rolling Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Rolling Thick Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Rolling Thin Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Parking the Machine . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Transporting the Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Roller Towing (400T Only) . . . . . . . . . . . . . . . . . . . . . . 4-10

Transporting Via Flatbed . . . . . . . . . . . . . . . . . . . . . . 4-12

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


Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

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

Preparing Machine for Maintenance . . . . . . . . . . . . . . . . . 5-6

10-Hour or Daily Routine Maintenance . . . . . . . . . . . . . . . . 5-6


vii

50-Hour or Weekly Routine Maintenance . . . . . . . . . . . . . . 5-6

100-Hour or Monthly Routine Maintenance . . . . . . . . . . . . . . 5-6

250-Hour or Quarterly Routine Maintenance . . . . . . . . . . . . . 5-6

500-Hour or Semi-Annual Routine Maintenance . . . . . . . . . . . 5-7

1000-Hour or Annual Routine Maintenance . . . . . . . . . . . . . 5-7

Maintenance Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . 5-7


Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Oil Lines and Fittings . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Air Intake Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Neutral Start System . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Battery Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

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

Check Battery Electrolyte Level . . . . . . . . . . . . . . . . . . . 5-10

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Fuses And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . 5-10

Tire Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Filling Tires with Air . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Changing Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Check Engine Lubrication Oil Level . . . . . . . . . . . . . . . . . 5-12

Changing Engine Lubrication Oil . . . . . . . . . . . . . . . . . . . 5-12

Change Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . . 5-13

Change Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . 5-13

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Engine Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Checking Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . 5-15

Change Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . 5-16

Check and Clean Hydraulic Oil Strainer Fill Cap . . . . . . . . . . . 5-16

Drain, Flush and Fill Hydraulic Oil Tank . . . . . . . . . . . . . . . . 5-17

Component Replacement Procedures . . . . . . . . . . . . . . . . . . . 5-17


viii

Introduction

Replace Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Replace Valve Bank Assembly (400T Only) . . . . . . . . . . . . . . 5-18

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

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

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

Electrical Schematic, Tow Pak, 400T . . . . . . . . . . . . . . . . . . . . 6-3

Panel, Gauges, Kubota, 400 . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Electrical Schematic, Option, 400 / 400T . . . . . . . . . . . . . . . . . . 6-7

Hydraulic Hose Layout, 400, 1 of 2 . . . . . . . . . . . . . . . . . . . . . 6-9


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

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

400 Main Frame Assembly, 1 of 2 . . . . . . . . . . . . . . . . . . . . . 7-4

400 Main Frame Assembly, 2 of 2 . . . . . . . . . . . . . . . . . . . . . 7-6

Water Tank and Rollbar Groups . . . . . . . . . . . . . . . . . . . . . . 7-8

Front Drum and Yoke Assembly . . . . . . . . . . . . . . . . . . . . . . 7-10

Front Wiper, Front Inner Wiper, and Rear Wiper, 400 / 400T . . . . . . . . 7-12

Rear Drum Assembly, Cut-Section . . . . . . . . . . . . . . . . . . . . . 7-14

Water System Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

Fuel System Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Steering and Drive Control Assembly . . . . . . . . . . . . . . . . . . . 7-20

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

Engine Group, 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

Engine Group, 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

25 HP, Tier4F, Engine, Kubota . . . . . . . . . . . . . . . . . . . . . . . 7-28

Battery Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

400 and 400T Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . 7-32

Sign (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

400T Main Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . 7-36

Tow/Lift Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

400T Towing Safety Pin and Pintle Eye . . . . . . . . . . . . . . . . . . . 7-40

Wheel Hub and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . 7-42

Valve Bank Assembly (400T Only) . . . . . . . . . . . . . . . . . . . . . 7-44

Alphabetical Parts Index (API) . . . . . . . . . . . . . . . . . . . . . . . 7-46


ix

INTRODUCTION

Thank you for purchasing the 400 or the 400T Roller. We wish you many years of safe and efficient operation of your roller.

READ THIS MANUAL PRIOR TO OPERATING the unit. This manual is an important part of the roller and should be kept with the roller at all times in the dedicated storage container on the roller. Even though you may be familiar with similar equipment, you MUST read and understand this manual before operating this roller. Reading the manual will help you and others avoid injury and prevent damage to the roller. If this manual becomes lost or damaged, contact your authorized LeeBoy Dealer immediately to order a replacement (Contact Information on Page 2-3).

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

This manual should be used along with all related supplemental books, engine and transmission manuals, and parts books. Related Service Bulletins may be issued later that provide information regarding any recent changes.

If any questions arise concerning this publication or others, contact your local LeeBoy Dealer for the latest available information.


x

NOTES

Page

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

Pre-Operation Hazard . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Safety Label Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Safety Decals Care . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Machine Specific Precautions . . . . . . . . . . . . . . . . . . . . . . . 1-8

Hot Material Precautions . . . . . . . . . . . . . . . . . . . . . . . 1-8

Hydraulic Systems Precautions . . . . . . . . . . . . . . . . . . . 1-8

Refueling Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Battery Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Tire Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . 1-10

Parking Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Storage Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . 1-11

LeeBoy Model 400 & 400T Rollers 1-1

SAFETY

Section 1

NOTES

Safety

LeeBoy Model 400 & 400T Rollers1-2

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

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

THOROUGHLY. HEED THE WARNINGS AND FOLLOW THE INSTRUCTIONS.

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

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

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

Indicates a situation which can cause damage to the equipment, personal property and/or the environment, or cause the LeeBoy Model 400 and 400T to operate improperly.

NOTE: Indicates a procedure, practice or condition that should be followed in order for the roller components to function properly.

This manual provides important information to familiarize you with safe operating and maintenance procedures. Even though you may be familiar with similar equipment, you MUST read and understand this manual before operating the LeeBoy Model 400 or 400T Roller and follow its instructions when operating the machine.

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

Keep safety labels in good condition. If safety labels become missing or damaged, replace them immediately. Replacement safety labels are available from your authorized dealer. .

1

Safety


The safety messages that follow have WARNING level hazards.

Crush Hazard

Keep bystanders away from work area before and during operation.

Modification Hazard

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

Exposure Hazard

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

Explosion Hazard

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

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

• Do not start the engine by shorting the starter circuit or any other starting method not stated in this manual. Only use the starting procedure as described in this manual on Page 4-6 to start the engine.

Fire and Explosion Hazard• Diesel fuel is flammable and explosive under certain

conditions.

• Never use a shop rag to catch fuel.

• Wipe up all spills immediately.

• Never refuel with the engine running.

SAFETY PRECAUTIONS

Pre-Operation HazardRead and understand this Operation Manual before operating or servicing the engine to ensure that safe operating practices and maintenance procedures are followed.

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

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

• Contact LeeBoy or an authorized LeeBoy Dealer for additional training.

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

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

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

Electrocution Hazard

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

• Stay in the operators seat.

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

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

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

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

Suffocation Hazard

Never operate the internal combustion engine on this machine in an enclosed area with poor ventilation. Ensure proper ventillation to

reduce risk of carbon monoxide poisoning or death.

Safety


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

Fire Hazard

Be sure appropriate safety equipment is available. Ensure all fire extinguishers are checked periodically for proper operation.

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

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

• Undersized wiring systems can cause electrical fires.

Exhaust Hazard

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

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

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

Entanglement/Sever Hazard

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

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

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

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

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

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

• Always turn the start switch to the OFF position after operation is complete and remove the key from the switch. Keep the key in your possession when the roller is not operating.

• Attach a “Do Not Operate” tag near the key switch while performing maintenance on the equipment.

• Never operate the engine while wearing a headset to listen to music or radio because it will be difficult to hear the warning signals.

• Always start the engine and operate the controls while seated in the operators seat.

Alcohol and Drug Hazard

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

Piercing Hazard

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

a hydraulic or fuel system leak such as a broken hydraulic hose or fuel injection line.

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

• Never check for a hydraulic fluid or fuel leak with your hands. Always use a piece of wood or cardboard. Have your authorized LeeBoy Dealer or distributor repair the damaged parts.

1

Safety


Flying Object Hazard

Always wear eye protection when cleaning the LeeBoy Model 400 or 400T Roller with compressed air or high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may cause eye injury.

Coolant Hazard

Wear eye protection and rubber gloves when handling engine coolant.

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

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

Burn Hazard

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

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

• Handle hot components with heat-resistant gloves.

The safety messages that follow have CAUTION level hazards.

Poor Lighting Hazard

• Ensure that the work area is adequately illuminated.

• Always install wire cages on portable safety lights.

Tool Hazard

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

The safety messages that follow have NOTICE level hazards.

• Any part found defective during inspection or does not satisfy the proper standard or limit must be replaced.

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

• Only use replacement parts approved by LeeBoy. Other replacement parts may affect warranty coverage.

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

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

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

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

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

Safety


SAFETY LABEL LOCATIONSIf your LeeBoy machine has been repainted, it is extremely important that all decals referring to CAUTION, WARNING, and DANGER be replaced in their proper locations. The illustrations on this page will aid you in determining the proper locations. For additional help, refer to Section 7, Illustrated Parts List.

A description of location is provided below for each safety label. For additional instructions, contact your dealer.

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

Figure 1-1. Safety Labels and Safety Label Locations

(Under water tank)

565 9

DA NG E R

or rollover p ote tion, tank MUS T be bolted

down.

F ailure to c omply will res ult in death or s erious inj ry.

1010489

PINCH POINT

PUNTO DE APRIETEPOINT DE PINCEMENT

DA NG E R P E L IG R O DA NG E R

D856542

DA NG E RFLAMMABLE – KEEP CLEAN

856529

CRUSH HAZARD!K eep c lear of mac hine.F ailure to c omply will res ult in death or s erious injury.

DA NG E R

1011475

WA R NING

DO

NO

T TOW

OVER 45 M

PH.

DO

NO

T TO

W O

VER

45 M

PH.

856558-01

RUN-AWAY VEHICLE HAZARD!

Mac hine mus t be in NE UT R A L and E mergenc y B rake applied before dis mounting.

F ailure to c omply will res ult in death or s erious injury.

DA NG E R

856539

Do not operate or tow unit before reading operators manual.F ailure to c omply c ould res ult in death or s erious injury.

WA R NING

No us ar ni remolc ar la máquina s in antes haber leído el manual del operador.

S i no s e c umple c on es ta dis pos ic ión, s e puede c aus ar la muerte o les iones graves .

A DV E R T E NC IA

Ne pas faire fonc tionner ni remorquer la mac hine avant de lire le manuel d’opérations .

L e non-res pec t de c ette règle ris que d’entraîner des bles s ures graves , voire mortelles .

AV E R T IS S E ME NT

856446

Hydraulic oil onlyK eep c lean

Huile hydrauliques eulementMaintenir propre

P R E C A UC ION

A T T E NT ION

A c eite hidráulic o s olamenteMantener limpio

C A UT ION

856526

DO NOT s tand or s tep here when mac hine is moving.F ailure to c omply will res ult in death or s erious injury.

DA NG E R

856528

WA R NING

RUN-AWAY VEHICLE HAZARD!

DO NOT attempt to dis c onnec t roller from hitc h when tow wheels are on ground.

F ailure to c omply c ould res ult in death or s erious injury.

(On engine)

1

Safety


Safety Decals Care• Keep safety decals and signs clean and legible at all

times.

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

• Replace decals and signs that are missing or become illegible.

• When replacing parts that display a safety decal, ensure the new part is also fitted with the correct safety decal.

• Obtain safety decals or signs from your authorized LeeBoy dealer when needed.

Decal Installation (Sticker Type)

1. Be sure the installation area is clean and dry. Use hot, soapy water to clean the surface where decal will be applied. Thoroughly dry.

2. Measure and determine decal positioning before removing the decal paper backing.

3. Remove the smallest adhesive backing of the split-backing paper.

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

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

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

Decal Installation (Top Protected)

1. Be sure the installation area is clean and dry. Use hot, soapy water to clean the surface where decal will be applied. Leave wet.

2. Measure and determine decal positioning. Remove protective backing and soak the decal in clean, soapy water before application. (This will help to alleviate air bubbles when applying the decal.)

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

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

5. When the decal is completely smooth, carefully remove the top paper.

MACHINE SPECIFIC PRECAUTIONS

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

operating the roller.

• Allow machine to cool before repairing or performing maintenance on working components.

If hot asphalt touches skin, flush area immediately with cold water. DO NOT apply ice to the affected area. DO NOT attempt to remove asphalt cement with products containing solvents or ammonia. Get medical attention as soon as possible.

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

Hydraulic Systems Precautions• Make sure all components are in good working

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

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

Wear proper hand and eye protection when searching for a high pressure leak. Use a piece of wood or cardboard as a back stop (instead of hands) to isolate and identify leaks. Pressurized hydraulic fluid or oil has sufficient force when it escapes to penetrate the skin, which could cause serious personal injury. Ensure pressure is relieved before disconnecting line, hoses and valves.

If injured by concentrated high pressure steam or hydraulic fluid, seek medical attention immediately. Serious infections or toxic reactions can develop from hydraulic fluid penetrating the skin’s surface.

Safety


Refueling Precautions• Fuel is highly flammable and should be handled with

care. Death or serious injury can occur due to an explosion or fire.

• When refueling, keep the hose nozzle or the funnel in contact with the metal of the fuel tank to avoid the possibility of an electrical spark lighting the fuel. Maintain control of filler nozzle.

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

• DO NOT overfill the fuel tank as overflow creates a fire hazard when spilled onto hot components.

DO NOT smoke when refueling and never refuel when the engine is running.

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

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

• Use the correct fuel grade for the operating season.

Battery Precautions Keep all sparks and flames away from

batteries. Gas emitted by electrolytes is explosive.

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

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

• Always disconnect the battery ground cable before working on the electrical system to avoid injury from sparks or short circuit.

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

• Use jumper cables ONLY as prescribed on Page 5-11. Improper use can result in battery explosion or unexpected roller motion.

Tire Precautions DO NOT mount or demount tires

without proper training. A violent explosion can occur.

Follow all procedures and safety instructions. Wall charts containing mounting and demounting instructions for all rims are available through the United States Department of Transportation (DOT), Washington, D.C.

When in doubt, contact a qualified tire dealer or repair service to perform required tire maintenance.

Inspection

• Clean rims and repaint to stop detrimental effects of corrosion and facilitate checking and tire mounting.

• Be very careful to clean all dirt and rust from rims. This is important for securing rims into the proper position.

• Check rim components periodically for cracks. Replace all cracked, badly worn, severely rusted, and otherwise damaged components with new parts of the same size and type. If you are not sure about proper mating of tire and wheel parts, consult a wheel and rim expert.

DO NOT attempt to rework, weld, heat, or braze any rim components that are cracked, broken or damaged. Replace damaged components with new parts of the same size and type. Mixing parts of one type with those of another is potentially dangerous.

DO NOT reinflate a flat tire without first inspecting the tire, tube, flap, rim, and wheel assembly for damage. Be sure parts are secured before inflation.

Demounting

• Do not attempt to demount a tire unless you have the proper equipment and experience to do the job.

• Remove valve core to exhaust all air from tire. ALWAYS exhaust all air from tire prior to removing rim components or wheel components (such as nuts or rim clamps). Check the valve stem by running a piece of wire through the stem to make sure it is not plugged.

1

Safety


Mounting and Inflation

• DO NOT inflate a tire before all components are in the proper position. Place tire in a safety cage and inflate to approximately 10 psi. Recheck components for proper assembly. If improperly assembled, deflate and correct.

• Never hammer on a tire/rim assembly that is not fully deflated. If assembly is proper at 10 psi, continue to inflate to fully seat the tire beads, then completely deflate the tire to prevent localized overstretching of the tube. Reinflate to recommended operating pressure.

• NEVER sit on or stand in front of a tire/rim assembly during inflation. Use a clip-on chuck and make sure inflation hose is long enough to stand to the side of the tire while inflating.

• DO NOT hammer components with steel hammers. Use rubber, lead, plastic or brass-faced mallets to tap components together.

Operation

DO NOT inflate tires beyond the maximum recommended inflation pressure.

NEVER run a vehicle one single tire of a dual assembly as the carrying capacity is dangerously exceeded and can result in damage to the rim and tire

Mismatched rim parts are dangerous and can cause severe injury.

Starting and Stopping Precautions• Check all around the roller to make sure there are no

people working on the machine or in the path of the machine before starting. DO NOT start until area is clear. Death or serious injury can occur to bystanders from being crushed under a moving machine.

Check brakes, steering and other control devices in accordance with instructions before starting. Be sure emergency brake is applied and the left Drive Throttle is in neutral.

• Latch seat belt (if equipped) and adjust to fit snugly.

• Only start and operate the machine from the operator’s seat. DO NOT bypass paver/finisher‘s neutral-start system. If the system malfunctions, it must be repaired.

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

Parking Precautions• Park roller on level ground whenever possible. On

grades, park machine with wheels securely blocked. Always apply parking brake.

• Before leaving operator’s station:

1. Place left drive handle in neutral.

2. Turn off all accessories.

3. Set emergency brake.

4. Shut off engine.

• Always remove ignition key when leaving roller parked or unattended.

Operating Precautions• Always comply with local regulations regarding

moving equipment on public roads and highways.

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

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

DO NOT stand between the equipment and the truck while the truck is being coupled with the paver/finisher. Death or serious injury can result from being crushed between the two machines. DO NOT ride on attachments.

Safety


Some work situations require more attention to stopping distances, particularly when going downhill. Steeper grades require longer stopping distances. Familiarize yourself with these variables so you can anticipate when longer stopping distances are required.

• Check all gauges and warning instruments for proper operation. If malfunctions are found, shut down the machine and report the problem for resolution. If the failure causes loss of steering control, loss of brake control or loss of engine power, stop roller motion as quickly as possible. Apply emergency brake and keep the machine securely parked until the failure is corrected or the machine can be safely towed.

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

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

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

• Obey flagmen, road signs and signals.

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

• Operator must know how to use signaling devices while on the road with the machine. Operator must also understand which circumstances require use of each light signal.

• When required, provide an escort for roading.

• DO NOT tow the Model 400 roller, except to remove from road or load on a trailer. The Model 400T is equipped for towing.

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

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

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

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

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

Refer to manuals and experienced repair personnel for help.

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

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

• Disconnect battery before working on the electrical system.

• Avoid lubrication or mechanical adjustments while the roller is in motion or while engine is operating. If lubrication or mechanical adjustment is necessary:

1. Place left drive handle control in neutral.

2. Apply emergency brake.

3. Shut off engine.

4. Place equipment in a safe position.

5. Use extreme caution.

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

• When inflating tires, use a self-attaching inflation chuck with remote shut-off.

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

• Keep brake and steering systems in good operating condition.

• Refer to Section 5, Maintenance, for more detailed information.

1

Safety


NOTES

Safety


Page

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

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

Record of Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Specifications Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

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

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

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

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

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


INFORMATION AND SPECIFICATIONS

Section 2

LIMITED WARRANTY POLICY

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

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

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

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

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

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

All new replacement parts purchased by a LeeBoy Dealer will carry a six-month warranty.

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

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESSED, STATUTORY AND IMPLIED

WARRANTIES APPLICABLE TO UNITS, ENGINES, OR PARTS INCLUDING WITHOUT LIMITATION, ALL IMPLIED WARRANTIES

OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR USE OR PURPOSE OR AGAINST INFRINGEMENT.

Items Not CoveredLeeBoy is not responsible for the following:

All used units or used parts of any kind.

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

Attachments not manufactured or installed by LeeBoy.

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

replacement equipment.

LimitationsVT LeeBoy , Inc. has no obligation for:

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

Unauthorized alterations.

Defects or failures caused by any replacement parts or attachments not manufactured by or approved by LeeBoy.

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

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

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

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

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

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

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

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



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

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

RECORD OF OWNERSHIPPlease complete the following information to use if you need to contact LeeBoy for service, parts or literature:

Sales Representative:

Dealership Name:

Dealership Address:

Dealership Phone:

Roller Model Number:

Roller Serial Number:

Date of Purchase:

Figure 3-1

Figure 2-1. Nameplate Location

NAMEPLATEThe nameplate contains the specific model and serial number used to identify the components for parts or service information. Look in the engine owner’s manual to find the specific location of the engine nameplate for your engine.

2



SPECIFICATIONS CHARTSThe specifications provided in this section are applicable to the LeeBoy Model 400 and 400T Roller.

Table 2-1. Machine Dimensions

ITEM SPECIFICATION

Model 400 400T

Overall Length 9’ 6” (2.896 m) 12’ 8” (3.86 m)

Overall Height 9’ 2” (2.794 m) 9’ 2” (2.794 m)

Overall Width (Static/Loaded 4’ 2” (1.27 m) 6’ 6” (1.981 m)

Overall Weight 5640 lb (2558 kg) 6760 lbs. (3066 kg)

Wheelbase 6’6” (1.981 m) 6’6” (1.981 m)

Front Drum Width 40” (1016 mm) 40” (1016 mm)

Rear Drum Width 44” (1117.6 mm) 44” (1117.6 mm)

6 ft 6 in

4 ft 2 in400 400

400T400T

9 ft 2 in

400 / 400T

12 ft 8 in

9 ft 6 in

Figure 2-2. Machine Dimensions

Replace original equipment only with LeeBoy authorized components. Section 7, IPL, for part numbers associated with the Model 400 and Model 400T assemblies.



Table 2-2. Engine Specifications

ITEM SPECIFICATION

Model: Kubota V1505-E4B Tier 4

Horsepower24.8 HP @ 3000 RPM

(18.5 kW)

Displacement91.41 cubic inches

(1.498 L)

Table 2-3. Electrical Specifications

ITEM SPECIFICATION

Batteries 12 Vdc

Cold Cranking Amps (CCA) 835 CCA

System Voltage 12 Vdc

Table 2-4. Steering Specifications

ITEM SPECIFICATION

Steering Hydraulic

Inside Turning Radius 14 ft 6 in (4.5 m)

Table 2-5. Hydraulic Specifications

ITEM SPECIFICATION

Function Pump 2100 psi (Relief)

Drive Motor 5800 psi (Relief)

Operating Pressure 5800 psi (Relief)

Hydraulic Filters Remote Pressure Filter

Oil CoolerRadiator/Oil Cooler, Engine Fan Cooling

Ground Speed 0 - 5 mph (0 - 8 kph)

Table 2-6. Fuel and Lubricant Specifications

ITEM SPECIFICATION

Engine Oil 15W-40

Hydraulic Oil 5W20 AWAT OIL

CoolantEthylene/Glycol or Propylene Glycol

Fuel Diesel

GreaseShell Avania EP Grease or Equivalent

Table 2-7. Machine System Capacity Specifications

ITEM SPECIFICATION

Fuel 8 gal (30.3 L)

Engine Lubrication Oil 1.59 gal (6.01 L)

Engine Coolant 1.28 gal (4.8 L)

Hydraulic Oil Reservoir 27 gal (102.20 L).

Water Tank 80 gal (302.83 L)

Table 2-8. Machine-Specific Specifications

ITEM SPECIFICATION

Calculated Maximum Gradeability

21.5%

Vibrator Vibrations Per Minute (vpm)

2600 vpm

Vibrator Centrifugal Force

2814 lb (1276 kg)

2



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

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

Conversion Formula

ft-lb to N•m [ft-lb]*1.3558 = [N•m)

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

N•m to in-lb [N•m]*8.8508 = [in-lb]

Standard Inch FastenersTable 2-9. Torque Specifications For Standard Inch Fasteners

SIZE THREAD

CAPSCREWS: SAE GRADE 5 CAPSCREWS: SAE GRADE 8

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

Dry Lubed Dry Lubed Dry Lubed Dry Lubed

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

28 UNF 10 7 14 9 14 10 19 14

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

24 UNF 19 15 26 20 27 20 37 27

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

24 UNF 35 26 47 35 49 37 66 50

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

20 UNF 55 41 75 56 78 58 106 79

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

20 UNF 85 64 115 87 120 90 163 122

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

18 UNF 121 91 164 123 171 128 232 174

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

18 UNF 170 127 230 172 240 180 325 244

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

16 UNF 297 223 403 302 420 315 569 427

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

14 UNF 474 355 643 481 669 502 907 681

1 8 UNC 644 483 873 655 909 681 1232 923

14 UNF 722 542 979 735 1020 765 1383 1037

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

12 UNF 1241 930 1683 1261 2012 1509 2728 2046

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

12 UNF 2194 1645 2975 2230 3557 2668 4823 3617



Metric Fasteners

Table 2-10. Torque Specifications for Metric Fasteners

NOMINAL SIZE AND PITCH

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

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

Dry Lubed Dry Lubed Dry Lubed Dry Lubed

M4 x 0.7 2 2 3 2 3 2 4 3

M5 x 0.8 5 3 7 4 7 5 9 7

M6 x 1 8 6 11 8 11 8 15 11

M8 x 1.25 19 14 26 19 27 20 37 27

M10 x 1.5 37 28 50 38 53 40 72 54

M12 x 1.75 65 49 88 66 93 70 126 95

M14 x 2 104 78 141 106 148 111 201 150

M16 x 2 161 121 218 164 230 173 312 235

M18 x 2.5 222 167 301 226 318 239 431 324

M20 x 2.5 314 236 426 320 449 337 609 457

M22 x 2.5 428 321 580 435 613 460 831 624

M24 x 3 543 407 736 552 777 582 1053 789

M27 x 3 796 597 1079 809 1139 854 1544 1158

M30 x 3.5 1079 809 1463 1097 1544 1158 2093 1570

Hydraulic Fittings

Tightening Flare-Type Tube Fittings

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

2. Align tube with fitting before tightening.

3. Lubricate connection.

4. Hand tighten swivel nut until snug.

5. To prevent twisting the tube(s), use two wrenches. Place one wrench on the connector body and tighten the swivel nut with the second to the torque shown in Table 2-11.

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

Table 2-11. Torque Specifications for Steel Flare Type Tube Fittings

TUBE SIZE OUTER

DIAMETER

NUT SIZE ACROSS

FLATSTORQUE VALUE

(IN) (IN) (LB FT) (N•m)

3/16 7/16 8 11

1/4 9/16 12 16

5/16 5/8 16 22

3/8 11/16 23 31

1/2 7/8 38 52

5/8 1 54 73

3/4 1 1/4 75 102

7/8 1 3/8 83 113

2



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

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

LAL

Figure 2-3. Torque Wrench - Crowfoot

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

There are several methods of determining the correct setting on the torque wrench when using a crowfoot. All of the methods involve making the setting proportional to the effective change in length of the wrench multiplied by the desired final torque. The equations and illustration below describe proper measurements. (Use LEGEND under Figure 2-4)

Equations

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

TS = TD * L / LA

OR

TS = TD * L / (L+E)

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

TS = TD * L / LH

OR

TS = TD * L / √(L2 + E2)

• To estimate the crowfoot size (E)

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

L

E

LA

LH

Figure 2-4. Measurements Needed

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

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

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

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

TD = Desired torque at the fitting

TS = Torque setting indicated on wrench



Coupling Installation

Use the following steps for proper coupling installation:

1. Determine the correct torque value for your coupling.

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

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

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

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

4. Mark a line across the coupling nut and backup hex for the flats method verification of coupling torque (Figure 2-12).

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

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

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

If a torque wrench cannot fit into the coupling area or if it is unavailable, the flats method may be used to ensure that the coupling is properly tightened, as shown in Figure 2-5:

Example 2 Flats difference

Mark Line on Nut

Figure 2-5. Flats Method Tightening

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

Table 2-12. Flats Method Values for Selected Terminations

FLATS METHOD VALUES

Termination Type

Dash Size Flats

JIC -4 1.5 - 1.75

JIC -6 1.0 - 1.5

JIC -8 1.5 - 1.75

JIC -10 1.0 - 1.5

JIC -12 1.0 - 1.5

JIC -16 .75 - 1.0

JIC -20 .75 - 1.0

JIC -24 .75 - 1.0

JIC -32 .75 - 1.0

JIS -4 .5 - 1.5

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

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

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

2



Table 2-13. Torque Specifications For US Style Coupling Terminations

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

DASH SIZE

JIC 37°, SAE 45° & Mega-Seal

(Steel)

JIC 37°, SAE 45° & Mega-Seal

(Brass)

Flat Face O-Ring Seal (Steel)

SAE O-Ring Boss (Steel) & Gates

Adapterless ≤ 4000 PSI

SAE O-Ring Boss (Steel) & Gates

Adapterless > 4000 PSI

Min Max Min Max Min Max Min Max Min Max

-3 8 10

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

-5 13 15 7 9 18 20

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

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

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

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

-14 65 80 160 180

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

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

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

-32 219 243 158 175

Table 2-14. Torque Specifications for DIN 24, DIN 60, and Inverted Cone Style Coupling Terminations

DIN 24, DIN 60, AND INVERTED CONE

Size (mm) Torque (lb ft)

Light Series

Tube OD

Heavy Series

Tube ODMin Max

6 7 15

8 15 26

10 8 18 30

12 10 22 33

14 12 26 37

15 14 30 52

16 30 52

18 20 44 74

22 25 59 89

28 30 74 111

38 74 162

35 133 184

42 148 221

Table 2-15. Torque Specifications for 4-Bolt Flange Connections

4-BOLT FLANGES

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

-8 0.31 17

-12 0.38 26

-16 0.44 43

-20 0.50 65

-24 0.63 130

-32 0.75 220

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

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

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



Table 2-17. Torque Specifications for BSP 30° Inverted Cone and JIS Coupling Terminations

Table 2-16. Torque Specifications for NPTF Dry Seal Pipe Threads

NPTF

Dash Size Max Torque (ft-lb)

-2 20

-4 25

-6 35

-8 45

-12 55

-16 65

-20 80

-24 95

-32 120

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

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

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

BSP 30° INVERTED CONE AND JIS

Dash SizeTorque (ft-lb)

Min Max

-2 7 9

-4 11 18

-6 19 28

-8 30 36

-10 37 44

-12 50 60

-16 79 95

-20 127 152

-24 167 190

-32 262 314

2



NOTES



Page

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

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

Location of Operation Panels and Controls . . . . . . . . . . . . . . . . . 3-4

Hydraulic Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6


COMPONENT LOCATION

Section 3

NOTES

Component Location


OPERATOR’S CONTROL CONSOLE

3

10

1

6

5

8472119

12

Figure 3-1. Operator’s Control Panel

ITEM NO.

CONTROL NAME FUNCTION

1 Ignition Switch

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

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

2Temperature Gauge (OPTION)

Displays engine coolant temperature.

3 Horn (OPTION) Sounds horn.

4Oil Pressure Gauge (OPTION)

Displays engine oil pressure in pounds per square inch (PSI).

5Vibratory Rear Roller Switch

This toggle switch controls the vibratory roller on the rear of the machine.

6 GaugeSTANDARD: Four (4) warning light clusters.

(OPTION) This gauge informs the operator of the current battery voltage.

7 Fuel Gauge (OPTION) Displays fuel level in the fuel tank.

8 Digital Usage Display Shows the total number of hours the machine has been in use.

9 Beacon Light This toggle switch turns the warning light on top of the canopy OFF and ON.

10 Water Sprayer Switch Controls the water spray nodules.

11Safety Start Button (OPTION)

Allows the operator to safely start the engine with low oil pressure.

12 Parking Brake Button Pull out and turn to apply or disengage parking brake.

3

Component Location


LOCATION OF OPERATION PANELS AND CONTROLS

Figure 3-2. Location of Operation Panels and Controls

24

17

14

23

11

18

21

1

3

2

20

4 5

8

22

12

76

1510

13

16

19

9

Component Location


Table 3-1. Location of Operation Panels and Controls

ITEM NO.

CONTROL NAME FUNCTION

1Engine and Battery Access Compartment

Used to access engine and battery. Located on right side of the roller.

2Hydraulic Oil Reservoir Tank Access

Used to access hydraulic oil reservoir. Located on the right side of the roller below the air cleaner.

3 Step (Left and Right Side) Used to enter and exit the operator station.

4 Fuel Tank Compartment Location for filling diesel fuel.

5 Work Light (OPTION) Used to illuminate in front of the machine during operation.

6Forward/Neutral/Reverse (FNR) Lever

Controls forward and reverse operation and variable speed of the traction pump.

7 Steering Wheel Steers machine.

8 Operator’s Control PanelGroup includes the Ignition Switch, THe Digital Usage Display, the Warning Light, the Water Sprayer Switch, as well as the Wait to Start Switch.

9 Tow Bar (400T Only) Towing bar (Optional) available only on the Model 400T.

10 Hydraulic CYLINDER Used to lift/lower the tow wheels for towing purposes.

11 Operator’s Seat Operator’s seat for controlling machine operation.

12ROPS (Roll Over Protection System) Bar

Safety bar.

13 Operator Manual Location for this manual.

14 Tow Leg (400T Only) Used to tow the roller.

15Hydraulic Oil Level/Temperature Gauge

Gauge that shows fill level and temperature of hydraulic oil.

16Hydraulic Supply Line Gate Valves Access

Used to turn on and off hydraulic supply lines.

17 Water Reservoir/Fill CapCools the drum to prevent asphalt from sticking to the drum surface during operation.

18Retractable Wheels (400T Only)

Used for towing the machine.

19 Canopy (Optional) Protects operator from sunlight, falling debris and light rain.

20 Front Roller Used for asphalt compaction and steering.

21 Rear Roller Used for asphalt compaction.

22 Water Line/Spray Sprays machine with water when engaged.

23 Tail Lights (400T Only) Tail light illuminates for towing.

24 Beacon Light Safety flashing light.

* Throttle (Not Shown)Used to increase/decrease the throttle on the engine. Located on the left-side of the steering column.

3

Component Location


HYDRAULIC LEVERS (400T ONLY)

1 32

Figure 3-3. Hydraulic Levers

ITEM NO. CONTROL NAME FUNCTION

1 Tongue Lever Raises and lowers tongue.

2 Left Wheel Lever Raises and lowers left wheel.

3 Right Wheel Lever Raises and lowers right wheel.

Component Location


Page


Operating Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

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

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

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

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

Adjusting Operator Seat . . . . . . . . . . . . . . . . . . . . . . . 4-5

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

Pre-Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Engine Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Engine Warm-Up . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Cold Weather Engine Warm-Up . . . . . . . . . . . . . . . . . . . 4-6

Directional Control . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Vibratory Compactor . . . . . . . . . . . . . . . . . . . . . . . . . 4-7


Parking the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Transporting the Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Roller Towing (400T Only) . . . . . . . . . . . . . . . . . . . . . . 4-8

Transporting Via Flatbed . . . . . . . . . . . . . . . . . . . . . . 4-10


OPERATION

Section 4

NOTES


Operation

OPERATING SAFETY• ALWAYS wear OSHA-required safety equipment

when operating the roller.

• ALWAYS fasten your seatbelt when in the operator’s seat while operating the equipment.

• ALWAYS make sure no person or object is in your line of travel BEFORE starting.

• Work SLOWLY in tight areas.

• DO NOT run engine in a closed building for long periods of time.

• AVOID steep hills and sharp turns if possible.

• REDUCE speed before turning.

• ALWAYS look BEFORE changing your direction of travel.

• DO NOT leave the engine running without the operator present.

• DO NOT start engine by “shorting” across starter terminals. Machine will start in gear if normal circuitry is bypassed.

• NEVER start engine while standing on the ground. Start engine only from operator’s seat, with forward/neutral/reverse (FNR) lever in NEUTRAL.

• Ensure water tank support is bolted down during operation.

• Check the parking brake button to make sure it is operating properly.

GENERAL INFORMATION This section provides the Operating instructions for the LeeBoy Model 400 and 400T Rollers. It is important to read, understand and follow all precautions, operating instructions, and warnings in this manual before starting and operating the machine.

Failure to observe the operating precautions and warning instructions provided in this manual can cause serious injury or death. Only authorized personnel who are trained in machine operation, mechanical characteristics and safe operation in varying terrain should operate the Model 400 and 400T Rollers.

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

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

DO NOT start or operate the Model 400 or 400T Roller before reading, understanding, and following all information given in this section and shown on the machine. The operator must read and understand the function of all controls, indicators and gauges before starting the engine. Serious injury or death can result if these procedures are not followed.

4

Operation


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

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

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

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

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

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

• DO NOT change the engine governor settings.

• ALWAYS replace damaged or lost decals.

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

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

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

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

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

RECEIVING THE ROLLERThe LeeBoy Model 400 and 400T rollers are thoroughly inspected at the factory before shipping. However, road hazards or other incidents may occur during transport that result in damage. Inspect the machine as outlined below and perform necessary repairs before placing the machine in service:

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

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

3. On the Roller, check all chains.

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

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

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

7. Check the vibrator to ensure it stops while the machine is in neutral.

8. Check for missing parts. If parts are missing or motor roller is damaged, consult your authorized LeeBoy dealer.

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

10. Check the seat belt.

Operation


PRELIMINARY PROCEDURES

Adjusting Operator Seat Adjust and fasten the seat belt before

operating the roller. NEVER operate the machine without wearing seat belt.

Do not attempt to adjust the seat while the roller is moving.

The seat can be adjusted for individual comfort. The seat position lever allows the operator to move the seat forward and backward for easy access to the steering wheel and hydraulic controls. The seat belt provides safe operator retention if the machine is involved in an accident or rollover incident. Adjust the seat belt for comfortable machine operation.

Seat Belt

Operator’s Manual Storage

Seat Adjustment

Lever

Figure 4-1. Operator’s Seat

Beacon LightThe beacon light switch on the control panel operates the flashing safety light on top of the roll bar or optional canopy. This light warns traffic of slow-moving equipment.

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

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

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

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

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

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

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

• Check for fuel level and refill if needed.

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

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

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

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

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

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

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

If protective devices are damaged, do not use roller until proper repairs are made.

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

4

Operation


MACHINE OPERATIONNOTE: Refer to the engine manufacturer’s operation

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

Engine Start-Up The Directional Control (FNR) lever

must be set in the NEUTRAL position before starting engine.

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

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

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

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

4. Check indicator and gauge operation.

5. Return to neutral position and turn ignition key counterclockwise to shut down engine.

Engine Warm-Up Allow engine and hydraulic oil to warm

up before activating components.

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

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

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

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

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

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

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

• Run engine for five minutes.

• Operate each of the hydraulic functions before moving machine.

Directional Control The LeeBoy Model 400 and 400T Rollers are designed to operate from forward to reverse with a single drive lever. There are, however, two drive levers: one on each side of the steering column. These levers are inter-connected and arranged in this manner for the operator’s convenience.

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

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

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

Operation


BrakingBraking is accomplished by bringing the drive lever to the NEUTRAL position.

If a loss of hydraulic pressure occurs, the roller can be stopped with the Parking Brake button:

• Place drive lever in NEUTRAL (center position).

• Pull Parking Brake button.

Parking Brake

Button

Figure 4-2. Parking Brake Button

Vibratory CompactorThe vibratory compactor drum provides the roller with additional compaction. (The non-towable roller weight is 5,640 pounds [2,558 kg] static, while the static weight of the towable roller is 6,760 pounds [3066 kg]).

The force of compaction will increase by 2,800 pounds [1,270 kg] the vibrator is engaged.

To start the vibrator:

1. Tum the vibrator switch to ON.

2. Move the roller forward or in reverse to start vibrator.

3. When the drive lever is in the NEUTRAL position, vibration will automatically stop. Vibration will begin again when the drive lever is engaged.

4. When finished with compaction, tum the vibrator switch to OFF.

Water Spray SystemThe water spray system is designed to provide an even spray across the surface of each roller drum, ensuring an even amount of water is on the drum during the rolling process.

To operate the water spray system:

1. Turn water spray valve to OPEN. The water spray valve is located on the left side of the console. (Figure 4-3)

2. Turn on pump (switch is on the operator’s console).

3. Spray down the front and rear drum using spray nozzle. (Figure 4-4)

4. Shut off water spray valve by turning valve to SHUT.

5. Close the water spray valve.

Water Spray Valve

Figure 4-3. Water Spray Valve

Spray Nozzles

Figure 4-4. Spray Nozzles

NOTE: To prevent water freezing in tank during cold weather, drain the water system by opening the valve below the pump.

Never operate the roller while the water tank is raised.

4

Operation


Parking the Machine Before leaving the operator’s seat, perform the following procedures:

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

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

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

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

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

TRANSPORTING THE ROLLER

Roller Towing (400T Only)The Model 400T is equipped with a tow package so the roller can be towed to and from job sites. The following procedures must be followed to ensure safe towing.

Read the following procedures very carefully and follow the step-by-step instructions.

Before towing the roller, check state, federal and local laws that apply.

Wheels must be blocked from moving while preparing machine for towing.

To tow the 400T Roller:

1. The vehicle towing the roller should be large enough to handle the weight of the roller in all driving situations.

NOTE: The pintle hook on the rear of the towing vehicle should be from 26 to 32 inches high from the ground.

2. Park the towing vehicle on a level surface and secure by engaging the parking brake.

3. Block wheels in both directions.

4. Move roller into position behind truck. Using tongue cylinder valve lever and roller drive lever, engage eyelet on tongue to the pintle hook on towing vehicle. (Page 3-6)

5. After engaging the pintle hook on towing vehicle, put drive lever in the NEUTRAL position. (Figure 4-5)

6. Dismount roller and secure safety latches on pintle hook.

7. Attach safety chains to structural member on rear of towing vehicle.

1

2

3

Figure 4-5. Maneuvering Tongue to Towing Vehicle

1 - Eyelet on Tongue

2 - Safety Chains

3 - Roller Drive Lever

8. From the operator’s seat, use tongue cylinder valve lever and extend tongue cylinder to full extension. This will lift front drum off the surface.

NOTE: The front roller drums should be a minimum of six inches off the ground (for towing).

9. Now use tow wheel cylinder valve lever and extend towing wheels to full extension. This will lift the rear drum off the surface.

10. While the roller is in this position, dismount and engage towing wheel lock on both sides of the roller, rotate tongue support latch into position, and insert yoke lock pin on yoke.

Operation


Tow Wheel Lock

Figure 4-6. Tow Wheel Lock

Never exceed 45 MPH while towing the roller. use reduced or lower speed when towing over slippery or uneven surface.

11. From the operator’s seat, turn OFF roller engine. SLOWLY release pressure on towing wheel extension cylinders and lower roller until wheel locks are in the lock position. Now slowly release pressure on tongue extension cylinder until tongue support latch is in positive lock position.

Check safety chains, tow wheel tongue support latch and yoke lock pin to ensure that these devices are in the proper position BEFORE towing.

Unhooking 400T Roller Towing Vehicle

To unhook the 400T Roller from the towing vehicle:

1. Park towing vehicle and roller on level surface. Secure towing vehicle by blocking wheels in both directions.

Raise the 400T wheels with rear drum on the ground before unhooking tongue from the towing vehicle.

2. Sitting in the operator’s seat, start the roller and extend the towing wheels until towing wheel locks are out of the lock position.

3. Extend tongue cylinder, lift tongue until tongue support latch is clear from stop.

4. Dismount and move towing wheel lock, tongue support latch, and yoke pin lock out of the way to prevent interference during lowering.

5. Put yoke locking pin into stow position and secure with the hitch pin.

Improper towing methods and equipment can result in severe personal injury or death.

6. Remove and store safety chains.

7. Disengage pintle hook safety devices.

8. From the operator’s seat, activate lever for towing wheels and lower rear drum to the surface.

9. Continue activating lever until towing wheels are in the full UP position.

10. Using tongue extension lever, lower the front drum to the surface.

11. Using the drive lever, move roller forward or backward as necessary, to release the pressure on the eyelet in pintle hook.

12. Raise the tongue extension slightly; then, back the roller up to disengage.

13. Restore tongue to full back position.

4

Operation


Transporting Via Flatbed When transporting the roller, use a flat bed vehicle that is large enough to handle the roller during all driving conditions and situations.

Use extreme caution when driving from one surface level or incline to another.

To transport the roller:

1. Park transport vehicle on level surface.

2. Secure transport vehicle by engaging parking brake and blocking wheels in both directions.

3. Load roller onto the flat bed vehicle.

4. Block roller drums to prevent roller from rolling forward or backwards.

5. Secure the roller to the flatbed vehicle with chains that have adequate strength to secure the roller during transport.

Operation


Page

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


Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

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

Preparing Machine for Maintenance . . . . . . . . . . . . . . . . . 5-6

10-Hour or Daily Routine Maintenance . . . . . . . . . . . . . . . . 5-6

50-Hour or Weekly Routine Maintenance . . . . . . . . . . . . . . 5-6

100-Hour or Monthly Routine Maintenance . . . . . . . . . . . . . . 5-6

250-Hour or Quarterly Routine Maintenance . . . . . . . . . . . . . 5-6

500-Hour or Semi-Annual Routine Maintenance . . . . . . . . . . . 5-7

1000-Hour or Annual Routine Maintenance . . . . . . . . . . . . . 5-7

Maintenance Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . 5-7


Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Oil Lines and Fittings . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Air Intake Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Neutral Start System . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Battery Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

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

Check Battery Electrolyte Level . . . . . . . . . . . . . . . . . . . 5-10

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Fuses And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . 5-10


MAINTENANCE

Section 5

Tire Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Filling Tires with Air . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Changing Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Check Engine Lubrication Oil Level . . . . . . . . . . . . . . . . . 5-12

Changing Engine Lubrication Oil . . . . . . . . . . . . . . . . . . . 5-12

Change Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . . 5-13

Change Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . 5-13

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Engine Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Checking Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . 5-15

Change Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . 5-16

Check and Clean Hydraulic Oil Strainer Fill Cap . . . . . . . . . . . 5-16

Drain, Flush and Fill Hydraulic Oil Reservoir . . . . . . . . . . . . . 5-17

Component Replacement Procedures . . . . . . . . . . . . . . . . . . . 5-17

Replace Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Replace Valve Bank Assembly (400T Only) . . . . . . . . . . . . . . 5-18

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

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

Maintenance


worn or damaged parts--replace or repair promptly to prevent damage to other areas of the machine. Daily inspections should include checking for loose bolts, fluid leaks, worn or damaged hoses, and debris or dirt accumulations to prevent potential service or safety problems.

The maintenance program must be done based on the machine “Operating Hours” recorded on the hour meter or based on the “Periodic Schedule,’’ which is typically done at the following time intervals:

Daily, Weekly, Monthly, Quarterly, Semi-Annually and Yearly

GENERAL INFORMATIONThis section gives the necessary procedures for routine and general maintenance on the Model 400 and 400T Rollers. Follow all Maintenance Schedules and Maintenance Procedures to maintain the machine in top operating condition.

Maintenance must be a planned program that includes periodic machine inspection and lubrication procedures. The first and most important requirement for satisfactory paver performance is a clean machine. The operator should inspect the machine daily for

Table 5-1. Periodic Maintenance Schedule

SYSTEM ITEM

Eve

ry 1

0 H

our

s

Dai

ly

Eve

ry 5

0 H

our

s

Wee

kly

Eve

ry 1

00

Ho

urs

Mo

nthl

y

Eve

ry 2

50

Ho

urs

Qua

rter

ly

Eve

ry 5

00

Ho

urs

Sem

i-A

nnua

lly

Eve

ry 1

00

0 H

our

s

Ann

ually

Roller Lubricate drum bearings. X

Hydraulic

Check oil level. X

Replace oil filter. X

Replace oil. X

Check/replace oil suction filter. X

Replace strainer fill cap. X

Engine

Inspect belts, replace if needed. X

Inspect air intake hoses and clamps. X

Inspect alternator and connections. X

Replace engine oil and oil filter cartridge. X

Check oil level - change at initial 50 hours. X

ElectricalCheck all wiring connections. X

Service battery. X

Engine Air

Cleaner

Check/clean air cleaner element. X

Replace air cleaner element. X

FuelReplace fuel filter. X

Inspect fuel system hoses and clamps. X

CoolingCheck coolant level, refill if needed. X

Inspect coolant hoses and clamps. X

5

Maintenance


LUBRICATION POINTSProper lubrication is necessary to maintain the machine at top efficiency. Lubrication points are shown in the

following figure. Lubricate these fittings every 40 hours for optimum performance.

NOTE: Grease with Shell Avania EP Grease or equivalent.

1

7

2

3

4

5

6

8

910

Figure 5-1. Lubrication Points

Maintenance


Table 5-2. Lubrication Chart

ITEM NO.

DESCRIPTION AND LOCATION INTERVAL

1 Yoke Vertical Pin Housing 40 Hrs

2 Tongue Support Latch, Pivot Housing 40 Hrs

3 Towbar Pin Housing, (2) 40 Hrs

4 Center Pin on Yoke Housing, Both Sides 40 Hrs

5 Front Drum, Both Sides 40 Hrs

6 Main Pivot on Tow Wheel Support, Both Sides 40 Hrs

7 Throttle Lever Housing 40 Hrs

8 Forward/Neutral/Reverse Lever Housing, Both Sides of Console 40 Hrs

9 Tow Wheel Cylinder Support, Both Sides 40 Hrs

10 Vibrator (See “Lubrication of Torque Hub” for more information) 40 Hrs

NOTE: Grease with Shell Avania EP Grease or Equivalent

MAINTENANCE SCHEDULE Before performing any maintenance procedures on the LeeBoy Model 400 and 400T Rollers, review Safety in Section 1.

Tool Hazard! ALWAYS use tools appropriate for the task at hand and use the correct sized tool for loosening or tightening screed parts.

Burn Hazard! ALWAYS handle hot components with heat-resistant gloves.

This section gives the necessary procedures for routine and general maintenance on the LeeBoy Model 400 and 400T Rollers. Follow all maintenance schedules and procedures to maintain the machine in top operating order. The Maintenance Schedule on Page 5-3 lists the recommended time intervals between maintenance inspections and lubrication procedures (Pages 5-4 and 5-5).

The “Hour” and “Periodic” time periods list most service intervals. The maintenance schedule begins with 10-hour (daily) maintenance intervals and continues through the 1000-hour (annual) maintenance schedule intervals.

Preventive maintenance on the roller will provide years of trouble-free operation. Adjustments can be performed in the field with ordinary tools. Engine preventive maintenance, other than oil, air and fuel filter changes, is not covered in this section. Refer to the Engine Operator’s Manual for engine service information.

Anytime the machine has been repainted or the decals have been removed, damaged, worn and illegible, a new set of decals should be ordered and re-installed for safe operation (see Safety Labels in Section 1).

Changing oil and cleaning the LeeBoy Model 400 and 400T Rollers should only be done in a designated area where the the oil and chemicals can be contained. These by-products should be discarded in accordance with environmental regulations.

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

NOTE: If the machine is operated more than 10 hours per day, follow the “Hour” schedule. If the roller is operated less than 10 hours per day, follow the “Periodic” schedules.

5

Maintenance


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

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

2. Place drive lever in NEUTRAL.

3. Apply Emergency Brake.

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

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

6. Place ignition switch in the OFF position.

If maintenance must be performed with engine running, do not leave machine unattended.

10-Hour or Daily Routine Maintenance1. Check the fuel level. Keep the fuel tank full to

prevent condensation. Fill at end of day.

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

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

4. Lubricate the required parts. (Pages 5-4 and 5-5)

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

6. Check lights bulbs and replace bulbs if needed.

7. Check battery cables and connections.

8. Check coolant level. Fill as needed.

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

10. Check tires and wheels for correct air pressure, cuts, bubbles, damaged rims or missing lug bolts.

11. Check the Emergency Brake to ensure proper operation.

100-Hour or Monthly Routine Maintenance 1. Check air filters. Clean or replace if required. (Page

5-13)

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

3. Perform 100-hour or monthly engine preventative maintenance as described in the Engine Operator’s Manual.

250-Hour or Quarterly Routine Maintenance 1. Check battery electrolyte level (Page 5-10). Check

battery terminals for corrosion. Check all battery connections and remove any corrosion.

Do not smoke when checking battery electrolyte level as the fumes can explode. Electrolyte is an acid that can burn if it contacts skin or eyes. If contact is made, flush area immediately with water.

2. Change engine oil and replace oil filter (Page 5-13). To assure complete removal of contaminants in the oil, perform the oil change while engine is warm.

3. Replace engine air filter. (Page 5-13)

4. Perform the 250-hour preventative maintenance as described in the Engine Operator’s Manual.

50-Hour or Weekly Routine Maintenance 1. Check the oil and lubricate the required parts.

(Pages 5-4 and 5-5)

2. Check all battery connections and remove any corrosion. (Check cables daily.)

3. Perform 50-hour and weekly engine preventative maintenance as described in the Engine Operator’s Manual.

Maintenance


MAINTENANCE ADJUSTMENTS

Water Spray System 1. Check the water tank level. Fill if necessary.

2. Locate the water energizing switch on console and position switch to ON.

3. Open the Shut Off Valve. (Figure 5-2)

Shut-OffValve

Figure 5-2. Shut-Off Valve

4. With drive levers in NEUTRAL, check spray patterns on both front and rear drums.

If the spray pattern needs adjustment, turn plastic twist-locks to loosen. Use a screwdriver to direct the spray from the three nozzles so it completely moisten an area across the drum.

5. To secure, hold the screwdriver so that the spray nozzle will not turn and tighten the plastic twist-lock. (Figure 5-4)

Spray Nozzles

Figure 5-3. Spray Nozzles

Durlng cold weather drain water reservoir to prevent freezing.

500-Hour or Semi-Annual Routine Maintenance 1. Change fuel filters.

2. Change hydraulic charge filter. (Page 5-15)

3. Check fuses. Replace if needed. (Page 5-10)

4. Check Neutral Start system and repair if needed.

5. Check Emergency Brake operation.

6. Check oil lines and fittings for leakage or damage and replace parts as required.

7. Perform the 500-hour preventative maintenance as described in the Engine Operator’s Manual.

Hydraulic oil under pressure can cause serious personal injury. Check for oil leaks with a piece of cardboard. Do not expose hands to possible high-pressure oil. Shut down engine before attempting to tighten oil lines and fittings.

1000-Hour or Annual Routine Maintenance 1. Check air intake hoses for damage and replace if

necessary. (Page 5-8)

2. Clean and check hydraulic oil strainer fill cap. (Page 5-16)

5

Maintenance


Parking BrakeRoutinely check the Parking Brake button to ensure it is functioning properly:

1. Pull Parking Brake button (Figure 5-4).

2. If the brake is functioning correctly, the machine will not move.

Parking BrakeButton

Figure 5-4. Parking Brake Button

Oil Lines and Fittings 1. Refer to Preparing Machine for Maintenance on

Page 5-6 and park machine.

2. Check the machine for indications of oil leakage around oil lines, hoses and fittings.

3. Tighten fittings as necessary. Replace damaged or worn hoses and fittings promptly.

Air Intake Hoses 1. Refer to Preparing Machine for Maintenance on


2. Check air intake hoses from the engine to the air cleaner assembly, and from the air cleaner assembly to the precleaner.

3. Check for cracked, dry rotted, loose, worn or damaged hoses, tubes and clamps.

4. Tighten, repair or replace parts as needed.

Drive Belt Belt drive systems are equipped with automatic (spring) belt tensioners cannot be adjusted or repaired. The automatic belt tensioner is designed to maintain proper belt tension over the life of the belt. If the tensioner spring tension is not within specifications, replace the tensioner assembly.

NOTE: Refer to the Engine Operator’s Manual for more detailed information.

1. Refer to Preparing Machine for Maintenance on Page 5-6 and park machine.

2. Inspect the belt frequently. Replace if stretched, cracked or worn.

3. Check belt tension. See the Engine Operator’s Manual for tension specifications.

4. If belt is not within specifications, replace it promptly.

Neutral Start System 1. Place drive lever in the FORWARD or REVERSE

position.

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

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

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

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

Maintenance


ELECTRICAL SYSTEMThe electrical system is a 12-volt negative ground system. The battery is located on the right side of the operator’s platform behind the disconnect switch.

Battery Servicing Batteries contain sulfuric acid that

produces explosive gases. DO NOT allow flames or sparks near the battery as serious injury can result.

Always wear safety goggles and protective clothing when servicing the battery. In case of acid contact with skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention.

When servicing batteries, ALWAYS disconnect the negative (-) (ground) cable first and connect it last. Generally, if the negative cable is grounded during removal, sparks will not occur. If the positive cable is grounded during removal, sparks will occur and could ignite explosive gases.

NOTE: The electrical system is a negative ground system. Connect the positive (+) cable to the positive (+) post of both batteries. Connect the ground (-) cable to the negative (-) post of both batteries.

NOTE: When replacing the batteries, discard the old batteries properly.

Be sure the terminals and battery posts are thoroughly cleaned and that battery cable terminals are tight. Dirty or loose connections can create high electrical resistance and permit arcing.

Keep the battery clean by washing it off whenever dirt build-up is excessive. If corrosion is present around terminal connections, remove them and wash with an ammonia solution or a solution consisting of 1/4 pound (0.11 kg) baking soda and one quart of warm water.

Make certain the vent caps are tight to prevent solution from entering the cells. After cleaning, pour clean water over the battery and surrounding area to wash the solution away. Check vent cap breather openings to make sure they are open.

When batteries are connected, follow these rules:

1. Disconnect negative (-) battery cable when working on or near the alternator.

2. DO NOT attempt to polarize alternator.

3. Make sure alternator wires are correctly connected before connecting battery terminals.

4. DO NOT ground alternator output terminal.

5. DO NOT disconnect or connect alternator wires while batteries are connected or while alternator is operating.

6. Connect batteries or booster battery in the correct polarity [positive (+) to positive (+), negative (-) to negative (-)].

7. DO NOT disconnect batteries when engine is running and alternator is charging.

8. Disconnect battery cables before connecting battery charger to batteries. Charge batteries separately.

Battery MaintenancePerform maintenance on the battery as follows:

1. Disconnect battery clamps, disconnecting the black (grounded) clamp first.

BatteryHold Down Bar

Negative Cable

Negative Terminal

Positive CablePositive Terminal

Figure 5-5. Battery Components

2. Clean terminals with a stiff brush or battery service tool. (Figure 5-6)

3. Apply grease at the base of the battery terminals to prevent gas from escaping.

4. Install and tighten battery clamps, connecting the black (grounded) clamp last.

5

Maintenance


Check Battery Electrolyte Level NOTE: If water is added to batteries during freezing

weather the battery must be charged imme-diately to prevent freezing. Charge battery using a battery charger or by running the engine.

1. If using serviceable batteries, fill each cell to specified range with distilled water. DO NOT overfill.

2. Check battery charge and charging rate.

3. Shut down machine by turning ignition switch key counterclockwise to the OFF position.

4. Using a multimeter, check the battery charge by placing the positive (red) multimeter lead on the positive (+) battery terminal, and the negative (black) multimeter lead on the grounded (-) battery terminal. With the multimeter set at the 12 Vdc setting, the battery should show a charge of at least 12 volts. If not, charge the battery or perform a load test.

5. Start the engine. From the operator’s seat, check the battery charge level. The multimeter should read at least 13.5 volts. If the multimeter does not indicate minimum charge, check the machine charging system.

AlternatorThe alternator supplies electrical current for charging the battery to supply power to the electronic controls. The built-in regulator in the alternator controls the voltage output. If for any reason the wires must be disconnected from the alternator, mark them so that they can be reconnected properly.

Use the following precautions to prevent damage to the alternator and/or regulator:

• An alternator should never be polarized. Never ground any alternator terminals or circuits.

• Always disconnect the battery before disconnecting or connecting the alternator. Never disconnect the alternator while operating. Be certain the wiring is properly connected before connecting the battery.

Cold Weather Starting Be sure to keep the battery fully

charged during cold weather to keep it from freezing. Freezing weather has little effect on a fully charged battery.

If a booster battery is necessary for cold weather starting:

1. Connect one end of the first jumper cable to the positive (+) terminal of the dead battery and the other end to the positive (+) terminal of the booster battery.

2. Connect one end of the second jumper cable to the negative (-) terminal of the booster battery and the other end to the frame of the machine with the dead battery.

Fuses And Circuit Breakers The fuse block is mounted inside the instrument control panel to the left of the operator’s seat. The blade-type fuse color codes are listed in Table 5-3. Circuit breakers are mounted on the back of the ignition control panel.

Replace fuses and circuit breakers with correct amperage to prevent damage from system overload.

When a circuit breaker opens due to short circuit or overloading, turn off lights and place ignition switch in the OFF position. Wait one minute before starting machine or turning on lights. The circuit breaker will automatically reset. If the circuit breaker continues to trip (open), check the electrical system for short circuits and defective components. Replace the circuit breaker if necessary.

Table 5-3. Blade Type Fuse Color Codes

AMPERAGE RATING COLOR

1 Black

3 Violet

4 Pink

5 Tan

7 1/2 Brown

10 Red

15 Light Blue

20 Yellow

25 Natural (White)

30 Light Green

Maintenance


TIRE MAINTENANCEValve StemWheel Lug Nuts (8)

Figure 5-6. Tire Lug Nuts and Valve

Filling Tires with Air Explosive separation of a tire and rim

parts can cause serious injury or death.

Never cut or weld on inflated tire/rim assembly. Heat from welding can cause an increase in pressure and may result in tire explosion.

• Use proper tire mounting equipment and experienced personnel for tire repair service.

• Carefully inspect any tire and rim assembly for damage before inflating tire. Contact a qualified repair service if needed.

NOTE: Use a tire pressure gauge with 1-PSI (.07 bar, 6.9 kPa) graduations.

NOTE: Limit air pressure to the proper level.

1. Install lock on air chuck or stand-off gauge on valve stem.

2. Turn on air supply. Stand to one side of the tire during inflation.

3. After proper inflation (the recommended pressure is 40 PSI), release chuck or stand off gauge.

Changing Tires Explosive separation of a tire and rim

parts can cause serious injury or death.

Never cut or weld on inflated tire/rim assembly. Heat from welding can cause an increase in pressure and may result in tire explosion.

1. Loosen, but do not remove, the wheel lug nuts. (Figure 5-6)

2. Raise towable leg.

3. Remove lug nuts and tire.

4. Install replacement tire on the machine;.

5. Tighten every other lug nut alternately in a star pattern.

5

Maintenance


Check Engine Lubrication Oil LevelThe engine lubrication oil must be kept at a level above the ADD mark, but not above the FULL mark, on the engine lubrication oil dipstick.

To accurately check the engine lubrication oil level:

1. Park the roller on a level surface and stop the engine.

2. Clean around the engine lubrication oil dipstick before removing it from the engine. (Figure 5-8)

Stop the engine before checking the engine lubrication oil level as hot oil can be thrown, causing serious injury.

3. Wait five minutes after engine shutdown before removing the dipstick from the engine and checking the oil level.

Changing Engine Lubrication OilThe engine oil must be changed according to the intervals given in the Engine Operator’s Manual.

NOTE: The color of the engine lubrication oil can-not be used as an indication of the need for an oil change. Using an engine lubrication oil “analysis service” is the only alternate reason for not following the required engine lubrication oil change schedule.

DO NOT change the engine lubrication oil when the engine and lubrication oil are hot. Hot oil can cause serious injury.

DO NOT change the engine lubrication oil while the engine is running as serious damage or engine failure can occur.

While the engine is warm, proceed as follows:

1. Clean the area around the engine lubrication oil drain.

2. Place a container that has sufficient capacity to hold the drained oil directly under the engine lubrication oil drain plug.

3. Carefully remove the engine lubrication oil drain plug.

4. Clean, install and carefully tighten the lubrication oil drain plug.

ENGINE MAINTENANCE The following engine maintenance information will cover engine general maintenance procedures that are most often required. For specific, engine maintenance information, see the Engine Operator’s Manual.

You can access the engine via the Engine Access Panel. (Figure 5-7)

Engine Access Panel

Figure 5-7. Engine Access Panel

Oil Fill Cap

Fan Belt

Air Filter

Engine Oil

Dipstick

Fan

Figure 5-8. Engine Maintenance Components

Maintenance


DO NOT overtighten the drain plug

5 . Fill the engine at the oil fill cap with 15 quarts (14.2 liters) of oil . (Figure 5-8)

6 . Reinsert the engine lubrication oil dipstick .

DO NOT start the engine before changing the engine lubrication oil filter. Follow the procedures listed here and in the Engine Operator’s Manual

Change Engine Oil FilterThe engine lubrication oil filter must be changed when the engine lubrication oil is changed . (Figure 5-9)

DO NOT change the engine lubrication oil when the engine and lubrication oil are hot Change when warm only Hot oil can cause serious injury

DO NOT change the engine lubrication oil filter with the engine running. Serious engine damage or failure can occur

OilFilter

Figure 5-9. Engine Oil Filter Location

After the engine lubrication oil has been changed, proceed as follows:

1 . Wipe the area around the engine lubrication oil filter element and its mounting base with a clean cloth .

2 . Place a container under the filter element.

3 . Use a filter removal wrench to loosen and remove the filter element by turning it in a counterclockwise direction. Drain and discard the removed filter element .

NOTE: Be sure the used rubber gasket is removed and discarded with the filter element.

NOTE: Comply with environmental laws by properly discarding used oil

4 . Wipe the inside area of the lubrication oil filter head using a clean, lint-free cloth .

5 . Put clean engine lubrication oil on the rubber gasket area of the new filter element. Fill the new filter element with the new oil .

6 . Install the new filter element onto the filter head. Carefully tighten the filter element (by hand only).

NOTE: Tighten the filter element as directed by the filter manufacturer.

Change Engine Air FilterThe engine inlet air filter assembly uses a replaceable filter element. (Figure 5-10)

Air Cleaner

Cover

Air Filter Access

Figure 5-10. Engine Air Filter Location

The air filter element should be replaced every 100 hours of normal paver operation or monthly. Replace the air filter element more often for a paver that is operated under more severe conditions NEVER operate the engine without an air cleaner element installed

DO NOT service the air cleaner element while the engine is running

Use the following procedures to service the air cleaner element:

1 . Remove the back cover on air breather housing .

2 . Remove the air filter outer element.

5

Maintenance


3. Remove the air filter inner element.

4. Clean the inside of the air cleaner housing with a clean, lint-free cloth.

5. Discard filters properly.

Severe engine damage can occur if engine is operated without air filter properly installed.

6. Carefully install the new air filter elements into the housing.

7. Install the rear covers.

8. Start the engine, checking that it runs smoothly.

FUEL SYSTEM

Fuel TankThe fuel level is indicated on the fuel gauge located on the dashboard, and indicates the amount of fuel in the tank. The green fuel cap for filling the machine with diesel fuel is located on the front part of the machine. (Figure 5-11)

Fuel Cap

Figure 5-11. Fuel Cap Location

NOTE: Fill the tank to FULL before the roller is stored overnight to reduce moisture accumu-lation in the tank from condensation.

The operator should NEVER be on the roller while fuel is being added. NO SMOKING while filling the fuel tank as all fuels for internal combustion engines are flammable. Fill the fuel tank only in a designated area where there is good ventilation and a fire extinguisher available.

NEVER fill the tank, check fuel level or check for fuel leaks near an open flame or near equipment that can create sparks.

Engine Fuel FiltersThe fuel filter elements must be replaced as directed in the Engine Operator’s Manual. (Figure 5-12) Replace the fuel filters using the following general procedure:

Diesel fuel is very flammable. Use extra caution and DO NOT spill fuel. DO NOT change the fuel filter while the roller is running. DO NOT change the fuel filter in an area near an open flame. DO NOT smoke while changing the fuel filter.

Fuel Filter

Figure 5-12. Engine Fuel Filter Location

Maintenance


To change the fuel filter:

1. Stop the engine.

2. Put a container under fuel filters before removing the filter elements.

NOTE: Consider the environment when discarding used filters and do so according to safe and lawful practices.

3. Wipe the area around the fuel filter elements and element mounting heads using a clean, lint-free cloth.

4. Use a filter removal wrench to loosen and remove fuel filter elements by turning in a clockwise direction. Drain and discard the removed elements.

5. Wipe the inside area of the filter heads with a clean, lint-free cloth. Fill the new fuel filter elements completely with clean fuel.

6. Put clean fuel onto the element rubber gaskets.

7. Install the new fuel filter elements onto the filter heads. Carefully tighten the elements (by hand only).

Tighten the fuel strainers or the fuel filter elements as directed on the filter element by the filter manufacturer. DO NOT overtighten the fuel filter elements onto the filter heads.

8. Start the engine and check for ANY fuel leaks.

STOP the engine immediately if any fuel leakage is noted. DO NOT start the engine until the leakage problem is corrected.

NEVER loosen a fuel injector line as contents are under high pressure. DO NOT try to bleed air by loosening injector lines.

HYDRAULIC SYSTEM Hydraulic oil under pressure can

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

Checking Hydraulic Oil Level 1. Park machine on level surface and turn off.

2. Make sure all cylinders are retracted.

3. Wait 10 minutes for oil to drain after engine has been shut down.

4. Check hydraulic oil level using the sight gauge located on the right side of the machine. (Figure 5-13). The hydraulic oil level should be in the upper half of the sight gauge, but never above the upper black fill line.

Hydraulic Oil Fill Line

Figure 5-13. Hydraulic Oil Level Sight Gauge

5

Maintenance


Hydraulic Oil Strainer

Fill Cap

Figure 5-14. Hydraulic Oil Strainer Fill Cap

5. If needed, add hydraulic oil at the hydraulic oil strainer fill cap. (Figure 5-14)

6. Check the hydrualic oil level at the sight gauge to assure oil level reaches the black fill line. (Figure 5-13)

7. DO NOT overfill the tank. Leave approximately one inch (25mm) of space for expansion of hot oil.

8. Clean any spilled oil with a clean cloth.

Change Hydraulic Filter Burn Injury Hazard! Hot hydraulic

oil can burn upon contact with the skin. Change hydraulic charge filter while system is warm, not hot. Avoid contact with hot hydraulic oil. Failure to obey this warning could result in serious injury.

1. Refer to Preparing Machine for Maintenance on Page 5-6 and park machine.

2. Allow the engine to cool completely.

3. Open the access panel on floor of the operator’s station to access the hydraulic oil tank.

4. Close the hydraulic oil tank supply line gate valves located on the hydraulic tank by turning the valve handles counterclockwise.

DO NOT start machine while the hydraulic oil tank supply line gate vales are closed. Starting the engine will damage the hydraulic pump.

HydraulicFilter

Figure 5-15. Hydraulic Filter

5. Turn the hydraulic oil filter counterclockwise to remove. (Figure 5-15)

6. Clean the mounting surface and remove any loose filter seals.

7. Install the new filter, turning it clockwise until the seal contacts the mounting surface. Tighten the filter 1/2 to 3/4 additional turns.

8. Open hydraulic tank supply line gate valves by turning the valve handles clockwise.

9. Start engine and check for leaks. Tighten filter if necessary.

Check and Clean Hydraulic Oil Strainer Fill Cap

Wear eye protection and chemical resistant gloves when using solvent for cleaning purposes. Some solvents can cause skin irritation and eye damage.

1. Remove hydraulic oil tank strainer fill cap (Figure 5-14) by turning counterclockwise and inspect for damage. Check strainer cap for dirt and clogging.

2. Using solvent, clean the strainer fill cap thoroughly and dry with compressed air.

3. Check the strainer fill cap for free air flow. Replace if necessary.

4. Reinstall hydraulic oil strainer fill cap by turning clockwise.

Maintenance


Drain, Flush and Fill Hydraulic Oil Tank1. Refer to Preparing Machine for Maintenance on


2. Close the hydraulic tank supply line gate valves by turning the valve handle counterclockwise.

DO NOT start machine while the hydraulic oil tank supply line gate vales are closed. Starting the engine will damage the hydraulic pump.

3. Remove the hydraulic oil strainer fill cap so air ventilation assists drainage of oil.

4. Remove the drain plug and drain the hydraulic oil into a suitable container. Dispose of oil properly.

5. Flush hydraulic tank completely.

6. Check the hydraulic suction strainer in bottom of the hydraulic oil tank. Refer to Section 6, Page 6-9.

7. Reinstall drain plug.

8. Replace the hydraulic oil filter. (Figure 5-15)

9. Fill hydraulic oil tank to the proper level.

10. Reinstall the strainer fill cap.

11. Open hydraulic tank supply line gate valves by turning valve clockwise.

12. Start engine and operate hydraulic control levers several times.

13. Check the hydraulic oil sight gauge and add more oil if necessary.

COMPONENT REPLACEMENT PROCEDURES

Replace Batteries Batteries create explosive gases

when charging. DO NOT expose these gases to sparks or open flame during maintenance. Always perform battery service in a well-ventilated area or outside. Serious injury can occur from exploding batteries.

1. Remove seat.

2. Remove the black ground (-) cable from the negative (-) battery terminal, followed by the red (+) cable from the positive (+) battery terminal. (Figure 5-16)

BatteryHold Down Bar

Negative Cable

Negative Terminal

Positive CablePositive Terminal

Figure 5-16. 12-Volt Battery System

If the negative cable is grounded during removal, sparks will not occur. If the positive cable is grounded during removal, sparks will occur and could ignite explosive gases.

3. Remove the hold down bar. (Figure 5-16)

4. Inspect the batteries for cracks, wear and damage that could result in leaks.

5. Carefully remove the batteries from the battery plate, noting battery position during removal.

5

Maintenance


DO NOT dry batteries using compressed air. Allow the batteries and surrounding area to dry. Battery acid can cause severe injury if blown into the face or other areas of the body. If injury occurs, seek medical attention immediately. Flush eyes and skin for 30 minutes with clean water.

6. Make sure the battery cells are sealed. Clean the batteries, battery tray, cables, and brackets with baking soda and warm water. Allow to air dry.

7. Place the batteries in proper position in the battery tray.

8. Install hold down bar. Tighten bar to retain battery, but not so tight as to damage battery.

When installing batteries, always install the positive cable first followed by the negative cable. Reversed polarity can damage the electrical system.

9. Install red (+) battery cable to the positive (+) battery terminal. (Figure 5-16)

10. Install the black (-) battery cable to the negative (-) battery terminal. (Figure 5-16).

11. Reattach the battery box cover and rehook battery box locks.

Replace Valve Bank Assembly (400T Only)1. Refer to Section 7 (Illustrated Parts List), Page

7-44, for a complete breakdown of the valve assembly parts.

2. Thoroughly clean the control valve and surrounding area, especially around the hydraulic hoses and fittings.

Valve BankAssembly

Figure 5-17. Valve Bank Assembly Location

3. Tag and disconnect hydraulic hoses. Immediately plug the hoses and control valve ports to prevent contamination of the hydraulic system.

4. Support the control valve and remove the control valve mounting bolts and washers.

5. Remove the control valve assembly.

6. Inspect the control valve levers and linkages for

Maintenance


wear and damage. Replace levers and linkages if necessary.

7. Remove control levers and linkage.

8. Inspect hydraulic fittings for wear and damage. Replace if necessary. Remove fittings for installation in replacement valve.

9. Install fittings into the replacement valve.

10. Reinsert control valve and secure with mounting bolts and washers.

11. While supporting valve and using tags created during removal, connect hydraulic hoses to fittings.

12. Install control levers and linkage.

13. Start engine and check operation. Repair leaks if necessary.

STORAGEThis section contains instructions to prepare the machine for long-term storage and monthly inspections needed during storage.

1. Inspect the machine thoroughly and repair worn or damaged parts.

2. Retract all hydraulic cylinders, if possible.

3. Shut down engine and remove ignition key.

4. Remove alternator belt.

5. Check air filter restriction gauge. Clean the air cleaner assembly and replace air filter elements if restricted.

6. Clean the machine. Paint chipped or rusty areas to prevent further rusting. Replace worn or damaged decals.

7. Cover seat with plastic.

8. Place a “DO NOT OPERATE” tag on the steering wheel.

9. Coat exposed cylinder rods with rust inhibitor.

NOTE: Some rust inhibitors can destroy painted surfaces. DO NOT use.

10. Lubricate all grease points. (Pages 5-4 and 5-5)

11. Check engine oil level and fill if necessary.

12. Check hydraulic oil sight gauge and fill if necessary.

13. Perform specific gravity test on engine coolant. Drain and replace or fill coolant reservoir to prevent freeze damage, if needed.

14. If possible, raise and support machine with tires off the ground or park machine on a hard surface to prevent tires from freezing to ground.

15. Store machine in a dry, protected area. If stored outside, cover with waterproof material.

5

Maintenance


NOTE: The following troubleshooting solutions include common problems encountered with diesel engines. For additional information and troubleshooting procedures, see the Engine Manufacturer’s Manual.

TROUBLESHOOTINGThe troubleshooting chart below identifies the most common symptoms of failure. Use this chart to help identify the failed component.

SYMPTOM CAUSE REMEDY

Engine will not turn over. Electrical issue (i.e., faulty wiring).

Check battery.

Check ignition switch.

Check neutral safety switch.

Check starter solenoid.

Check engine ground.

Engine will not start. See Engine Manual. See Engine Operator’s Manual.

Water system will not operate.

No water in machine.

Water flow is restricted.

Water pump isnot working properly.

water pump electrical connections are faulty.

Check water level.

Check strainer under the tank.

Check nozzle strainer.

Check water pump:

• Check pump switch.

• Check hot wire to pump.

• Check ground to pump.

Forward/Reverse Lever will not stay in position or is too tight.

Lack of grease.

Improper adjustment.

Grease.

Adjust friction nut at bottom of left lever.

Difficulty with steering while vibrator is in operation.

Vibrator bearings worn or damaged.Check hydraulic system.

Replace bearings.

Vibrator will not operate. Electrical issue.

Lack of hydraulic pressure.

Mechanical issue with motor.

Check neutral safety switch to make certain power is reaching the vibratory valve.

Unfasten pressure line to vibrator motor and attach the pressure guage. Start engine. Pressure should immediately reflect 1800 - 2000 psi on the gauge when vibrator is engaged. Turn off engine.

Unbolt hydraulic motor from the drum. Refasten pressure line. Start engine to see if motor is operating. Turn off engine.

Check if vibrator shaft turns freely. If the shaft turns freely, the motor needs to be replaced.

NOTE: Shaft is heavier on one side than the other.

Table 5-4. Troubleshooting Chart

Maintenance


SYMPTOM CAUSE REMEDY

Vibrator will not operate.Bad bearings, broken housing or broken shaft.

Remove vibratory mechanism from the drum.

Roller does not move.

Parking brake engaged.

Hydraulic pumpor drive motor worn or damaged.

Disengage parking brake button.

Replace damaged component.

5

Maintenance


NOTES

Maintenance


Page

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

Electrical Schematic, Option, 400 / 400T . . . . . . . . . . . . . . . . . . 6-3

Electrical Schematic, Tow Pak, 400T . . . . . . . . . . . . . . . . . . . . 6-5

Panel, Gauges, Kubota, 400 . . . . . . . . . . . . . . . . . . . . . . . . 6-7




SCHEMATICS

Section 6

NOTES


76


Schematics

Figure 6-1. Electrical Schematic for Tow Pak (400T only)

ELECTRICAL SCHEMATIC, TOW PAK, 400T

REDGRN

RIGHT TAIL LIGHT

RED

BRN

BRN

BRN

LEFT TAIL LIGHT

A

BLU

BLU

BLU

LEFT

BLU

BLU

RED

RIGHT


Schematics

NOTES

76


Schematics

Figure 6-2. Schematic for Kubota Panel Gauges

PANEL, GAUGES, KUBOTA, 400

+

_ _

S+

_

S+

_

S+

+_

50

AC

30

19 17

C

S

B

SFE14AFUSE

G

WK

STARTER

B+

FUELSOLENOID

PULL

HOLD

B+

ALTERNATOR

GLOW PLUGS

RED

14G

RED 12G

RED 10G

YEL 10G

PRP 14G

RED 20G

YEL 10G

NEUTRALSAFETYSWITCH

#10 RINGTERMINALS

ENGINE BLOCKGROUND

RED 14G

RED 20G

RED 20G

BLK 20GBLK 20G

BLK 20G

BLK 20G

BLK 20G

BLK

BLK

BLKBLK

RED 20GRED 20G

ORN/WHT 14G

HYDRAULIC TEMPERATURESWITCH (OPTIONAL)

TEMPERATURESWITCH

RED/WHT 14G

FUEL LEVELSENDER

TEMPERATURESENDER

OIL PRESSURESENDER/SWITCH

5-POSITIONCONNECTOR

8-POSITIONCONNECTOR

ORN 14G

PNK 14G

YEL/BLK 14G

BRN 14GBLU 14G

GRY/RED 14G

BLK 14G

YEL 16G

RED 10G

YEL 10G

PRP 14G

ORN/WHT 14G

RED/WHT 14G

ORN 14G

PNK 14G

YEL/BLK 14G

BRN 14GBLU 14G

YEL 14G

RED 10G

YEL 10G

PRP 14G

RED

10G

WHT

16G

YEL/BLK 14G

YEL/

BLK

14G

BLU 14G

GRY/RED 14G

GRY/RED 14G

MURPHY 117PHRELAY

IGNITIONSWITCH

HOURMETER

VOLTMETER OILPRESSURE WATER

TEMPERATURE

FUELGAUGE

TACH WIRE(OPTIONAL)

CASE GND

MALE PIN

YELLOW 10GBLUE 14G

FEMALE SOCKET

BROWN 14GPURPLE 14G

BLACK 14GYELLOW 14GGREY/RED 14GRED 10G

PINK 14GORG/WHT 14GORANGE 14G

RED/WHT 14GYEL/BLK 14G

BLACK 14GYELLOW 14G

GREY/RED 14GRED 10G

YELLOW 10GBLUE 14GBROWN 14GPURPLE 14G

RED/WHT 14GYEL/BLK 14G

PINK 14GORG/WHT 14GORANGE 14G

WIRE HARNESS PLUG LEGENGPANEL SIDE ENGINE SIDE

N.C.


Schematics

NOTES

76


Schematics

Figure 6-3. Electrical Schematic for Options

ELECTRICAL SCHEMATIC, OPTION, 400 / 400T

FUSE

M

WATER PUMP

SWITCH

SWITCH WATER PUMP

SWITCH BEACON LIGHT

SWITCH

W

DIODE

LIMIT SWITCH

BEACON LIGHT

ORN

RED

BLU

BRN

REDRED

BLU

BRNBRNBRN

ORNORN

W

W

WBLU

BLU

BLU

BLU1012563

1012563

1012563

1012563


Schematics

NOTES

76


Schematics

Figure 6-4. Hose Layout for 400 Hydraulics (1 of 2)

HYDRAULIC HOSE LAYOUT, 400, 1 OF 2

ENGINE

MGEAR PUMP

STEERING UNIT

STEERING COLUMN

A

BC

D E

S

B

T

R L

F

G

RDB

L

A

P

L R

D


Schematics

NOTES

76


Schematics

Figure 6-5. Hose Layout for 400 Hydraulics (2 of 2)

HYDRAULIC HOSE LAYOUT, 400, 2 OF 2

M3

T P

L R

STEERING UINT

STEERING COLUMN

L

R

D

M

FILTER

L

R

D

B

A

BS

GEAR PUMP ENGINE

B

IN SI SO T

OIL COOLER


Schematics

NOTES

Page

Illustrated Parts List 7-1

Quick Reference Guide 7-3

400 Main Frame Assembly, 1 of 2 7-4

400 Main Frame Assembly, 2 of 2 7-6

Water Tank and Rollbar Groups 7-8

Front Drum and Yoke Assembly 7-10

Front Wiper, Front Inner Wiper, and Rear Wiper, 400 / 400T 7-12

Rear Drum Assembly, Cut-Section 7-14

Water System Assembly 7-16

Fuel System Group 7-18

Steering and Drive Control Assembly 7-20

Seat Assembly 7-22

Engine Group, 1 of 2 7-24

Engine Group, 2 of 2 7-26

25 HP, Tier4F, Engine, Kubota 7-28

Battery Group 7-30

400 and 400T Miscellaneous 7-32

Sign (Option) 7-34

400T Main Frame Assembly 7-36

Tow/Lift Group 7-38

400T Towing Safety Pin and Pintle Eye 7-40

Wheel Hub and Brake Assembly 7-42

Valve Bank Assembly (400T Only) 7-44

Alphabetical Parts Index (API) 7-46


ILLUSTRATED PARTS LIST

Section 7

NOTES

Illustrated Parts List


QUICK REFERENCE GUIDE

Part Number Description

987715 Optional, Grp , Canopy, 400 Roller

981772 Optional, Coco Mats, 400

985185 Optional, Work Lights, 400

1005444 Optional, Gauge Package

982050 Optional, Vandalism Protection

920235 Optional, Umbrella

982078 Optional, Horn, Rollers

982110 Optional, Slow Moving Sign, Rollers

5MB6H Fire Extinguisher, 5 Lbs

986598-05SRV Kit, Filter, 400 Series, Kubota

1001911 Optional, W/M, Tongue Ext Drop, 400T

985184 Back Up Alarm, 400

986765 Grill Assembly, 400/420 Kubota

987389 Assembly, Rear Wipe W/O Brkt

987390SRV Assembly, Rear Wipe

1008292SRV Spring, Front Scraper Drum Com

400894 Scraper, Front Inner 400

38778-1 Filter Element, Oil

985909 Filter Element, Air, Primary

985911 Filter Element, Air, Safety

1011485-23 Fuel Filter With Mount

290030 Element, Charge Filter From #400-104

7



400 MAIN FRAME ASSEMBLY, 1 OF 2

Figure 7-1. 400 Main Frame Assembly, 1 of 2

1

2

3

4



400 Main Frame Assembly, 1 of 2, Parts List

Item No

Part Number Qty Description Remarks

1 987151 1 Weldment, Frame 400

2 100-16-12-56-5F 1 Cshh, 1-12 X 3 5, Gr5, Ft

3 400793 1 Tank Safety

4 1000281 1 Rnd, 500, Bent, Safety Latch

7



400 MAIN FRAME ASSEMBLY, 2 OF 2

Figure 7-2. 400 Main Frame Assembly, 2 of 2

17

10, 13, 15

2

7

1820

21

8

20

612

54

3

911, 14, 16

1



400 Main Frame Assembly, 2 of 2, Parts List

Item No


1 987151 1 Weldment, Frame 400

2 989117 2 W/M, Hinge Assembly, Water Tank Plate

3 400762 1 Shaft, Control

4 857137 1 Key Stock

Ref 490092 1 Handle, 400 Lh Drive Assembly

5 490071 1 Spacer

6 490080 1 Washer, Belleville 5/8”

7 400781 1 Threaded Rod & Tube

8 300213 1 Support, Plate Floorboard welded to 300212

9 1009905 1 Lever, Forward/Reverse-Rh welded to 857135

10 100-8-13-32-5 4 Cshh, 1/2-13 X 2, Gr5

11 100-6-16-24-5 1 Cshh, 3/8-16 X 1 5, Gr5

12 102-607-1A 1 Cshh, 625-11 X 1 500, Gr5

13 118-5 4 Washer, Lock, 500

14 300-6 6 Washer, Flat, Sae, 3/8

15 200-8-13-5 4 Nut, Hex, 1/2-13, Gr5

16 116-3 3 Nut, Hex, 375-16

17 858526 1 Rnd, 688 X 8 75, Crs

18 400761 1 Bushing, Drive Handle, Lh, 400 welded to 400764

19 300-6 2 Washer, Flat, Sae, 3/8

20 100-6-16-36-5 1 Cshh, 3/8-16 X 2 25, Gr5

21 1009904 1 Handle, 400 Lh Drive

7



WATER TANK AND ROLLBAR GROUPS

Figure 7-3. Water Tank and Rollbar Groups

2

34

56

75

87

1

9



Water Tank and Rollbar Groups Parts List

Item No


1 988558 1 Tank, Water, 80Gal, Poly

2 987507 1 Rollbar, Complete

3 987719 1 Weldment, Canopy

4 100-6-16-16-5F 2 Cshh, 3/8-16 X 1, Gr5, Ft

5 301-6 6 Washer, Flat, Uss, 3/8

6 116-3 4 Nut, Hex, 375-16

7 118-3 6 Washer, Lock, 375

8 987718 2 Clamp, Rops

9 36151 1 Filler, Tank, 4 In, Cap And Strainer

7



23

7

FRONT DRUM AND YOKE ASSEMBLY

Figure 7-4. Front Drum and Yoke Assembly



Front Drum and Yoke Assembly Parts List

Item No


Ref 400877 1 Front End Assembly, 400

1 851436SRV 1 Cyl , Hyd , 2 00 X 12 00 X 1 00 Rod

2 420022 1 Washer, Steering Yoke Pin (400)

3 420032ASRV 1 Steering Yoke, 400 N/S

4 420042SRV 1 Pin, 400 Steering Yoke

5 420043SRV 1 Crossmember, 400 Front End

6 420063SRV 1 Scraper, 400, Front

7 420064SRV 1 Rear Wiper Blade, Front Roller

8 420082ASRV 2 Spacer, Front Axle, 400 N/S

9 210180 4 Bearing Cone

10 210190 4 Bearing Cup

11 420112ASRV 1 Axle, 400, Front Drum N/S

12 420124ASRV 2 Drum, 400, Front, Half W/Bearings

13 210240A 1 Seal, Front Yoke, 400 N/S

14 210180A 2 Bearing Cone

15 210190A 2 Bearing Cup

16 210170A 1 Washer, Lock, ‘Tang’ Style

17 38671 1 Nut, Lock, ‘Tang’ Style

18 420180 2 Pipe, Plug, 1 000 Pvc, Hex

19 857178SRV 1 Bracket, 400 Cocomat Front

20 430160-44 1 Cocoa Mat, 6” X 44” Plastic

Ref 981772 1 Opt,Coco Mats,400

21 420032ASRV 1 Steering Yoke, 400 N/S

22 510041SRV 1 Pin, Towing Tongue Safety

23 210010 2 Bushing, 2 00 Id X 2 50 Od X 1 75Lg

24 210240 4 Seal

25 420211 1 Machined Nut, Front Axle, 400

26 420102A 2 Clamp Assembly, 2 Pc Split 2 Bolt

7



FRONT WIPER, FRONT INNER WIPER, AND REAR WIPER, 400 / 400T

Figure 7-5. Front Wiper, Front Inner Wiper, and Rear Wiper

1

2

4

3

5



Wiper, Front Inner Wiper, and Rear Wiper Parts List

Item No


1 420063SRV 1 Scraper, 400, Front

2 400894 1 Scraper, Front Inner 400

3 987326 1 Group, Rear Wiper

4 987390SRV 1 Assembly, Rear Wipe

5 987389SRV 1 Assembly, Rear Wipe w/o Brk

7



REAR DRUM ASSEMBLY, CUT-SECTION

Figure 7-6. Rear Drum Assembly, Cut-Section

A

A

23



Rear Drum Assembly Parts List

Item No


1 400887-04 1 Rear Drum, I d Machined

2 520280 1 Flange W/Hub,Inner Bearing Support-400

3 520060 1 Bearing, Insert,1 50

4 858248 1 Vibrator Hub/400

5 400595 1 Hub, Counterweight

6 400596 1 Counter Weight, Vibe

7 988504 1 Motor, Hydraulic, Gear, 67Cir

8 300-6 2 Washer, Flat, Sae, 3/8


10 118-3 2 Washer, Lock, 375

11 118-6 12 Washer, Lock, 562

12 118-5 42 Washer, Lock, 500

13 102-6-16-20-F 2 Cssh, 3/8-16 X 1 25, Ft

14 858312 1 Vibrator Hub To Frame Mount

15 100-10-11-24-8F 12 Cshh, 5/8-11 X 1 5, Gr8, Ft

16 100-8-13-24-5 24 Cshh,1/2-13 X 1 5, Gr5

17 100-8-13-16-5F 16 Cshh, 1/2-13 X 1, Gr5, Ft

18 100-8-13-20-8F 2 Cshh, 1/2-13 X 1 25, Gr8, Ft

19 858309 2 Mount, Motor To Frame (400 W/Poclain)

20 520020A 6 Shear Mount, Frame To Drum

21 200-8-13-5 24 Nut, Hex, 1/2-13, Gr5

22 116-7 9 Nut, Hex, 625-11

23 986811 9 Washer, Lock, 670, Nord Wedge

24 811361 1 Motor, Hyd, Drive, 7000 7



Figure 7-7. Water System Assembly

WATER SYSTEM ASSEMBLY



Water System Assembly Parts List

Item No


1 480010 6 Nozzle, Assembly , 08 Pipe Nyl, 90 Deg

2 480022SRV 1 Spraybar, 400 Rear Drum

3 X427 2 Adapter, Pipe To Hose

4 33167 4 Clamp, Hose, # 20 (1-1/2”)

5 99400WS-02 1 8Lola X 61”

6 480140 1 Tee, 3/8” Brass

7 99400WS-05 1 8Lola X 28”

8 480100SRV 1 Spraybar, 400 Front Drum

9 99400WS-03 1 8Lola X 80”

10 480220SRV 1 Pipe Nipple Weldment

11 480230 1 Street Elbow, 3/8” Brass

Ref 99400WS 1 Hose Kit, 400 Water System Kit

13 480160 2 Valve, Ball, 375

14 Ref 1 Reducer

15 99400WS-04 1 8Lola X 21”

16 480250 1 Hose,Water Tank To Pump, 400

17 1005660 1 Pump, Water Spray

18 480170 1 Brass

19 480120 1 Pipe, Nipple, 375Xclose, Brass

20 480080 1 Y-Strainer, 3/4” Fpt Brass

21 480070 1 Pipe, Nipple, 750Xclose, Brass

22 480060 1 Elbow, Pipe, 90, 750, Brass

23 480050 1 Red Bushing, 3/4 Mpt X 1/2 Fpt

24 480260 1 Bracket, Water/Fuel Pump Mount

25 38656 1 Cap, Water Spray Nozzle

26 38716 1 Tip, Water Spray Nozzle

27 480010-4 1 Washer,Water Spray Nozzle

28 480010-2 1 Strainer, Nozzle, 100 Mesh

7



FUEL SYSTEM GROUP

Figure 7-8. Fuel System Group

2

3

1

9

4

7

6

5

8

10

10

10



Fuel System Group Parts List

Item No


1 988663 1 Tank, Fuel, 8 Gal, Poly

2 988816 1 Clamp, Tank, Hold Down

3 988820 2 Pad, Tank, Fuel, Poly

4 P81743 1 Gasket, Fuel Sender Mount

5 980689 1 Cover, Fuel Level Sending Unit

6 140030FL 1 Cap, Fuel Tank, Lockable

7 140030FN 1 Filler Neck, Hyd Oil/Fuel Cap

8 71812 2 Hose, 05, Push-On, 3125

9 853930 1 Gasket, Filler Breather Cap

10 Ref 1 Weldment (for reference only)

7



STEERING AND DRIVE CONTROL ASSEMBLY

Figure 7-9. Steering and Drive Control Assembly



Steering and Drive Control Assembly Parts List

Item No


1 490010 2 Hand Grip, Drive Lever

2 490022 1 Lever Assembly, 400 Rh Drive

3 490031SRV 1 Lever Assembly, 400 Pump Upper

4 490040 1 Switch, Neutral Safety

5 490052SRV 1 Lever Assembly, 400 Throttle

6 490062 1 Bushing, Drive Lever, Lh, 400

7 490071 1 Spacer

8 490080 1 Washer, Belleville 5/8”

9 490092 1 Handle, 400 Lh Drive

10 490100 1 Hand Grip, Throttle Lever

11 36127 1 Motor, Hyd, Power Steering

12 300030 1 Steering Wheel, 17 00, 36 Spline

13 300020 1 Nut, Hex, 813-20

14 300010 1 Cap, Steering Wheel

15 300040 1 Steering Column, 6 00

16 500770 1 Cable, Push/Pull, Fwd/Rev

17 920090 1 Ball Joint, 250, Fm, w/ 375 Stud

7



SEAT ASSEMBLY

Figure 7-10. Seat Assembly

3

2

1



Seat Assembly Parts List

Item No


1 315000 1 Seat Assembly

2 315010 1 Seat, Cushion, Back

3 315030 1 Seat, Cushion, Bottom

7



ENGINE GROUP, 1 OF 2

Figure 7-11. Engine Group, 1 of 2

6

12347

6 5



Engine Group - 1 of 2 - Parts List

Item No


1 1011485 1 Engine, Kubota, 25Hp T4f

2 986770SRV 1 Brkt-Cable, Throttle/Pump 400

3 981223 1 Extension, Pump Actuator

Ref 530040B 1 Pump, 400S Hydraulic Drive

4 530040B-01 1 Main Pump

5 851214 1 Cable, Push/Pull, 90” X 3” Stroke

6 37846 2 Clevis, 10-32 X 1 25, W/ 25 Pin

7 320232 1 Pump, Hyd, Gear, 85 Cir

Ref 36808 1 Oring, 3 237 Id X 103, Sae 152 (not shown)

Ref 986598-08 1 Mount Kit (not shown) - includes the coupling

7



ENGINE GROUP, 2 OF 2

Figure 7-12. Engine Group, 2 of 2

4

3

2 1



Engine Group - 2 of 2 - Parts List

Item No


1 119-2 2 Washer, Flat, Sae, 312

2 100-M8-1 25-25-8 8F 2 Cshh, M8x1 25 X 25, C8 8, Ft

3 33306 1 Clamp, Muffler, 1.5 Id

4 1012543 1 Weldment, Exhaust Bracket

7



25 HP, TIER4F, ENGINE, KUBOTA

Figure 7-13. 25HP Kubota Engine

1

2 4

5

8

9

6

10

11

13

14

15

16

19

20

712

17

18

21

2223

3

13



Kubota Engine Parts List

Item No


1 1011485 1 Engine, Kubota, 25Hp T4f

2 1011485-16 1 Radiator, Cap

3 1011485-03 1 Radiator, Stay

4 1011485-01 1 Radiator, Oil Cooler

5 1011485-04 1 Radiator, Shroud

6 1011485-05 1 Wire, Fan, Guard

7 1011485-17 1 Radiator, Isolators

8 1011485-02 1 Radiator, Mount Plate

9 1011485-18 1 Radiator, Mount

10 320090-2L 1 Belt, Alternator/Blower, Hatz (not used)

11 1011485-06 1 Lower, Radiator, Hose

12 38778-1 1 Filter Element,Oil

13 1011485-22 4 Engine, Isolators

14 1011485-21 1 Hydraulic, Pump Mount

15 1011485-11 1 Air, Cleaner, Mount

16 1011485-14 1 Cylinder, Head Bolts

17 1011485-20 1 Muffler

18 1011485-07 1 Exhaust, Pipe

19 1011485-09 1 Mount, Foot

20 1011485-10 1 Air, Cleaner, Hose

21 1011485-12 1 Air, Cleaner

22 1011485-13 1 Air Cleaner, Mount Band

23 1011485-08 1 Upper, Radiator, Hose

Ref 985909 1 Filter Element, Air, Primary

Ref 985911 1 Filter Element, Air, Safety

Ref 1008298 1 Muffler Stay

Ref 1011485-15 1 Pusher Fan

Ref 1011485-19 1 Muffler Brace

Ref 1000956 1 Hydraulic Pump Mount

Ref 1011485-23 1 Fuel Filter With Mount

Ref 1011485-24 1 Coolant Reserve Tank

Ref 1011485-25 1 Thermostat Cover

Ref 1011485-26 1 Temperature Sender

Ref 989707 1 Oil Pressure Sender

Ref 1011485-27 1 Temperature Switch

Ref 1011485-28 1 Oil Pressure Switch

Ref 985628 1 Oil Pressure Fitting

Ref 1011485-29 1 Engine Harness

Ref 1011485-30 1 Fuel Solenoid Connector

Ref 986598-01 1 Starter, Engine, Kubota 400 Roll

7



BATTERY GROUP

Figure 7-14. Battery Group

3

1

2

4

5 8

6

7



Battery Group Parts List

Item No


Ref 987005 1 Group, Battery 400/400T Group Number

1 400709SRV 1 Battery Box

2 Ref 1 Battery, 12V, 835 Cca, Group 24 Buy Locally

3 857106 1 Battery Box Mount/400

4 300286 1 Battery Hold Down, Diesel

5 400020 1 Cable, Battery, Neg, 16”, Eye/Post

6 852510 1 Cable, Battery, Pos, 44”, Eye/Post

7 5804 1 Cable, Battery, Neg, 13”, Eye/Eye

8 410050 1 Pad, Battery Hold Down

7



400 AND 400T MISCELLANEOUS

Figure 7-15. 400 and 400T Miscellaneous

1

2

11

1112

13

8

10

9

6

4

14

7

3



400 and 400T Miscellaneous Parts List

Item No


1 1012563 1 Light, Led Circular (old light was 1003862)

2 39146-14 1 Switch, Ignition, W/Heat St

3 982008-04 1 Key, Ignition, Kubota

4 500040 1 Switch, Toggle

5 500090 1 Valve, Solenoid

6 500050 1 Cable, Throttle

7 500770 1 Cable, Forward & Reverse

8 500070 1 Gauge, Hydraulic Oil Level & Temp

9 290010 1 Head, Charge Filter

10 290030 1 Element, Charge Filter From #400-104

11 500080 1 Valve, Relief, 2000 P s i

12 500140 1 Switch, Vibrator Actuator

13 910080 1 Valve, Emergency Stop

14 500190 1 Gauge, Hour Meter

7



SIGN (OPTION)

Figure 7-16. Sign (Option)

54

4

3

2

1



Sign Parts List

Item No


1 P70036 1 Sign, Slow Moving Vehicle

2 1009906 1 Bar, Bracket, Slow Moving Sign

3 100-4-20-12-5F 2 Cshh, 1/4-20 X 0 75, Gr5, Ft


5 205-4-20-5 2 Nut, Lock, Nylon, 1/4-20, Gr5

7



400T MAIN FRAME ASSEMBLY

Figure 7-17. 400T Main Frame Assembly

1

2

6

9

74

311

85

10



400T Main Frame Assembly Parts List

Item No


1 987150 1 Weldment, Frame 400T

2 988796SRV 1 Weldment, Poly Water Tank Mount

3 510023SRV 1 Housing, Tongue

4 400872 1 Roller, Tongue Lock, Pin

5 400829SRV 1 Lock, Tongue


7 400837 2 Tube, Towbar Pivot Housing

8 400862 1 Arm, Tow Bar

9 510014SRV 1 Tongue, Tow

10 116-3 2 Nut,Hex, 375-16

11 400836 2 Spacer, Tongue Pivot Pin

7



TOW/LIFT GROUP

Figure 7-18. Tow/Lift Group

1

1

2

4

4

2

38

5

6

7

6



Tow/Lift Group Parts List

Item No


1 1005464-01 2 Tire, L T225 / 75R-16, Lre

2 1005464-02 2 Wheel, 16 X 6, 8 Hole

3 510134LSRV 1 Arm, Lh Tow/Lift (400T)

4 33799 2 Tire Valve, Tubeless, 453, 1 25

5 1005273 1 Assembly, 400T Roller

6 1005464 2 Tire & Wheel Assembly, 8 Hole, 2680 Lbs

7 510134RSRV 1 Arm, Rh Tow/Lift (400T)

8 510014SRV 1 Tongue Extension, 400T

7



400T TOWING SAFETY PIN AND PINTLE EYE

Figure 7-19. 400T Towing Safety and Pintle Eye

1

5

4

23



400T Towing Safety Pin and Pintle Eye Parts List

Item No



2 150210ASRV 1 Pintle Eye Assembly, 2-1/2 W/Fastn

3 150210B 1 Channel, 3 Position Pintle/Ball

4 510200 1 Pintle Eye, 2 1/2”

5 510014SRV 1 Tongue Extension, 400T

7



WHEEL HUB AND BRAKE ASSEMBLY

Figure 7-20. Wheel Hub and Brake Assembly



Wheel Hub and Brake Assembly Parts List

Item No


1 340060R-A 1 Backing Plate (Right)

Ref 340060L-A 1 Backing Plate (Left)

2 340100 1 Magnet Kit, Electric Brake

3 340070 1 Brake Shoe, W/Lining, 12” X 2”

4 340110 1 Adjuster & Spring Assembly

5 Ref 1 Spring, Adjuster

6 340130 1 Spring Kit, Brake Shoe Return

7 340140 1 Seal, Brake Drum

8 610210 1 Bearing, Front Axle

9 Ref 1 Bearing, Cup

10 340150 1 Hub & Drum Assembly, 8 On 6 50

11 Ref 1 Stud

12 340170 1 Bearing Cup, Wheel Hub, Outer

13 340180 1 Bearing Cone, Wheel Hub, Outer

14 340190 1 Axle, 5200Lb Stub

15 610260 1 Nut, Spindle

16 620200 1 Dust Cap, 635 Tandem Axle

7



VALVE BANK ASSEMBLY (400T ONLY)

Figure 7-21. Valve Bank Assembly (400T Only)



Valve Bank Assembly (400T Only) Parts List

Item No


Ref 1000487 1 Valve, 3-Section, Vo40

1 670230 1 Mounting Kit, Valve Lever

2 670230 1 Clevis, Valve Spool End

3 670220 2 Bracket, Valve Lever Pivot

4 510180 1 Valve, Relief, V-12

5 510190 1 End Cover, Rh

6 510200 1 Pintle Eye, 2 1/2”

7 510210 1 Stud Kit

8 510220 1 Spring Return Kit

9 510230 1 Cover, Valve Spool

10 510240 1 O-Ring Kit, V-12 Valve Section

11 510250 1 Load Check Kit

12 510260 1 Valve Section, Spring Return

13 984849 1 Valve Assembly, 3-Section

Note: The 400 Model Does Not Have A Valve Bank Assembly

7



ALPHABETICAL PARTS INDEX (API)

DESCRIPTION PART NUMBER FIG NO ITEM NO

8Lola X 21” 99400WS-04 Figure 7-7 15

8Lola X 28” 99400WS-05 Figure 7-7 7

8Lola X 61” 99400WS-02 Figure 7-7 5

8Lola X 80” 99400WS-03 Figure 7-7 9

Adapter, Pipe To Hose X427 Figure 7-7 3

Adjuster & Spring Assembly 340110 Figure 7-20 4

Air Cleaner, Mount Band 1011485-13 Figure 7-13 22

Air, Cleaner 1011485-12 Figure 7-13 21

Air, Cleaner, Hose 1011485-10 Figure 7-13 20

Air, Cleaner, Mount 1011485-11 Figure 7-13 15

Arm, Lh Tow/Lift (400T) 510134LSRV Figure 7-18 3

Arm, Rh Tow/Lift (400T) 510134RSRV Figure 7-18 7

Arm, Tow Bar 400862 Figure 7-17 8

Assembly, 400T Roller 1005273 Figure 7-18 5

Assembly, Rear Wipe 987390SRV Figure 7-5 4

Assembly, Rear Wipe w/o Brk 987389SRV Figure 7-5 5

Axle, 400, Front Drum N/S 420112ASRV Figure 7-4 11

Axle, 5200Lb Stub 340190 Figure 7-20 14

Backing Plate (Left) 340060L-A Figure 7-20 Ref

Backing Plate (Right) 340060R-A Figure 7-20 1

Ball Joint, 250, Fm, w/ 375 Stud 920090 Figure 7-9 17

Bar, Bracket, Slow Moving Sign 1009906 Figure 7-16 2

Battery Box 400709SRV Figure 7-14 1

Battery Box Mount/400 857106 Figure 7-14 3

Battery Hold Down, Diesel 300286 Figure 7-14 4

Battery, 12V, 835 Cca, Group 24 Ref Figure 7-14 2

Bearing Cone 210180 Figure 7-4 9

Bearing Cone 210180A Figure 7-4 14

Bearing Cone, Wheel Hub, Outer 340180 Figure 7-20 13

Bearing Cup 210190 Figure 7-4 10

Bearing Cup 210190A Figure 7-4 15

Bearing Cup, Wheel Hub, Outer 340170 Figure 7-20 12

Bearing, Cup Ref Figure 7-20 9

Bearing, Front Axle 610210 Figure 7-20 8

Bearing, Insert,1 50 520060 Figure 7-6 3

Belt, Alternator/Blower, Hatz 320090-2L Figure 7-13 10

Bracket, 400 Cocomat Front 857178SRV Figure 7-4 19

Bracket, Valve Lever Pivot 670220 Figure 7-21 3




Bracket, Water/Fuel Pump Mount 480260 Figure 7-7 24

Brake Shoe, W/Lining, 12” X 2” 340070 Figure 7-20 3

Brass 480170 Figure 7-7 18

Brkt-Cable, Throttle/Pump 400 986770SRV Figure 7-11 2

Bushing, 2 00 Id X 2 50 Od X 1 75Lg 210010 Figure 7-4 23

Bushing, Drive Handle, Lh, 400 400761 Figure 7-2 18

Bushing, Drive Lever, Lh, 400 490062 Figure 7-9 6

Cable, Battery, Neg, 13”, Eye/Eye 5804 Figure 7-14 7

Cable, Battery, Neg, 16”, Eye/Post 400020 Figure 7-14 5

Cable, Battery, Pos, 44”, Eye/Post 852510 Figure 7-14 6

Cable, Forward & Reverse 500770 Figure 7-15 7

Cable, Push/Pull, 90” X 3” Stroke 851214 Figure 7-11 5

Cable, Push/Pull, Fwd/Rev 500770 Figure 7-9 16

Cable, Throttle 500050 Figure 7-15 6

Cap, Fuel Tank, Lockable 140030FL Figure 7-8 6

Cap, Steering Wheel 300010 Figure 7-9 14

Cap, Water Spray Nozzle 38656 Figure 7-7 25

Channel, 3 Position Pintle/Ball 150210B Figure 7-19 3

Clamp Assembly, 2 Pc Split 2 Bolt 420102A Figure 7-4 26

Clamp, Hose, # 20 (1-1/2”) 33167 Figure 7-7 4

Clamp, Muffler, 1.5 Id 33306 Figure 7-12 3

Clamp, Rops 987718 Figure 7-3 8

Clamp, Tank, Hold Down 988816 Figure 7-8 2

Clevis, 10-32 X 1 25, W/ 25 Pin 37846 Figure 7-11 6

Clevis, Valve Spool End 670230 Figure 7-21 2

Cocoa Mat, 6” X 44” Plastic 430160-44 Figure 7-4 20

Coolant Reserve Tank 1011485-24 Figure 7-13 Ref

Counter Weight, Vibe 400596 Figure 7-6 6

Cover, Fuel Level Sending Unit 980689 Figure 7-8 5

Cover, Valve Spool 510230 Figure 7-21 9

Crossmember, 400 Front End 420043SRV Figure 7-4 5

Cshh, 625-11 X 1 500, Gr5 102-607-1A Figure 7-2 12

Cshh, 1/2-13 X 1, Gr5, Ft 100-8-13-16-5F Figure 7-6 17

Cshh, 1/2-13 X 1 25, Gr8, Ft 100-8-13-20-8F Figure 7-6 18

Cshh, 1/2-13 X 2, Gr5 100-8-13-32-5 Figure 7-2 10


Cshh, 1-12 X 3 5, Gr5, Ft 100-16-12-56-5F Figure 7-1 2

Cshh, 3/8-16 X 1, Gr5, Ft 100-6-16-16-5F Figure 7-3 4

Cshh, 3/8-16 X 1 5, Gr5 100-6-16-24-5 Figure 7-2 11

7




Cshh, 3/8-16 X 2 25, Gr5 100-6-16-36-5 Figure 7-2 20


Cshh, M8x1 25 X 25, C8 8, Ft 100-M8-1 25-25-8 8F Figure 7-12 2

Cshh,1/2-13 X 1 5, Gr5 100-8-13-24-5 Figure 7-6 16

Cssh, 3/8-16 X 1 25, Ft 102-6-16-20-F Figure 7-6 13

Cyl , Hyd , 2 00 X 12 00 X 1 00 Rod 851436SRV Figure 7-4 1

Cylinder, Head Bolts 1011485-14 Figure 7-13 16

Drum, 400, Front, Half W/Bearings 420124ASRV Figure 7-4 12

Dust Cap, 635 Tandem Axle 620200 Figure 7-20 16

Elbow, Pipe, 90, 750, Brass 480060 Figure 7-7 22

Element, Charge Filter From #400-104 290030 Figure 7-15 10

End Cover, Rh 510190 Figure 7-21 5

Engine Harness 1011485-29 Figure 7-13 Ref

Engine, Isolators 1011485-22 Figure 7-13 13

Engine, Kubota, 25Hp T4f 1011485 Figure 7-11 1

Engine, Kubota, 25Hp T4f 1011485 Figure 7-13 1

Exhaust, Pipe 1011485-07 Figure 7-13 18

Extension, Pump Actuator 981223 Figure 7-11 3

Filler Neck, Hyd Oil/Fuel Cap 140030FN Figure 7-8 7

Filler, Tank, 4 In, Cap And Strainer 36151 Figure 7-3 9

Filter Element, Air, Primary 985909 Figure 7-13 Ref

Filter Element, Air, Safety 985911 Figure 7-13 Ref

Filter Element,Oil 38778-1 Figure 7-13 12

Flange W/Hub,Inner Bearing Support-400 520280 Figure 7-6 2

Front End Assembly, 400 400877 Figure 7-4 Ref

Fuel Filter With Mount 1011485-23 Figure 7-13 Ref

Fuel Solenoid Connector 1011485-30 Figure 7-13 Ref

Gasket, Filler Breather Cap 853930 Figure 7-8 9

Gasket, Fuel Sender Mount P81743 Figure 7-8 4

Gauge, Hour Meter 500190 Figure 7-15 14

Gauge, Hydraulic Oil Level & Temp 500070 Figure 7-15 8

Group, Battery 400/400T 987005 Figure 7-14 Ref

Group, Rear Wiper 987326 Figure 7-5 3

Hand Grip, Drive Lever 490010 Figure 7-9 1

Hand Grip, Throttle Lever 490100 Figure 7-9 10

Handle, 400 Lh Drive 490092 Figure 7-2 Ref

Handle, 400 Lh Drive 1009904 Figure 7-2 21

Handle, 400 Lh Drive 490092 Figure 7-9 9

Head, Charge Filter 290010 Figure 7-15 9




Hose Kit, 400 Water System 99400WS Figure 7-7 Ref

Hose, 05, Push-On, 3125 71812 Figure 7-8 8

Hose,Water Tank To Pump, 400 480250 Figure 7-7 16

Housing, Tongue 510023SRV Figure 7-17 3

Hub & Drum Assembly, 8 On 6 50 340150 Figure 7-20 10

Hub, Counterweight 400595 Figure 7-6 5

Hydraulic Pump Mount 1000956 Figure 7-13 Ref

Hydraulic, Pump Mount 1011485-21 Figure 7-13 14

Key Stock 857137 Figure 7-2 4

Key, Ignition, Kubota 982008-04 Figure 7-15 3

Lever Assembly, 400 Pump Upper 490031SRV Figure 7-9 3

Lever Assembly, 400 Rh Drive 490022 Figure 7-9 2

Lever Assembly, 400 Throttle 490052SRV Figure 7-9 5

Lever, Forward/Reverse-Rh 1009905 Figure 7-2 9

Light, Led Circular 1012563 Figure 7-15 1

Load Check Kit 510250 Figure 7-21 11

Lock, Tongue 400829SRV Figure 7-17 5

Lower, Radiator, Hose 1011485-06 Figure 7-13 11

Machined Nut, Front Axle, 400 420211 Figure 7-4 25

Magnet Kit, Electric Brake 340100 Figure 7-20 2

Main Pump 530040B-01 Figure 7-11 4

Motor, Hyd, Drive, 7000 811361 Figure 7-6 24

Motor, Hyd, Power Steering 36127 Figure 7-9 11

Motor, Hydraulic, Gear, 67Cir 988504 Figure 7-6 7

Mount Kit 986598-08 Figure 7-11 Ref

Mount, Foot 1011485-09 Figure 7-13 19

Mount, Motor To Frame (400 W/Poclain) 858309 Figure 7-6 19

Mounting Kit, Valve Lever 670230 Figure 7-21 1

Muffler 1011485-20 Figure 7-13 17

Muffler Brace 1011485-19 Figure 7-13 Ref

Muffler Stay 1008298 Figure 7-13 Ref

Nozzle, Assembly , 08 Pipe Nyl, 90 Deg 480010 Figure 7-7 1

Nut, Hex, 375-16 116-3 Figure 7-2 16

Nut, Hex, 375-16 116-3 Figure 7-3 6

Nut, Hex, 625-11 116-7 Figure 7-6 22

Nut, Hex, 813-20 300020 Figure 7-9 13

Nut, Hex, 1/2-13, Gr5 200-8-13-5 Figure 7-2 15

Nut, Hex, 1/2-13, Gr5 200-8-13-5 Figure 7-6 21

Nut, Lock, ‘Tang’ Style 38671 Figure 7-4 17

7




Nut, Lock, Nylon, 1/4-20, Gr5 205-4-20-5 Figure 7-16 5

Nut, Spindle 610260 Figure 7-20 15

Nut,Hex, 375-16 116-3 Figure 7-17 10

Oil Pressure Fitting 985628 Figure 7-13 Ref

Oil Pressure Sender 989707 Figure 7-13 Ref

Oil Pressure Switch 1011485-28 Figure 7-13 Ref

Opt,Coco Mats,400 981772 Figure 7-4 Ref

O-Ring Kit, V-12 Valve Section 510240 Figure 7-21 10

Oring, 3 237 Id X 103, Sae 152 36808 Figure 7-11 Ref

Pad, Battery Hold Down 410050 Figure 7-14 8

Pad, Tank, Fuel, Poly 988820 Figure 7-8 3

Pin, 400 Steering Yoke 420042SRV Figure 7-4 4

Pin, Towing Tongue Safety 510041SRV Figure 7-4 22



Pintle Eye Assembly, 2-1/2 W/Fastn 150210ASRV Figure 7-19 2

Pintle Eye, 2 1/2” 510200 Figure 7-19 4

Pintle Eye, 2 1/2” 510200 Figure 7-21 6

Pipe Nipple Weldment 480220SRV Figure 7-7 10

Pipe, Nipple, 375Xclose, Brass 480120 Figure 7-7 19

Pipe, Nipple, 750Xclose, Brass 480070 Figure 7-7 21

Pipe, Plug, 1 000 Pvc, Hex 420180 Figure 7-4 18

Pump, 400S Hydraulic Drive 530040B Figure 7-11 Ref

Pump, Hyd, Gear, 85 Cir 320232 Figure 7-11 7

Pump, Water Spray 1005660 Figure 7-7 17

Pusher Fan 1011485-15 Figure 7-13 Ref

Radiator, Cap 1011485-16 Figure 7-13 2

Radiator, Isolators 1011485-17 Figure 7-13 7

Radiator, Mount 1011485-18 Figure 7-13 9

Radiator, Mount Plate 1011485-02 Figure 7-13 8

Radiator, Oil Cooler 1011485-01 Figure 7-13 4

Radiator, Shroud 1011485-04 Figure 7-13 5

Radiator, Stay 1011485-03 Figure 7-13 3

Rear Drum, I d Machined 400887-04 Figure 7-6 1

Rear Wiper Blade, Front Roller 420064SRV Figure 7-4 7

Red Bushing, 3/4 Mpt X 1/2 Fpt 480050 Figure 7-7 23

Reducer Ref Figure 7-7 14

Rnd, 500, Bent, Safety Latch 1000281 Figure 7-1 4

Rnd, 688 X 8 75, Crs 858526 Figure 7-2 17




Rollbar, Complete 987507 Figure 7-3 2

Roller, Tongue Lock, Pin 400872 Figure 7-17 4

Scraper, 400, Front 420063SRV Figure 7-4 6

Scraper, 400, Front 420063SRV Figure 7-5 1

Scraper, Front Inner 400 400894 Figure 7-5 2

Seal 210240 Figure 7-4 24

Seal, Brake Drum 340140 Figure 7-20 7

Seal, Front Yoke, 400 N/S 210240A Figure 7-4 13

Seat Assembly 315000 Figure 7-10 1

Seat, Cushion, Back 315010 Figure 7-10 2

Seat, Cushion, Bottom 315030 Figure 7-10 3

Shaft, Control 400762 Figure 7-2 3

Shear Mount, Frame To Drum 520020A Figure 7-6 20

Sign, Slow Moving Vehicle P70036 Figure 7-16 1

Spacer 490071 Figure 7-2 5

Spacer 490071 Figure 7-9 7

Spacer, Front Axle, 400 N/S 420082ASRV Figure 7-4 8

Spacer, Tongue Pivot Pin 400836 Figure 7-17 11

Spraybar, 400 Front Drum 480100SRV Figure 7-7 8

Spraybar, 400 Rear Drum 480022SRV Figure 7-7 2

Spring Kit, Brake Shoe Return 340130 Figure 7-20 6

Spring Return Kit 510220 Figure 7-21 8

Spring, Adjuster Ref Figure 7-20 5

Steering Column, 6 00 300040 Figure 7-9 15

Steering Wheel, 17 00, 36 Spline 300030 Figure 7-9 12

Steering Yoke, 400 N/S 420032ASRV Figure 7-4 3

Steering Yoke, 400 N/S 420032ASRV Figure 7-4 21

Strainer, Nozzle, 100 Mesh 480010-2 Figure 7-7 28

Street Elbow, 3/8” Brass 480230 Figure 7-7 11

Stud Ref Figure 7-20 11

Stud Kit 510210 Figure 7-21 7

Support, Plate Floorboard 300213 Figure 7-2 8

Switch, Ignition, W/Heat St 39146-14 Figure 7-15 2

Switch, Neutral Safety 490040 Figure 7-9 4

Switch, Toggle 500040 Figure 7-15 4

Switch, Vibrator Actuator 500140 Figure 7-15 12

Tank Safety 400793 Figure 7-1 3

Tank, Fuel, 8 Gal, Poly 988663 Figure 7-8 1

Tank, Water, 80Gal, Poly 988558 Figure 7-3 1

7




Tee, 3/8” Brass 480140 Figure 7-7 6

Temperature Sender 1011485-26 Figure 7-13 Ref

Temperature Switch 1011485-27 Figure 7-13 Ref

Thermostat Cover 1011485-25 Figure 7-13 Ref

Threaded Rod & Tube 400781 Figure 7-2 7

Tip, Water Spray Nozzle 38716 Figure 7-7 26

Tire & Wheel Assembly, 8 Hole, 2680 Lbs 1005464 Figure 7-18 6

Tire Valve, Tubeless, 453, 1 25 33799 Figure 7-18 4

Tire, L T225 / 75R-16, Lre 1005464-01 Figure 7-18 1

Tongue Extension, 400T 510014SRV Figure 7-18 8

Tongue Extension, 400T 510014SRV Figure 7-19 5

Tongue, Tow 510014SRV Figure 7-17 9

Tube, Towbar Pivot Housing 400837 Figure 7-17 7

Upper, Radiator, Hose 1011485-08 Figure 7-13 23

Valve Assembly, 3-Section 984849 Figure 7-21 13

Valve Section, Spring Return 510260 Figure 7-21 12

Valve, 3-Section, Vo40 1000487 Figure 7-21 Ref

Valve, Ball, 375 480160 Figure 7-7 13

Valve, Emergency Stop 910080 Figure 7-15 13

Valve, Relief, 2000 P s i 500080 Figure 7-15 11

Valve, Relief, V-12 510180 Figure 7-21 4

Valve, Solenoid 500090 Figure 7-15 5

Vibrator Hub To Frame Mount 858312 Figure 7-6 14

Vibrator Hub/400 858248 Figure 7-6 4

W/M, Hinge Assembly, Water Tank Plate 989117 Figure 7-2 2

Washer, Belleville 5/8” 490080 Figure 7-2 6

Washer, Belleville 5/8” 490080 Figure 7-9 8

Washer, Flat, Sae, 312 119-2 Figure 7-12 1

Washer, Flat, Sae, 1/2 300-8 Figure 7-6 9





Washer, Flat, Uss, 3/8 301-6 Figure 7-3 5

Washer, Lock, 375 118-3 Figure 7-3 7








Washer, Lock, 670, Nord Wedge 986811 Figure 7-6 23

Washer, Lock, ‘Tang’ Style 210170A Figure 7-4 16

Washer, Steering Yoke Pin (400) 420022 Figure 7-4 2

Washer,Water Spray Nozzle 480010-4 Figure 7-7 27

Weldment Ref Figure 7-8 10

Weldment, Canopy 987719 Figure 7-3 3

Weldment, Exhaust Bracket 1012543 Figure 7-12 4

Weldment, Frame 400 987151 Figure 7-1 1

Weldment, Frame 400 987151 Figure 7-2 1

Weldment, Frame 400T 987150 Figure 7-17 1

Weldment, Poly Water Tank Mount 988796SRV Figure 7-17 2

Wheel, 16 X 6, 8 Hole 1005464-02 Figure 7-18 2

Wire, Fan, Guard 1011485-05 Figure 7-13 6

Y-Strainer, 3/4” Fpt Brass 480080 Figure 7-7 20

7



NOTES



1012791-01Printed in the U.S.A.

500 Lincoln County Parkway Ext.

Lincolnton, North Carolina 28092

Phone: (704) 966-3300 - Fax Sales: (704) 483-5802

www.LeeBoy.com

Documents

Operations, Service, and Parts Manual€¦ · Operations, Service, and Parts Manual Manual No. 1012791-01 LeeBoy Model 400 & 400T Rollers 400 400 T This manual applies to Serial Number