JCB Vibromax 1103 Single Drum Roller Service Repair Manual – PDF Download

1103 SINGLE DRUM ROLLER SERVICE MANUAL SM90001 July 1998

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

TABLE OF CONTENTS

SECTION ONE GENERAL INFORMATION MACHINE DESCRIPTION ......................................................................... 1 - 3 SERIAL NUMBERS .........................................................................1 - 5 IDENTIFYING MACHINE COMPONENTS ......................................1 - 6 SAFETY, GENERAL .................................................................................. 1 - 7 SPARK ARRESTER ........................................................................1 - 7 SAFETY, PERSONAL................................................................................ 1 - 7 SAFETY, MACHINE OPERATION............................................................. 1 - 8 SAFETY, MAINTENANCE .........................................................................1 - 9 GENERAL INFORMATION ......................................................................1 - 12 CLEANING ....................................................................................1 - 12 INSPECTION .................................................................................1 - 12 BEARINGS ....................................................................................1 - 12 NEEDLE BEARINGS .....................................................................1 - 12 GEARS ..........................................................................................1 - 12 OIL SEALS, O-RINGS, & GASKETS ............................................ 1 - 12 SHAFTS ........................................................................................ 1 - 12 SERVICE PARTS ..........................................................................1 - 12 LUBRICATION ..............................................................................1 - 12 STANDARD TORQUE DATA ...................................................................1 - 13 MACHINE SPECIFICATIONS ..................................................................1 - 15 FLUID SPECIFICATIONS ........................................................................1 - 17 DIESEL FUEL SPECIFICATION...............................................................1 - 18 ENGINE OIL SPECIFICATION ................................................................ 1 - 19 TIRE BALLAST ........................................................................................1 - 20

SECTION TWO ENGINE CUMMINS ENGINE WARRANTY ..............................................................2 - 3 ENGINE REMOVAL ...................................................................................2 - 4

SECTION THREE ELECTRICAL GENERAL INFORMATION ........................................................................3 - 2 INSTRUMENT PANEL ............................................................................... 3 - 4 UNDERSTANDING ELECTRICAL SCHEMATICS ....................................3 - 7 UNDERSTANDING RELAYS .....................................................................3 - 9 VIBROMAX RELAYS ....................................................................3 - 11 STARTER/CHARGING CIRCUIT (before JKC8302000) .........................3 - 13 STARTER/CHARGING CIRCUIT (AFTER JKC8302000) ........................3 - 15 UNDERSTANDING BATTERIES .............................................................3 - 15 BATTERY DIAGNOSTICS ............................................................3 - 16

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3

TABLE OF CONTENTS UNDERSTANDING ALTERNATORS ...................................................... 3 - 17 CHARGING SYSTEM DIAGNOSTICS ......................................... 3 - 18 VOLTAGE CHECKS AT ALTERNATOR ..................................... 3 - 19 SYSTEM LEAKAGE ..................................................................... 3 - 19 CIRCUIT WIRING TEST ............................................................... 3 - 19 MEASURING ALTERNATOR OUTPUT ....................................... 3 - 20 UNDERSTANDING STARTERS ................................................... 3 - 20 STARTER SOLENOID .................................................................. 3 - 21 STARTER SYSTEM DIAGNOSTICS ...................................................... 3 - 21 SOLENOID CIRCUIT TEST .......................................................... 3 - 21 STARTER CIRCUIT WIRING TEST ............................................. 3 - 22 STARTER MOTOR TEST ............................................................. 3 - 23 INSTRUMENTATION PANEL ................................................................. 3 - 25 EMERGENCY STOP SWITCH/ BRAKE SWITCH .................................. 3 - 27 VIBRATION CIRCUIT .............................................................................. 3 - 29 VIBRATION AFTER JKC8300700 .......................................................... 3 - 31 LIGHTING CIRCUIT ................................................................................ 3 - 33 WORK LIGHTS, ACCESSORY PLUG, HEATER AND WIPERS ........... 3 - 35 CAB WIRING ........................................................................................... 3 - 46 WIRE HARNESS 7250/16315 ................................................................. 3 - 47 WIRE CHART 7250/16315 ...................................................................... 3 - 52 WIRE HARNESS 7250/16110 ................................................................. 3 - 56 WIRE CHART 7250/16110 ...................................................................... 3 - 59

SECTION FOUR HYDRAULIC PUMP SUCTION LINES ............................................................................ 4 - 2 HYDRAULIC COOLING SYSTEM............................................................. 4 - 4 HYDRAULIC DRAIN LINES ...................................................................... 4 - 6 HYDRAULIC TEST SYSTEM .................................................................... 4 - 8 HYDRAULIC TEST STATION ................................................................... 4 - 9 CHARGE SYSTEM .................................................................................. 4 - 11 PROPULSION SYSTEM ......................................................................... 4 - 13 MULTIFUNCTION VALVES .................................................................... 4 - 17 PROPULSION SYSTEM DIAGNOSTICS................................................ 4 - 18 INTERNAL LEAKAGE .................................................................. 4 - 18 PUMP SERVO CONTROL ...................................................................... 4 - 19 VIBRATION SYSTEM .............................................................................. 4 - 21 VIBRATION FREQUENCY ...................................................................... 4 - 23 VIBRATION AMPLITUDE ........................................................................ 4 - 25 VIBRATORY SYSTEM DIAGNOSTICS .................................................. 4 - 26 STEERING SYSTEM............................................................................... 4 - 27 PARKING BRAKE SYSTEM .................................................................... 4 - 30 TOWING YOUR MACHINE .......................................................... 4 - 31 PARKING BRAKE DIAGNOSTICS .......................................................... 4 - 31

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July 1998

TABLE OF CONTENTS DIFFERENTIAL LOCK SYSTEM .............................................................4 - 35 HYDRAULIC SCHEMATIC ......................................................................4 - 38

SECTION FIVE FINAL DRIVES GENERAL INFORMATION ........................................................................5 - 2 OPERATION ..............................................................................................5 - 3 KESSLER AXLE..........................................................................................5 - 4 SPETH STANDARD AXLE ........................................................................ 5 - 5 REAR AXLE REMOVAL .............................................................................5 - 6 AXLE INSTALLATION ................................................................................5 - 7 AXLE TUBE DISASSEMBLY .....................................................................5 - 8 PLANETARY DISSASSEMBLY ...............................................................5 - 10 DIFFERENTIAL LOCK REMOVAL ..........................................................5 - 12 DIFFERENTIAL LOCK ASSEMBLY .........................................................5 - 13 AXLE TUBE AND PLANETARY ASSEMBLY ..........................................5 - 14 INTERMEDIATE GEARBOX DISASSEMBLY .........................................5 - 18 INTERMEDIATE GEARBOX ASSEMBLY ...............................................5 - 20 DIFFERENTIAL DISASSEMBLY .............................................................5 - 22 DIFFERENTIAL ASSEMBLY ................................................................... 5 - 24 DRUM REMOVAL ....................................................................................5 - 29 DRUM INSTALLATION ............................................................................5 - 29 DRUM DRIVE ...........................................................................................5 - 30 DRUM DRIVE BEARING REMOVAL....................................................... 5 - 34 DRUM DRIVE BEARING INSTALLATION ...............................................5 - 36 DRUM DRIVE MOTOR REPAIRS ...........................................................5 - 36

SECTION SIX PARKING BRAKE SYSTEM DESCRIPTION ...........................................................................................6 - 2 RELEASE AND TOWING ..........................................................................6 - 4 DRUM MOTOR BRAKE .............................................................................6 - 5 DISASSEMBLY OF MOTOR BRAKE.............................................. 6 - 6 ASSEMBLY OF MOTOR BRAKE ....................................................6 - 6 STANDARD AXLE BRAKE ........................................................................ 6 - 8 BAND BRAKE ADJUSTMENT ................................................................... 6 - 9 BAND BRAKE CYLINDER ....................................................................... 6 - 10 HEAVY DUTY AXLE BRAKE ...................................................................6 - 11

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TABLE OF CONTENTS

SECTION SEVEN VIBRATION SYSTEM VIBRATION SYSTEM ................................................................................ 7 - 2 VIBRATION FREQUENCY ........................................................................ 7 - 3 VIBRATION AMPLITUDE .......................................................................... 7 - 5 VIBRATORY SYSTEM DIAGNOSTICS .................................................... 7 - 6 LIFTING DEVICE ....................................................................................... 7 - 7 DRUM REMOVAL ..................................................................................... 7 - 8 DRUM INSTALLATION ............................................................................. 7 - 8 EXCITER BEARING REMOVAL ............................................................... 7 - 9 EXCITER BEARING ASSEMBLY............................................................ 7 - 14 SMOOTH DRUM SHAFT ........................................................................ 7 - 15 PADFOOT DRUM SHAFT ....................................................................... 7 - 16

SECTION EIGHT STEERING SYSTEM SPECIAL TOOLS ...................................................................................... 8 - 2 ARTICULATION JOINTS ........................................................................... 8 - 3 JOINT DISASSEMBLY .............................................................................. 8 - 5 JOINT ASSEMBLY .................................................................................... 8 - 9 STEERING CYLINDER ........................................................................... 8 - 12

SECTION NINE CHASSIS DRUM FRAME .......................................................................................... 9 - 2 REAR FRAME ........................................................................................... 9 - 3 SIDE FRAME ............................................................................................. 9 - 4 ENGINE COMPARTMENT PANELS......................................................... 9 - 5 OPERATOR PLATFORM .......................................................................... 9 - 6 ROLLOVER PROTECTION STRUCTURE ............................................... 9 - 7

SECTION TEN ATTACHMENTS LEVELING BLADE .................................................................................. 10 - 2 BLADE CONTROL .................................................................................. 10 - 3 BLADE HYDRAULIC LINES .................................................................... 10 - 4

6

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1

SECTION ONE

GENERAL INFORMATION

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

July 1998

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1-2

July 1998

SECTION ONE

GENERAL INFORMATION

MACHINE DESCRIPTION The 1103 Vibratory Roller is the replacement for the 1102. Like the 1102, the 1103 is available in smooth drum or pad foot drum configuration. The 1103 however, is also offered with a standard Speth axle or a heavy duty Speth axle for high gradeability applications.

The 1103 uses the Cummins 5.9 liter 6 cylinder turbocharged engine at 130 gross horsepower. Changes in the drive pump and the addition of a heavy duty axle drive motor result in improved machine performance. The vibratory drum diameter remains the same and drum width is two inches narrower. The drum’s centrifugal force has been increased 22%.

A Sauer Sundstrand Series 90 variable displacement, axial piston hydrostatic pump, used for machine propulsion, is mounted to the flywheel end of the engine. It provides oil to a Poclain MS25 drum drive motor and a Sauer Sundstrand 2 speed axle drive motor in a parallel path.

The Poclain motor is mounted on the left side of the drum and is isolated from the drum by rubber buffers. The axle drive motor on the standard axle has a displacement of 80 cc while the motor on the heavy duty axle displaces 110cc.

The vibration system uses a Sauer Sundstrand Series 90 hydrostatic pump similar to the propulsion pump and mounted directly behind the propulsion pump. The vibratory pump supplies oil to a Sauer Sundstrand hydrostatic motor mounted at the right side of the drum. Like the 1102, the 1103 smooth drum operates at frequencies of 1680 or 2160 vibrations per minute,

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SECTION ONE

GENERAL INFORMATION

while the pad foot version operates only at the lower frequency.

A steering pump, mounted to the rear of the vibration pump, provides the oil needed for steering. The steering pump is also a second charge pump in the propulsion/vibration circuit. The steering pump draws oil from the reservoir, passes it through the steering control valve, through the inline hydraulic filter, and into the charge circuit.

The charge pump draws oil from reservoir, joins the steering oil at the filter, passes it through the filter and into the charge circuit.

The 1103 has brakes at both the front drum and the rear axle. A spring applied-hydraulically released multi disc brake is part of the drum drive motor. The standard axle machine uses a spring applied-hydraulically released band brake at the intermediate gearbox while the heavy duty axle incorporates multiple disc brakes at the intermediate gearbox.

Pressure testing of the 1103 has been made easier by placing all the test ports at a centrally located test station under the operators platform on the right side of the machine.

The electrical system of the 1103 consists of a 12 volt battery, starter, alternator system, optional lighting and standard instrumentation.

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July 1998

SECTION ONE

GENERAL INFORMATION

SERIAL NUMBERS 1

Model / Serial Number

2

Front Drum Drive Motor S/N

3

Steering Unit S/N

4

Axle S/N

5

Vibratory Motor S/N

6

Hydraulic Pumps S/N

7

Axle Drive Motor S/N

8

Engine S/N

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SECTION ONE

GENERAL INFORMATION

IDENTIFYING MACHINE COMPONENTS 1 2 3 4 5 6 7 8 9 10 11 12

Articulation joint Smooth drum Lifting eye Operator’s stand Battery Hydraulic tank Engine Planetary gear Differential Drum drive motor Isolation buffer Scraper

13 14 15 16 17 18 19 20 21 22 23 24

1-6

Lifting and towing eyes Fuel tank Air filter system Hydraulic oil cooler Roll over protective structure Vibration motor Steering cylinder Hydraulic pumps Parking brake cylinder Intermediate gear box Axle drive motor Radiator

July 1998

SECTION ONE

GENERAL INFORMATION

SAFETY, GENERAL The information in this manual does not replace any safety rules and laws used in your area. Before you operate this machine, learn the rules and laws for your area and make sure your machine has the correct equipment according to these rules and regulations.

Your safety and the safety of other persons in the work area are dependent on your correct operation of this machine.

•

Know the location and function of all machine controls.

•

Foreign materials and loose objects on the steps, hand rails, and in the operator’s compartment can cause accidents and injury.

Keep the steps, hand rails, and operator’s compartment clear at all times.

Clear the area of other persons before you start the engine.

•

A fire can cause injury or death. Always have a fire extinguisher on the job site near the machine. Make sure the fire extinguisher is serviced according to the manufacturer’s instructions.

Check all controls in a safe area before you operate the machine.

•

Understand the limits of the machine.

•

Do not try to do too much too fast.

•

Keep the machine under control at all

Always use the seat belt when operating the machine.

Make sure the buckle for the seat is fastened correctly.

Make sure cab windows are clean and unobstructed.

times.

Know and understand the arrangements for movement of trucks, machines, and persons on your job site. Understand and follow the instructions of flagmen, road signs, or signals.

SPARK ARRESTER NOTE: Rules or laws in some areas can make it necessary for this machine to be equipped with a spark arrester or spark arrester muffler. Check the rules or laws in your area.

Always wear the proper ear protection when operating this machine. Permanent hearing loss can result from extended exposure to loud noises.

SAFETY, PERSONAL Loose clothing and jewelry can cause an accident. Do not wear loose clothing or jewelry that can catch on controls, etc. Do wear safety shoes, hard hat, heavy gloves, etc. when required for your protection.

July 1998

Check machine controls for proper operation prior to starting the machine.

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SECTION ONE

GENERAL INFORMATION

Look at the instruments and gauges frequently when you operate. Make sure all systems are in the proper operating range.

Holes, obstructions, debris, and other work area hazards can cause injury or death.

Always walk around and look for these and other hazards before you operate your machine in a new work area.

This machine uses an articulating joint. Keep all persons clear of this pinch area when the engine is running. Machine movement can cause personal injury.

Electrical cables, gas pipes, water pipes, sewers, or other underground objects can cause injury or death. Know the location of underground hazards before you operate your machine in a new work area.

A machine out of control can cause injury or death. You must make a judgement if weather and earth conditions will permit safe operation on a hill, ramp, or rough ground. Adjust machine operation accordingly.

Not doing, or wrong machine inspection and maintenance can cause accidents. Always follow the instructions in this manual for machine inspection and maintenance.

Operating your machine in, on, or near a trench, high bank, or overhang is extra dangerous and can cause injury or death. You must make a judgement if your machine can be safely operated near any of these areas. Use wall supports if necessary.

SAFETY, MACHINE OPERATION Dust, smoke, fog, etc. can decrease your vision and cause an accident. Always stop or slow the machine until you can see your work area and the surrounding traffic

Sparks from the electrical system or engine exhaust can cause a fire or explosion. Before you operate this machine in an area with flammable dust or vapors, use good ventilation to remove the flammable dust or vapors.

Operate the controls from the operator’s seat only, and keep your hands on the controls during operation.

Engine exhaust fumes can cause injury or death. If you operate this machine in an enclosed area, use good ventilation to replace the exhaust fumes with fresh air.

Do not permit other persons to ride on the machine.

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July 1998

SECTION ONE

GENERAL INFORMATION

The vibrations from this machine can cause the walls of a trench or high bank to collapse. If you must operate this machine close to a trench or high bank, make sure the walls of the trench or bank are braced.

If you do not follow these instructions, you can cause personal injury or death to persons working in these areas.

Operating this machine too close to High Voltage electrical lines can cause injury or death. Follow the guide lines listed below.

NOTE: IF THE CLEARANCES IN THE SPECIFICATIONS BELOW ARE LESS THAN THE CLEARANCES GIVEN IN THE RULES AND LAWS OF YOUR AREA, YOU MUST FOLLOW THE RULES AND LAWS OF YOUR AREA!

Electrical Safety Rules

Cable Voltage

Minimum Clearance From Cable When Machine is Working

Minimum Clearance From Cable When Transporting Machine

50,000 volts or less

10 feet (3 meters)

4 feet (1.2 meters)

50,000 volts to 345,000 volts

10 feet (3m) plus 1/2 inch (13mm) for every 1000 volts over 50,000 volts

10 feet (3 meters)

345,000 volts to 750,000 volts

10 feet (3m) plus 1/2 inch (13mm) for every 1000 volts over 50,000 volts

16 feet (5 meters)

SAFETY, MAINTENANCE Engine fuel is flammable and can cause a fire or an explosion. Do not fill the fuel tank or service the fuel system while the machine is running, or near an open flame, welding, burning cigars and cigarettes, etc.

Machine movement without an operator can cause injury or death. If you must service this machine with the engine running, have another person help you and follow the instructions in the machine manuals. Lock the articulation joint and do not leave the machine when the engine is running.

Flammable cleaning solvents can cause injury or death. Use nonflammable cleaning solvents for cleaning purposes.

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SECTION ONE

GENERAL INFORMATION

Batteries produce explosive gases. Keep sparks and flame away. Ventilate when charging.

Always wear eye protection when working near batteries. Do not wear jewelry or watch bands when working on batteries.

Improper service or repair can cause injury or death. If you do not understand the service procedures for this machine, see your Vibromax dealer.

Missing shields, guards, or access panels can cause injury or death. Always install all shields, guards, or access panels before you start the engine.

When you install a battery or use a booster battery, connect the negative ground cable last.

When you remove a battery or booster battery, disconnect the negative ground cable first.

Do not make any modifications or repairs to the machine ROPS. If your ROPS is damaged, replace with new parts. Welding, drilling, etc. can weaken the ROPS structure.

Never charge or jump a battery when the electrolyte is frozen. If you do not follow this instruction the battery can explode.

Unauthorized modifications to this machine can cause injury or death. Never make modifications to this machine without prior written approval from Vibromax.

Never wear rings or other jewelry when working on machine maintenance. Severe burns can result when jewelry is shorted on an electrical system.

Metal chips or debris can cause eye injury. Wear eye protection when you service this machine. If you use a hammer to drive hardened pins or for other service, use a hammer with a soft face (brass, plastic, etc.).

Never wear loose clothing which can catch on objects or be tangled in moving parts.

Use suitable floor (service) jacks and safety stands when lifting the machine off the ground.

Unauthorized modifications to cast iron parts can cause injury or death. Welding can cause cast iron parts to break. Do not use welding to repair or attach items to cast iron parts on this machine.

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July 1998

SECTION ONE

GENERAL INFORMATION

Hydraulic oil under pressure can penetrate the skin. If hydraulic oil has penetrated the skin, seek medical treatment immediately.

Do not use your hands to check for hydraulic leaks, use a piece of cardboard or wood.

Keep your work area clean and free of spilled oil and grease to avoid accidentally slipping.

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SECTION ONE GENERAL INFORMATION

CLEANING Clean all metal parts, except bearings, in mineral spirits or by steam cleaning. Do not use caustic soda for steam cleaning. After cleaning, dry and put oil on all parts. Clean oil passages with compressed air. Clean bearings in kerosene, dry the bearings completely and put oil on the bearings.

INSPECTION Check all parts when the parts are disassembled. Replace all parts that have wear or damage. Small scoring or grooves can be removed with a hone or crocus cloth.

Complete visual inspection for indications of wear and pitting. Replacement of bad parts will prevent early failure.

GENERAL INFORMATION GEARS Check all gears for wear and damage.

Replace gears that have wear or damage.

OIL SEALS, O-RINGS, & GASKETS Always install new oil seals, o-rings and gaskets. Put petroleum jelly or the specified oil on seals and o-rings.

SHAFTS Check all shafts that have wear damage.

Check the surfaces where bearings and oil seals operate for signs of wear.

SERVICE PARTS Always install genuine Vibromax service parts. When ordering refer to the parts manual for the correct part numbers. Failure to use genuine Vibromax replacement parts can void your warranty.

BEARINGS

LUBRICATION

Check bearings for easy movement. If bearings have a loose fit or rough action replace the bearing. Wash bearings in kerosene and allow to air dry. DO NOT USE COMPRESSED AIR TO DRY BEARINGS.

Use the oils and lubricants specified in the Operator’s or Service Manual. Failures due to the use of non specified lubricants are not covered by warranty.

NEEDLE BEARINGS Before pressing needle bearings into a bore always remove any metal protrusions in the bore or edge of the bore. Before pressing bearing lubricate the inner and outer diameters as needed.

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SECTION ONE

GENERAL INFORMATION

STANDARD TORQUE DATA Where no special torque data is specified, the following torque figures should be applied.

Threads should be lubricated with engine oil or grease.

STANDARD TORQUE SPECIFICATIONS +/- 10% GRADE 8.8

GRADE 10.9

GRADE 12.9

SIZE

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

5mm

4

5.5

5.5

7.5

6.6

9

6mm

6.6

9

9.2

12.5

11

15

8mm

16.5

22.5

23

31.5

26.5

36

10mm

32

44

45

62

55

75

12mm

57

77.5

81

110

95

130

14mm

88

120

125

170

155

210

16mm

140

190

195

265

236

320

18mm

192

260

269

365

320

435

20mm

273

370

383

520

457

620

22mm

369

500

516

700

619

840

24mm

471

640

665

900

796

1080

27mm

702

950

996

1350

1195

1620

30mm

955

1300

1328

1800

1593

2160

NUTS FOR TUBES AND HOSES

July 1998

DIAMETER & PITCH

NEWTONS/METER

POUNDS/FOOT

16MM X 1.5

20

14.5

18MM X 1.5

35

26

20MMX1.45

45

33.2

24MM X 1.5

60

44

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SECTION ONE

GENERAL INFORMATION

FITTINGS, CONNECTIONS AND PLUGS DIAMETER & PITCH

NEWTONS/METER

POUNDS/FOOT

10MM X 1

20

14.5

12MM X 1.5

35

26

14MM X 1.5

45

33.2

16MM X 1.5

60

44

18MM X 1.5

70

51

22MM X 1.5

100

73

27MM X 2

200

147

33MM X 2

280

207

42MM X 2

380

281

FLANGES DIAMETER & PITCH

NEWTONS/METER

POUNDS/FOOT

8MM X 1.5

28

21

10MM X 1.5

55

41

12MM X 1.75

90

67

14MM X 2

145

107

16MM X 2

230

170

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SECTION ONE

GENERAL INFORMATION

MACHINE SPECIFICATIONS

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1 - 15

inch

mm

a

112

2845

b

88.6

2250

c

62.2

1580

d1

59.8

1520

d2

59.1

1500

d3

55.1

1400

d4

63

1600

h1

123.6

3140

h2

106.3

2700

k

18.1

216.5

l

216.5

5500

o

3

75

s

1

25

w

82.7

2100

e1

30

30

e2

40

40

SECTION ONE

GENERAL INFORMATION ENGINE DATA

Make / Model / Type Cooling Displacement - cu.in. (cc) HP, SAE net (kW) @ 2500 rpm Air Cleaner Fuel filter Fuel consumption gal/hr (l/hr) Fuel Capacity - gal (liter) Electrical system

Cummins 6BT5.9C, 6 cylinder, turbo diesel Water 359 (5880) 122 (91) Dual replacement elements Spin-on Cartridge 5.3 (19.5) 74 (280) 12 volt

DRIVE SYSTEM DATA Propulsion - front and rear Travel speed 1st. - mph (km/hr) Travel speed 2nd. - mph (km/hr) Theoretical gradeability, forward -% Brakes, front drum Brakes, rear 1103 Brakes, rear 1103H Steering Tire size

1103D/1103HD Infinitely variable hydrostatic 0 - 3.1 (0-5) 0 - 6 (0-9) 45/65 hydraulic disc hydraulic drum, intermediate shaft hydraulic disc, intermediate shaft Articulated, hydraulic powered 23.1x26 8PR diamond tread

1103PD/1103HPD Infinitely variable hydrostatic 0 - 3.3 (0-5.5) 0 - 6.6 (0-11) 45/65 hydraulic disc hydraulic drum, intermediate shaft hydraulic disc, intermediate shaft Articulated, hydraulic powered 23.1x26 8PR tractor tread

OPERATING DATA Operating Weight - lbs (kg) Weight, front - lbs (kg) Static linear drum load - lb/in (kg/cm) Drum wt, unsprung - lbs (kg) Articulation/oscillation - degrees Turning radius, inside - ft (m) Drum shell thickness - in. (mm) Number of pad feet/height of foot - in (mm) Contact area of foot - sq. in (sq. cm) Max compaction depth - in (cm) Frequency - vpm (Hz) Nominal Amplitude - in. (mm) Centrifugal force - lbf (kN) Centrifugal force/drum width - lb/in (N/cm) Total applied force - lb/in (N/cm) Total applied linear force

1103D/1103HD 1103PD/1103HPD 24475 (11100)/25740 (11700) 25300 (11500) / 26620 (12100) 12789 (5813) 13668 (6212) 155 (27.6) ------------------7055 (3206) 7934 (3606) 37/15 37/15 12 (3.7) 12 (3.7) 1.0 (25) 1.0 (25) -------------------144/4.0 (100) -------------------14.8 (95) 1st stage 2nd stage 1st stage 39 (100) 23.6 (60) 39 (100) 1680 (28) 2160 (36) 1680 (28) .063 (1.6) .023 (0.6) .063 (1.6) 47211 (210) 24053 (107) 47211 (210) 570 (1000) 291 (510) 570 (1000) 60000 (267) 36842 (164) 60879 (271) 725 (1271) 445 (781) 736 (1290)

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SECTION ONE

GENERAL INFORMATION

FLUID SPECIFICATIONS MACHINE PART

CAPACITY USA (metric)

SPECIFICATIONS

Fuel tank

74 gal (280 l)

see diesel fuel

Engine crankcase

15 qts(14.2 l)

engine oil API classification API-CD MIL-L-2104C multigrade engine oil (see oil chart) single grade engine oil (see oil chart)

Hydraulic system

29.1 gal (110 l)

Reservoir only

18.5 gal (70 l)

cold weather HLP 46 DIN 51524/2 hot weather HLP 68 DIN 51524/2 Mobil DTE 25,26 Shell Tellus OL 46,68 Amoco Rykon HD 46,68 Texaco Rando HD 46,68

Vibration system

12.7 qts. (12 l)

CLP DIN 51517/3 Mobil Gear 629 Shell Omala 150 Texaco Meropa 150

Battery

as required

Distilled water

Grease

as required

KP3K DIN 51502 Mobil Oil - Mobilux 3 Shell Oil - Alvania 3 Texaco Oil - Starplex 3

Engine coolant

20 qts (19 l)

50% ethylene glycol and 50% water

Tire ballast

see chart

Calcium Chloride (77%CaCl2 )

Intermediate gear standard duty heavy duty

1.1 qts (1 ltr) 1.6 qts (1.5 ltr)

Axle gear standard duty heavy duty

5.3 qts (5 ltr) 14.8 qts (14 ltr)

Planetary gear standard duty heavy duty

2.2 qts (2 ltr) 1.9 qts (1.8 ltr)

July 1998

SAE 90 API GL-5 gear lubricant

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SECTION ONE

GENERAL INFORMATION

DIESEL FUEL SPECIFICATION If fuel is stored for a long time, foreign particles or water can collect in the fuel storage tank.

Many engine problems are caused by contaminated fuel. Store fuel outside and keep the fuel as cool as possible. Drain water from the fuel storage tank at regular intervals.

NOTE: Paraffin crystals will start to form in fuel when the fuel temperature falls below the fuel’s cloud point. These paraffin crystals will clog the fuel filter and cause the engine to stop or lose power. At ambient temperatures above 32OF (0OC) use #2 diesel fuel. At temperature below 32OF (0OC) use #1 diesel fuel.

Different brands of fuel can exhibit different properties. Make sure that the number 2 diesel fuel you use meets the following minimum requirements.

MINIMUM REQUIREMENTS FOR NO.2 DIESEL FUEL: Maximum cloud point Maximum pour point

-10OF (-23OC) 42OF (6OC) below the lowest ambient air temperature at which the engine must start

Cetane number, min Max. sulphur content, by weight Max. water content & sediment by volume Max, ash content, by weight Max. carbon residue (10% point)

40 (45 to 55 in winter or at high altitude) 0.50% 0.05% 0.01% 0.20%

Distillation temperature @ 90% point Distillation temperature @ end point Minimum flash point

540 to 625OF (282-329OC) 675OF (357OC) 125OF (52OC)

Viscosity at 100OF (38OC) Centistokes Saybolt Universal Seconds (SUS) Copper strip test, 3 hours @ 212OF (100OC) Minimum API gravity

2.0 to 4.3 32 to 40 No 3 ASTM 30

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SECTION ONE

GENERAL INFORMATION

ENGINE OIL SPECIFICATION Use multigrade or single grade engine oil with API engine oil service classification “CD”.

NOTE: DO NOT use performance additives or other oil additives in your engine crankcase.

See the chart below for recommended oil viscosity at the various ambient air temperature range

July 1998

1 - 19

SECTION ONE

GENERAL INFORMATION

TIRE BALLAST Refer to the weight chart below for the maximum weight of tire ballast that you can add to the machine. The Calcium choride will prevent freezing of the ballast to -30o F (-34o C). Tire pressure is set at 13 to 20 PSI (0.9 to 1.40 bar). See your Vibromax dealer for more information.

NOTE: The following information is for one tire only and for a tire size of 23.1-26 AW 8PR.

Water

Calcium Chloride

Liters

US Gal.

kg

484.5

128

412.6

109

173.3

389.9

103

233.6

Lbs

Total Mixture Weight kg

Lbs

481.7

1062

382

585.2

1291

515

623.3

1374

1 - 20

July 1998

SECTION TWO

ENGINE

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

July 1998

2-1

SECTION TWO

ENGINE

2-2

July 1998

SECTION TWO

ENGINE

CUMMINS ENGINE WARRANTY All Cummins Engines manufactured by Cummins Diesel and installed in Vibromax products are covered by Cummins warranty and are to be serviced by an Authorized Cummins Servicing Dealer and/or Distributor. The engines used in Vibromax equipment have a two (2) year warranty period.

Warranty on Cummins engines begins when any of the following conditions are met: * * * *

a claim is submitted to Cummins engine has accumulated 50 running hours unit is rented, leased, or retailed Cummins representatives perform a start-up service

Cummins engine warranty is transferable throughout its term. Terms are not adjustable nor reversible.

Start up Service is not required at the start of warranty on the engine. Warranty service is provided by your local Cummins Service Outlet. If you require assistance with locating a Service Outlet, call the Cummins Customer Relations Department, 1-800-343-7357.

ENGINE DATA Make / Model / Type Cooling Displacement - cu.in. (cc) HP, SAE net (kW) @ 2500 rpm Air Cleaner Fuel filter Fuel consumption gal/hr (l/hr) Fuel Capacity - gal (liter) Electrical system

Cummins 6BT5.9C, 6 cylinder, turbo diesel Water 359 (5880) 122 (91) Dual replacement elements Spin-on Cartridge 5.3 (19.5) 74 (280) 12 volt

It is not the intent or purpose of this manual to supersede the manufacturers technical instruction for repair or overhaul of this engine. After the expiration of warranty, those wishing to do their own engine service work should obtain the Cummins Shop Manual for the “B� series engine from their local Cummins distributor.

July 1998

2-3

SECTION TWO

ENGINE

ENGINE REMOVAL 1.

Disconnect the negative battery cable. The battery is located on the operator platform to the right side of the seat.

2.

Remove the engine compartment hood and side panels.

3.

Drain the engine cooling system. A drain valve is provided and is located to the rear side of the radiator overflow tank on the left side of the machine.

4.

Drain the engine oil using the fitting provided in the left rear frame behind the tire. After the oil has been drained disconnect the drain hose from the engine oil pan.

2-4

July 1998

SECTION TWO

ENGINE

5.

Remove the air intake system.

6.

Loosen the four bolts which secure the hydraulic pumps to the engine. Support and block the triple pump combination. Remove the four bolts and slide the pump forward away from the engine. The engine will be removed without the pumps.

7.

Remove the upper and lower radiator hoses. The radiator can stay in place.

8.

Disconnect the radiator overflow tank from the left side of the engine.

9.

Remove the engine muffler.

10. Disconnect the following electrical wires: Starter wires located on left side of engine Alternator wires located on left side of engine Oil pressure switch wire located on left side of engine Temperature sensor wire located on top of engine Fuel solenoid wire located on right side of engine Engine ground strap located on right side of engine 11. Disconnect the throttle cable located on the right side of the machine.

12. Disconnect the fuel supply and fuel return lines located on the right side of the machine.

13. Remove the fan shroud and move it forward over the fan.

July 1998

2-5

SECTION TWO

ENGINE

14. Prepare the engine for lifting using a sling and the two lifting eyes provided on the engine. Approximate engine weight is 1200 lbs. (544 kg).

15. Remove the three engine mounts and lift the engine clear of the machine. Take extra care not to damage the radiator.

2-6

July 1998

SECTION THREE

ELECTRICAL

July 1998

3-1

SECTION THREE

ELECTRICAL

GENERAL INFORMATION The electrical system on the 1103 is a 12 volt, negative ground system. A solenoid controlled, gear driven, engine starter is standard along with a belt driven alternator. The battery is located in an enclosure to the right of the operator’s seat and is accessible by tilting the operator’s seat forward or by removal of the enclosure.

A drop down panel under the dash contains a housing for the fuses and relays. The fuses are positioned at the front edge of the housing under three separate covers.

There are thirteen relays mounted on top of the housing for various functions. They are easily removable from their plug-in terminals. A delay relay, mounted in front of the relays, is used in the automatic vibration circuit.

FUSE

FUNCTION

RELAY

FUNCTION

F1

instrument panel & backup alarm

D1

vibration delay (before JKC8300700)

F2

alternator

K1

starter interlock (anti-restart)

F3

park brake

K2

brake monitor and alternator

F4

vibration

K3

brake monitor and neutral position

F5

two speed drive

K4

neutral position

F6

cab heater

K5

brake release

F7

emergency off switch

K6

vibration control

F8

differential lock

K7

vibration control (before JKC8300700)

F9

lighting

K8

vibration control (before JKC8300700)

F10

accessory plug

K9

emergency off

F11

work lights

K10

lighting system

F12

directional lights

K11

back up alarm

F13

lighting system

K12

automatic vibration

F14

hazard warning lights

K13

directional flasher

F15

side lights, left

F16

side lights, right

F17

dimmed lights, left

F18

dimmed lights, right

3-2

July 1998

SECTION THREE

ELECTRICAL

FUSE LOCATION

AFTER S/N JKC8300700

RELAY LOCATION

AFTER S/N JKC8300700

July 1998

3-3

SECTION THREE

ELECTRICAL

INSTRUMENT PANEL

1 2 3 4 5 6

Water tank level indicator Hydraulic filter indicator Brake indicator Alternator indicator Engine oil PSI indicator Eng. coolant temp. indicator

7 Engine oil temp. indicator 8 Sprinkler indicator 9 Air cleaner indicator 10 Fuel level indicator 11 Neutral position indicator 12 Directional indicator

3-4

July 1998

SECTION THREE

ELECTRICAL

INSTRUMENT PANEL, LEFT SIDE 1 ) differential lock light 2 ) differential lock switch 3 ) drive range switch 4 ) engine temperature gauge 5 ) vibratory switch #1 6 ) vibratory switch #2 7 ) instrument light switch 8 ) hazard warning light switch 9 ) high beam light switch 10) auto vibration switch 11) directional light switch

INSTRUMENT PANEL, RIGHT SIDE 1) 2) 3) 4) 5)

ignition switch fuel level gauge parking brake switch front working light switch rear working light switch

July 1998

3-5

SECTION THREE

ELECTRICAL

UNDERSTANDING ELECTRICAL SCHEMATICS

3-6

July 1998

SECTION THREE

ELECTRICAL

UNDERSTANDING ELECTRICAL SCHEMATICS European electrical schematics differ somewhat from U S schematics in that the European schematic is drawn in a form of a ladder diagram. Ladder diagrams are easy to draw and simple to interpret.

Ladder diagrams have the B+ power lines across the top of the drawing, ground across the bottom, and all components shown vertically between the power lines and ground. Each vertical line is numbered below the ground line.

Ladder diagrams seldom allow crossing lines. This keeps the diagram clean and easy to follow. To maintain the rules of noncrossing lines, it is sometimes necessary to split the functions of a component and show these functions separately (see drawing).

K2 Relay on line 5 shows terminal 86 as power to the coil while 85 is coil ground.

The number shown in parentheses below the line number (in this case, 16) indicates there is more to the relay which is shown on line 16. Line 16 shows the relay again, but this time it illustrates terminal 87a as power to the relay contacts and 30, power from the relay contacts. Shown between the contacts, in parentheses, is the number (5).

This indicates there is more to the relay which is shown on line 5.

July 1998

3-7

Another example of how ladder diagrams overcome line crossing problems is the x1/ 2 connector on line 2. Connectors normally handle multiple wires. Rather than drawing the X1 connector with all the wires going to and from it, a ladder diagram will show the connector and port number for each wire in the connector. In this case, X1/2 indicates it is the X1 connector, wire #2. X2/4 on line 13 means it is the X2 connector, wire #4.

There are times when it is necessary to cross lines on the diagram. In that case, a horizontal line is terminated with an arrowhead, followed by a component number and a line number (see drawing, line 10). At the line number indicated, in this case line 28, the component number is shown, followed by the line number 10 and the completion of the circuit.

All components on a ladder diagram are labeled by a letter and a number. The letter designations on Vibromax diagrams are standard to all Vibromax diagrams and have the following designations:

SECTION THREE

ELECTRICAL

UNDERSTANDING ELECTRICAL SCHEMATICS

3-8

July 1998

SECTION THREE

ELECTRICAL All drawings are shown without power

D E F G H K M P R S V X Y

Delay relay Element (headlight, tail lights, panel lights, etc.)

Fuse Battery, alternator Indicator (panel indicator light, horn, alarm) Relay Motor Gauges (hour meter, temperature gauge, etc.)

Resistor Switch Diode Connector Solenoid control valve

An identification chart on the diagram lists each component, the component description and its location on the diagram by line number.

The layout of all Vibromax electrical diagrams is similar in regards to the location of components. The battery will always be located on line 1, starter on line 2, alternator on line 3, etc. Slight variations can be seen on different models, but the major components will be located in the same general area of the diagram. This similar layout makes locating components easier as you become more familiar with the drawings.

Other items which may help you understand the diagram:

July 1998

3-9

All components are shown in the OFF position All relay contact #87 are normally open contacts All relay contact #87a are normally closed contacts Relay terminal #30 is power to the contacts (when possible) Relay terminal #87 or #87a is power from the contacts (when possible) Power to control the relay is always terminal #86 Ground is always terminal #85

UNDERSTANDING RELAYS An electrical relay is basically a solenoid operated switch used to turn a circuit on or off similar to a manual switch. A relay has a work circuit (A) and a control circuit (B).

SECTION THREE The work circuit is switched on and off by the relay. Connected to the work circuit is the equipment to be operated (a lamp in the following illustration). A relay can be used to shorten the distance from the power supply to the equipment being operated. They are also used where the work circuit operates at higher or lower voltage than the control circuit.

ELECTRICAL the relay work circuit contacts closed.

Opening the control circuit switch will drop the magnetic holding force and cause the work circuit contacts to open due to the return spring.

The following control circuit uses an on/off type manual switch to control the work circuit contacts. This could be one of the dash switches on the machine for controlling the sprinkler pump, emergency flashers, etc.

In the next example, the part of the relay that is connected to the control circuit consist of the windings of an electromagnet.

When the control circuit switch is closed, a magnetic field is produced by the electromagnet. This magnetic force is used to pull

3 - 10

July 1998

SECTION THREE

ELECTRICAL

VIBROMAX RELAYS

A variation of the simple relay just shown is what we refer to as an either/or relay. The control circuit on this relay is no different from that of the simpler relay. The difference is found in the work circuit which has two sets of contacts; one normally closed and one normally open. Either of the two work circuits are activated depending on the status of the relay control circuit.

Most common relays are the simple on/off type which have a control circuit and one set of simple work circuit contacts.

The numbering system mentioned earlier will apply.

Relay terminal #30 is power to the work circuit contacts when possible.

Relay terminals #87 or #87a is power from the work circuit contacts.

Relay contact #87 indicates a normally open work contact while #87a indicates a normally closed work circuit contact.

Relay terminal #86 is power to the control circuit electromagnet.

Relay terminal #85 is always ground.

July 1998

3 - 11

One additional relay common to some Vibromax circuits is the delay relay. In a delay relay, the work circuits will be one of the two types mentioned above. The major difference is found in the relay control circuit.

In a delay relay, one or more timers are added to the control circuit. These timers can be fixed or adjustable depending on the applications.

With the advances in technology you might also encounter what we refer to as smart relays. These are relays with micro-circuitry built into the relay for various control logics.

SECTION THREE

ELECTRICAL

before JKC8302000

3 - 12

July 1998

SECTION THREE

ELECTRICAL

STARTER/CHARGING CIRCUIT (before JKC8302000) The major components of the starter and charging circuit are the starter motor, alternator, battery, ignition switch and the neutral start switch.

The ignition switch (S1) receives power from the battery (G1) at terminal 30 [line 1].

When the ignition switch is turned to the ON position, power is connected to terminals 15/54, energizing all ignition controlled components. The alternator indicator light (H1) will illuminate, indicating the ignition is on but there is no alternator output. The ground for H1 is in the regulator of the alternator [line 3]. The P1 hour meter [line 4] and the K2 brake relay [line 5] will not function because battery ground occurs on both sides of these components. When the engine is started and the alternator provides output current, the regulator produces 12 volts in place of ground. With 12 volts to the P1 hour meter and K2 brake relay, these components now function. The HI indicator extinguishes as a result of having 12 volts on each side of the indicator.

To start the machine, S2 neutral start switch must be closed, energizing the coil of the K4 relay [line 11]. This closes the contacts of the K4 relay [line 8]. Ignition current flows through the K4 contacts, providing power to H2 neutral indicator light and K1 relay coil [line 8]. K1 coil will be energized because of 12 volts at terminal 86 and ground at ter-

July 1998

3 - 13

minal 85 from the alternator regulator [line 3]. K1 relay contacts [line 2] close, providing a current path from the start terminal 50 at the ignition switch to the starter motor.

When the engine starts and the alternator provides current, the regulator produces 12 volts in place of ground. Without ground, K1 contacts open, preventing a restart of a running engine.

SECTION THREE

ELECTRICAL

3 - 14

July 1998

SECTION THREE

ELECTRICAL

STARTER/CHARGING CIRCUIT (AFTER JKC8302000)

UNDERSTANDING BATTERIES

With the use of the turbocharged engine introduced in 1997 there was a slight change to the starter circuit.

To start the machine, S2 neutral start switch must be closed, energizing the coil of the K4 relay [line 11]. This closes the contacts of the K4 relay [line 8]. Ignition current flows through the K4 contacts, providing power to H2 neutral indicator light and K1 relay coil [line 8]. K1 coil will be energized because of 12 volts at terminal 86 and ground at terminal 85 from the alternator regulator [line 3]. K1 relay contacts [line 2] close, providing a current path to the control coil of relay K0 [line 0] and to ground at control coil terminal 85. K0 relay contacts [line2] close, providing a current path to the starter motor terminal 50 and to the engagement coil of engine fuel shutdown solenoid Y6 [line 6].

When the engine starts and the alternator provides current, the regulator produces 12 volts in place of ground. Without ground on the K1 control coil K1 contacts open, preventing a restart of a running engine . Contacts K0 [line 2] open removing power to the starter and the engagement coil of Y6 solenoid. Holding power for Y6 is provided through fuse F1.

July 1998

3 - 15

A battery is a device which stores chemical energy and converts it into electrical power as required. The amount of electrical energy that a battery is able to supply depends mainly on the actual size of the battery. The capacity of a battery is measured in Amp/ hours.

The rate at which a battery will convert chemical energy into electrical energy will vary according to the temperature. The lower the temperature, the lower the conversion rate. This is often referred to as Cold Cranking Amperage.

Batteries can be dangerous and should be handled carefully. Battery acid causes severe burns; Avoid contact with skin, eyes or clothing.

SECTION THREE

ELECTRICAL BATTERY DIAGNOSTICS

Batteries produce explosive gases.

Keep away from open flames, sparks, or smoking material and provide good ventilation, especially when recharging.

Batteries can be tested to determine the state of charge and the battery condition.

On nonsealed batteries, a hydrometer can be used to measure the specific gravity of the electrolyte to determine the state of charge.

On sealed batteries (or if a hydrometer is not available), turn on the headlights for 5 minutes or apply a 300 amp load for 15 seconds to remove the surface charge. Let the battery sit for 30 seconds to recover from the load then measure the voltage across the battery with an accurate voltmeter.

Simple steps to battery care are: 1) Keep the battery clean and dry.

2) Keep terminals free of corrosion 3) Keep battery secured tightly.

4) Keep the electrolyte level topped off.

5) Keep the alternator belt tight.

Use the following readings as a guideline for determining the battery’s state of charge.

3 - 16

July 1998

SECTION THREE

ELECTRICAL Apply a load of approximately 1/2 of the cold crank amperage rating for 15 seconds.

Measure the voltage just before removing the load.

STATE OF CHARGE VOLTAGE READING

SPECIFIC GRAVITY

% CHARGE

If your measurement is less than that shown on the table below, the battery needs replacing.

12.66

1.260

100

12.60

1.250

91

12.54

1.240

83

Temp C

21

16

10

4

-1

12.48

1.230

75

Temp F

70

60

50

40

30

12.42

1.220

62*

Min-voltage

9.6

9.5

9.4

9.3

9.1

12.36

1.210

58

12.30

1.200

0**

UNDERSTANDING ALTERNATORS

* = WILL FREEZE AT -31F. ** = WILL FREEZE AT +20F.

A battery must be load tested to determine the battery’s overall condition. To perform a load test, the battery must be at least 80% charged prior to conducting the test.

Using a heavy discharge tester, apply a load of 300 amps for a 15 second period.

Wait 30 seconds for the battery to recover.

July 1998

3 - 17

The purpose of the charging circuit is to maintain the battery in a fully charged condition. The alternator, which is used to perform this function, has two main parts; the rotor which is attached to the shaft, and the stator which is fixed in the housing. The stator normally has three windings.

SECTION THREE The rotor (A), when supplied with a small amount of current, will produce an electromagnetic field (C). The power to the rotor is

ELECTRICAL terminal to the positive terminal of the starter solenoid.

On a machine the sequence will be as follows. When the ignition key is turned on but the engine is still off, current is allowed to flow from the battery, through the instrument cluster alternator light, the rotor brushes, the rotor, the regulator and to ground, causing the warning lamp to illuminate.

controlled through the ignition switch to prevent battery drain when the engine is not running.

As the rotor is turned by the shaft, the magnetic field of the rotor (C) will pass through the windings of the stator (B) and produce an electrical current in the stator windings.

The amount of current produced will vary depending on the speed of the rotor and the strength of the magnetic field.

When the engine is started, alternating current is generated in the separate stator windings. Each winding has a pair of diodes to change the alternating current to direct current which is sent out the B+ terminal to the battery.

When the engine is started and the alternator begins to produce an output, the regulator is no longer grounded but is at 12 volts.

This causes the warning indicator lamp on the instrument panel to go out.

CHARGING SYSTEM DIAGNOSTICS Normal warning lamp operation.

KEY

ENGINE

LAMP

OFF

OFF

OFF

ON

OFF

ON

ON

ON

OFF

Abnormal warning lamp operation and probable cause: The output of the stator will be an AC sine wave and must be rectified to obtain a DC output. The rectification of the stator output is accomplished by a pair of diodes for each stator winding. The DC output is then controlled by the regulator/brush assembly on the alternator. The actual battery charging output of the alternator flows out of the B+

Key (Off); Engine (OFF); Lamp (ON) short in wiring to excite rotor Key (ON); Engine (OFF); Lamp (OFF) bad alternator diode Key (ON); Engine (ON); Lamp (ON) regulator problem 3 - 18

July 1998

SECTION THREE

ELECTRICAL

VOLTAGE CHECKS AT ALTERNATOR

going to ground. This will eventually discharge the battery.

With the engine OFF, connect the positive lead of a voltmeter to the B+ terminal and connect the negative lead to a good engine ground. The meter should read the system (12) volts.

If no voltage is indicated, move the positive lead to the starter solenoid. If the proper voltage is recorded at the starter solenoid, the cable between alternator B+ and the solenoid is defective.

If there is still no voltage indicated, move the positive lead of the voltmeter to the battery positive terminal. If voltage is recorded, the cable to the starter solenoid is defective or the cable connection is corroded. If no voltage is indicated, check the battery negative ground cable.

To determine if current is available from the ignition switch to the alternator rotor field circuit, turn on the ignition switch, connect the voltmeter positive lead to the wire from the switch and connect the voltmeter negative to a good engine ground. The voltmeter should read system voltage.

SYSTEM LEAKAGE Remove the ground cable from the battery.

Make sure the ignition switch is in the OFF position. Connect a test lamp between the negative battery post and the battery cable.

The lamp should not illuminate with the key in the OFF position. If the lamp does illuminate, this is an indication of a power source

July 1998

3 - 19

CIRCUIT WIRING TEST To determine if there is excessive resistance in the alternator wiring or connectors, perform the following two tests: Run the engine at half throttle with the lights on. Place an accurate voltmeter at location shown as “V1” and measure the voltage. It should not exceed 0.5 volts. Place the voltmeter at location shown as “V2” and measure the voltage. It should not exceed 0.25 volts. Excessive voltage in either location is an indication of resistance in the cables or connectors.

SECTION THREE MEASURING ALTERNATOR OUTPUT Maximum current output can be determined by replacing the B+ to solenoid cable with an ammeter.

With a load device, apply a load that is greater than the specified output of the alternator. Start the engine and increase the speed to maximum. the ammeter reading should equal the rating of the alternator.

The output voltage can be determined with the ammeter still in the circuit and by placing a voltmeter across the battery. Run the engine at medium speed until the ammeter is less than 10 amps. The voltmeter reading of the battery should measure between 13.6 and 14.4 volts for a 12volt system.

ELECTRICAL UNDERSTANDING STARTERS All starter motors function similarly and serve the same purpose on the engine.

A heavy cable connects the battery to a switch (1). When the switch is “ON�, current flows from the battery, through the switch and to the starter (2). Current flows through the field coils (3) and then to the armature (4) by means of insulated brushes (5). Current flows through the armature coils and the ground brushes (6) to ground.

The current passing through the field and armature coils generates magnetic forces which oppose each other causing the armature to rotate.

Pre-engaged starters are used on most engines. They provide a positive engagement by not allowing full battery power to the starter motor until the drive pinion is fully engaged into the flywheel.

3 - 20

July 1998

SECTION THREE

ELECTRICAL

STARTER SOLENOID A starter solenoid has two coils. They are the “hold-in coil” (1) which connects to ground, and the “closing coil” (2) which is connected to ground through the starter motor windings.

When the plunger (3) moves to full stroke and the drive pinion is fully engaged, the solenoid contacts (5) are closed, allowing full power to the starter motor.

STARTER SYSTEM DIAGNOSTICS When the switch is “ON”, current passes through the hold-in coil (1), creating a magnetic field around the plunger (3). Current also passes through the closing coil (2), creating a second field.

The current that flows from the closing coil into the starter motor windings causes the motor to rotate slowly. The combined magnetic fields of the two coils causes the plunger to engage. This moves the arm (4) causing engagement of the drive pinion into the flywheel.

SOLENOID CIRCUIT TEST CAUTION: Fasten the manual shut off lever on the injection pump in the "OFF" position prior to this test.

Connect a test light or voltmeter to test point (1) and the other lead to a good ground.

Turn the key switch to the start position.

The test light should illuminate or the voltmeter should indicate system voltage. If not, there is a problem in the supply of current to the solenoid.

July 1998

3 - 21

SECTION THREE Next, connect the test light or voltmeter to the starter terminal (1). Connect the other lead to ground. Turn the key to the start position.

ELECTRICAL Connect the positive lead of a voltmeter to the positive battery terminal (1) and the negative lead to the starter supply terminal (2).Turn the key to the start position and measure the voltage on the meter. If the reading is less than 0.2 volts there is high resistance in the battery supply cable or the contact plate inside the solenoid is corroded and worn.

Connect the positive voltmeter lead to the starter case (1) and the negative lead to the negative battery terminal (2). Turn the key switch to start and read the voltmeter.

The test light should indicate system voltage. If not, it indicates the solenoid is at fault.

NOTE: A clicking from the solenoid indicates the following: 1) Poorly charged battery 2) Corroded cables 3) Bad connection 4) Poor ground 5) Bad solenoid

STARTER CIRCUIT WIRING TEST

If the reading was 0.5 or less, the ground is satisfactory. If the reading is more than 0.5 volts, the starter is poorly grounded.

CAUTION: Fasten the manual lever on the fuel injection pump in the "OFF" position.

3 - 22

July 1998

SECTION THREE

ELECTRICAL

STARTER MOTOR TEST CAUTION: Fasten the manual lever on the fuel injection pump in the "OFF" position.

Connect the positive voltmeter lead to the starter motor supply terminal (1) and the negative lead to a good ground (2). Turn the key switch to the start position and read the meter. The voltmeter should read 8.5 to 10.0 volts.

If the reading is less than 8.5 volts or more than 10.0 volts it indicates a problem with the armature, field or the brushes.

July 1998

3 - 23

SECTION THREE

ELECTRICAL

3 - 24

July 1998

SECTION THREE

ELECTRICAL

INSTRUMENTATION PANEL The instrumentation panel receives power from terminal 15/54 of the ignition switch.

Power flows from Fuse F1 and is available to the panel when the ignition switch is in the ON position.

Power is available to the backup alarm [line14] if the direction control lever is placed in the reverse direction, energizing the coil of Relay K11 [line 13] causing the K11 relay contacts [line 14] to close. Placing the direction control lever in neutral or forward removes the power from K11 relay and the contacts open.

The brake indicator light H3 [line15] will illuminate if Switch S3 [line15] is closed due to insufficient brake pressure. When brake pressure is sufficient, the switch opens and the light extinguishes.

The horn H4 [line 17] will sound if Switch S4 [line 17] is depressed. The horn also provides a warning signal if (1) the running machine is placed in forward or reverse when brake pressure is insufficient, or (2) engine coolant temperature is excessively high.

The current path when brake pressure is insufficient is through the horn, through K2 relay [lines 16 & 5] (closed contacts if alternator has output), Diode V2, K3 relay [lines 16 & 10] (opens when neutral light goes on) and through the brake pressure switch S3 [line 15] to ground. The current

July 1998

3 - 25

path when the engine temperature is excessive is through the horn, through Diode V1 and Temperature switch S5 [line 18]. Diodes V1 and V2 prevent the illumination of H3 or H5 when the horn button is depressed.

Indicator light H9 [line 19] will illuminate if the hydraulic oil filter differential pressure switch S18 closes.

Engine oil pressure indicator light H6 [line 20] will illuminate if oil pressure is not high enough to open oil pressure switch S6.

Panel gauges P2 [line 21] and P3 [line 22] indicate engine coolant temperature and fuel level. These gauges function whenever the ignition is ON.

SECTION THREE

ELECTRICAL

EMERGENCY STOP / BRAKE CIRCUIT

3 - 26

July 1998

SECTION THREE EMERGENCY STOP BRAKE SWITCH

ELECTRICAL SWITCH/

The Emergency stop switch S23 [line 24] receives power from the ignition switch, terminal 15/54, when the ignition switch is in the ON position. Current from the ignition switch passes through Fuse F7, through the normally closed Emergency stop switch S23, through the coil of the Emergency stop relay K9 and to ground. Power through the coil of the K9 relay causes the contacts of the K9 relay [line 25] to close, providing power to the brake circuit [line 26] as well as the vibration, two speed and differential lock circuits.

When the emergency stop switch is depressed, current to the K9 relay is removed causing the contacts to open. This removes power from the brake, vibration, two speed and differential lock circuits.

The Brake solenoid Y5 [line 26] receives power to release the brakes provided the ignition switch is in the ON position, the normally closed contacts of Brake switch S17 are closed, and the normally closed contacts of the K5 relay are closed. The brakes will apply if (1) the ignition is turned off, (2) Brake switch S17 is depressed, (3) there is insufficient brake pressure at Switch S3 [line 15] causing the switch to close, energizing the coil of the K5 relay [line 16] causing the contacts of relay K5 [line 26] to open.

July 1998

3 - 27

A second set of contacts in the S17 Brake switch [line 27] close when the brake switch is depressed to apply the brakes. This portion of the switch sends current to the Y4 differential lock solenoid, locking the differential, improving the brake holding capabilities.

SECTION THREE

ELECTRICAL

VIBRATION CIRCUIT BEFORE S/N JKC8300700

3 - 28

July 1998

SECTION THREE

ELECTRICAL

VIBRATION CIRCUIT Power for the vibration control circuit is available through Fuse F4 [line 29] if the ignition switch is in the ON position and the emergency stop switch is not depressed.

Solenoids Y1 and Y2 [lines 29 and 30] provide the vibration at either high or low frequency and are controlled by Selector Switches S7 or S7A. Selector Switch S7B provides the option of manual vibration (started and stopped by the operator) or automatic vibration (vibration will stop when machine enters neutral).

With Selector Switch S7B in the manual mode and Switch S7 or S7A selected, Relay Contacts K6 must close to provide current flow to one of the two solenoids.

K6 relay is controlled by the Momentary Contact Switch S24 [line 33] on the forward/reverse control lever. The contacts of the switch are closed only when the button is depressed. When depressed, current from Fuse F4 passes through the switch, through the V5 Diode, through the normally closed contacts of the K8 Relay, through the coil of the K7 Relay to ground. The contacts of Relay K7 [line 32] close, creating a current path through the coil of Relay K6 to ground, causing the K6 Relay contacts [line 29] to close. With the contacts closed, the vibration circuit is activated.

As the push button of Switch S24 is released, the contacts open, however, nothing changes because with the K7 Contacts closed, current still flows through the K6 Relay Coil, the K7 Relay Coil and the D1 Delay Relay. After a time delay, the D1 Contacts [line 35] close but with Switch S24 open, nothing happens.

When Switch S24 is momentarily depressed to stop vibration, current flows

July 1998

3 - 29

through the switch, through the closed D1 Contacts, through the coil of the K8 Relay to ground. The normally closed contacts of the K8 Relay [line 33] now open, causing the coil of the K7 Relay to lose power, opening the K7 Contacts. This causes Relay Coil K6 to lose power, opening the K6 Contacts [line 29].

Diodes V4 and V5 are isolation diodes. V4 prevents current flow to Relay Coil K6 from Switch S24, while V5 prevents current flow from K7 Contacts to the D1/K8 Circuit.

When Switch S7B is placed in the automatic mode, current passes through the automatic switch contacts, through normally closed K12 Relay Contacts, and through the remainder of the circuit. When the machine is placed in neutral, the coil of Relay K12 [line28] is energized, opening the K12 Relay Contacts

SECTION THREE

ELECTRICAL

3 - 30

July 1998

SECTION THREE

ELECTRICAL

VIBRATION AFTER JKC8300700 The smooth drum 1103D and 1103HD models are equipped with a high and low frequency vibratory system. Models with the padfoot drum are setup to operate at only the lower frequency. The padfoot (PD models) do ship with the extra switches and solenoids needed for high/low frequency operation but not all connections are made.

This configuration allows for easily changing the machine drum between smooth and padfoot. Never run the padfoot drum with the high frequency vibration circuit. Doing so will shorten bearing life.

Power for the vibration control circuit is available through Fuse F4 [line 29] if the key is on and the emergency stop switch is not depressed. Power from the fuse is available at both Switch S7B and S24. In manual mode the manual/automatic selector switch S7B passes current through the manual mode contacts [S] to terminal 2 of the K6 latching relay [line 33]. When the momentary push button, switch S24 [line 33] on the forward/reverse lever, is depressed and released, K6 latches contacts 2 and 5, allowing current to flow to the S7 (high frequency) and S7A (low frequency) vibration control switches. Activating switch S7 or S7A allows current to solenoids Y1 or Y2 on the vibration control valve. When switch S24 is depressed and released a second time K6 unlatches, removing power from terminal 5 of the K6 relay, and shuts off vibration. Switches S7 and S7A work inde-

July 1998

3 - 31

pendently once K6 relay is latched, however it is recommended that the vibration system on smooth drum machines be shut down by using S24 before changing between high and low frequency with switches S7 and S7A. In the automatic vibration mode, current passes through switch S7B [line 29], through the contacts of relay K12 [line29], and onto terminal 30 of switches S7 and S7A. Switch S24 and relay K6 are not part of the active circuit so the button on the forward/reverse lever has no effect on vibration operations in the automatic mode. The automatic vibration off in neutral is controlled through relay K12. The contacts of K12 open whenever the forward/reverse lever is moved into the neutral position.

SECTION THREE

ELECTRICAL

LIGHTING CIRCUIT

3 - 32

July 1998

SECTION THREE

ELECTRICAL

LIGHTING CIRCUIT The lighting circuit on the 1103 includes the instrument panel lighting, optional parking and taillights, optional directional and hazard lighting and optional work lights.

The instrument panel lighting receives power from the ignition switch ON position through Fuse F9. When depressed, Switch S11 [line 52] energizes lights in the fuel gauge and in the engine temperature gauge, as well as Indicator Light H13 in the button of Switch S11 [line 53].

If the optional park and taillight circuit is provided, the instrument panel switch also energizes the coil of Relay K10 [line 54]. The optional circuit receives power from Terminal 30 of the ignition switch and does not need the ignition to be on to provide power to Fuse F13 and Switch 25, provided the K10 Relay Contacts are closed.

Separate fuses are used for each pair of park/tail lights.

Fuse F12 [line 63] receives power from the ignition switch ON position and provides current to the optional directional light circuit. Current enters Switch S27 at terminal 15, passes through Relay K13 and enters the Directional Switch S26,Terminal A. When the lever is moved left or right, it energizes the proper lights. As the current passes through the K13 Flasher Relay, intermittent output occurs.

July 1998

3 - 33

Fuse F14 [line 62] receives power from Terminal 30 and does not need the ignition switch on. It provides power to the optional Hazard Light Switch S27, Terminal 30.

When the switch is activated, power is passed through the K13 Relay as well as to all four directional lights.

SECTION THREE

ELECTRICAL

WORK LIGHTS / ACCESSORY PLUG / HEATER / WIPERS

July 1998

3 - 34

SECTION THREE

ELECTRICAL

WORK LIGHTS, ACCESSORY PLUG, HEATER AND WIPERS The optional work light circuit is an ignition controlled circuit, protected by Fuse F11 and controlled by Switch S28 [line 70] for the front work lights and Switch S28a [line 73] for the rear work lights. Indicator Lights H17 [line 71] and H18 [line 74] illuminate the light switches when activated.

The accessory plug circuit [line 76] is an ignition controlled circuit, protected by Fuse 10.

The optional heater/ wiper circuit [line 78] is not ignition controlled. Power is available at Fuse F6, supplying current to Wiper Switch S12 and to the front wiper motor [line 80], to Wiper Switch S13 and to the rear wiper motor [line 81], to Fan Switch S15 and to the heater fan [line 82] and to the Heater Switch S16 and into the heater [line 78].

July 1998

3 - 35

3 - 36

July 1998

60

2

3

E11

E12

F1

F2

17

18

H4

H5

45

14

19

30

H7

H8

H9

H11

20

15

H6

9

H3

F16

H2

57

F15

3

56

F14

2

62

F13

H1

56a

F12

G2

63

F11

1

70

F10

G1

76

F9

59

52

F8

60

46

F7

F18

24

F6

F17

35

78

F5

26

59

E10

29

58

E9

F4

57

E8

F3

55

56

E7

72

70

E4

73

69

E3

E6

52

E2

E5

51

ITEM LINE

E1

DESCRIPTION

INDICATOR LIGHT, AUTO VIBRATION

INDICATOR LIGHT, HYDRAULIC FILTER

BACK UP ALARM

INDICATOR LIGHT, DIFFERENTIAL LOCK

INDICATOR LIGHT, ENG. OIL PSI.

INDICATOR LIGHT, ENG. TEMP.

HORN

INDICATOR LIGHT, BRAKE

INDICATOR LIGHT, NEUTRAL

INDICATOR LIGHT, ALTENATOR

ALTENATOR

BATTERY

FUSE, RIGHT DIM LIGHT

FUSE, LEFT DIM LIGHT

FUSE, RIGHT PARK LIGHTS

FUSE, LEFT PARK LIGHTS

FUSE, HAZARD LIGHTS

FUSE, LIGHTING

FUSE, DIRECTIONAL LIGHTS

FUSE, WORK LIGHTS

FUSE, PLUG SOCKET

FUSE, LIGHTING

FUSE, DIFFERENTIAL LOCK

FUSE, EMERGENCY OFF

FUSE, CAB FUNCTIONS

FUSE, TWO SPEED

FUSE, VIBRATION

FUSE, BRAKE

FUSE, ALTENATOR

FUSE, INSTRUMENTATION

LIGHT, RIGHT DIM

LIGHT, LEFT DIM

LIGHT, RIGHT TAIL

LIGHT, FRONT RIGHT PARK

LIGHT, LEFT TAIL

LIGHT, FRONT LEFT PARK

LIGHT, FRONT LEFT WORK

LIGHT, REAR LEFT WORK

LIGHT, FRONT RIGHT WORK

LIGHT, FRONT LEFT WORK

LIGHT, FUEL GAUGE

LIGHT, TEMPERATURE GAUGE

S5

S4

S3

S2

S1

R2

R1

P3

P2

P1

M7

M6

M5

M4

M3

M2

M1

K13

K12

K11

K10

K9

K6

K5

K4

K3

K2

K1

K0

H24

H23

H22

H21

H19

H18

H17

H16

H15

H14

H13

18

17

15

11

1

22

21

22

21

4

78a

78

82

81

80

79

2

64

28-29

13-14

54-56

24-25

32-33

16-26

8-11

10-16

5-16

2-8

0-2

66

65

64

63

77

74

71

68

65

64a

53

35

ITEM LINE H12

DESCRIPTION

SWITCH, HIGH ENGINE TEMP.

SWITCH, HORN BUTTON

SWITCH, BRAKE RELEASE PRESSURE

SWITCH, NEUTRAL POSITION

SWITCH, KEY

SENSOR, FUEL LEVEL

SENSOR, ENGINE TEMPERATURE

GAUGE, FUEL LEVEL

GAUGE, ENGINE TEMPERATURE

HOUR METER

MOTOR, HEATER PUMP

MOTOR, HEATER

MOTOR, FAN

MOTOR, WASHER PUMP

MOTOR, REAR WIPER

MOTOR, FRONT WIPER

MOTOR, STARTER

RELAY, DIRECTIONAL FLASHER

RELAY, AUTOMATIC VIBRATION

RELAY, BACK UP ALARM

RELAY, LIGHTING SYSTEM

RELAY, EMERGENCY OFF

RELAY, VIBRATION MANUAL CONTROL

RELAY, BRAKE RELEASE

RELAY, NEUTRAL POSITION

RELAY, BRAKE MONITOR, NEUTRAL

RELAY, BRAKE MONITOR, ALTENATOR

RELAY, ANTI-RESTART

RELAY, AUXILIARY START

LIGHT, REAR RIGHT DIRECTIONAL

LIGHT, FRONT RIGHT DIRECTIONAL

LIGHT, REAR LEFT DIRECTIONAL

LIGHT, FRONT LEFT DIRECTIONAL

INDICATOR LIGHT, HEATER

INDICATOR LIGHT, WORK LIGHT REAR

INDICATOR LIGHT, WORK LIGHT FRONT

INDICATOR LIGHT, DIRECTION ARROW

INDICATOR LIGHT, HAZARD LIGHTS

INDICATOR LIGHT, DIRECTIONALS

INDICATOR LIGHT, LIGHTS

INDICATOR LIGHT, 2 SPEED AXLE

V4

V3

V2

V1

Y6

Y5

Y4

Y3

Y2

Y1

S28A

S28

S27

S26

S25

S24

S23

S19

S18

S17

S16

S15

S13

S12

S11

S10

S9

S8

S7B

S7A

S7

46

7

16

17

6

26

46

35

30

29

73

70

65

65

56

33

24

13

19

26

77

82

80

79

52

46

46

35

29

29

29

20

ITEM LINE S6

DESCRIPTION

DIODE, ISOLATION

DIODE, ISOLATION

DIODE, ISOLATION

DIODE, ISOLATION

SOLENOID, ENGINE SHUT DOWN

SOLENOID, BRAKE/SERVO

SOLENOID, DIFFERENTIAL LOCK

SOLENOID, 2 SPEED AXLE

SOLENOID, VIBRATION LOW FREQ.

SOLENOID, VIBRATION HIGH FREQ.

SWITCH, REAR WORK LIGHTS

SWITCH, FRONT WORK LIGHTS

SWITCH, HAZARD LIGHTS

SWITCH, DIRECTIONAL LIGHTS

SWITCH, LIGHTING

SWITCH, THUMB,VIBRATION ON/OFF

SWITCH, EMERGENCY OFF

SWITCH, BACK UP ALARM

SWITCH, HYDRAULIC FILTER PSI.

SWITCH, HYDRAULIC BRAKE

SWITCH, HEATER

SWITCH, FAN

SWITCH, REAR WIPER

SWITCH, FRONT WIPER

SWITCH, LIGHTING SYSTEM

SWITCH, ARTICULATION POSITION

SWITCH, DIFFERENTIAL LOCK

SWITCH, TWO SPEED AXLE

SWITCH, AUTO/MANUAL VIBRATION

SWITCH, VIBRATION LOW FREQ.

SWITCH, VIBRATION HIGH FREQ.

SWITCH, ENGINE OIL PRESSURE

July 1998

3 - 37

3 - 38

July 1998

60

2

3

E11

E12

F1

F2

17

18

H4

H5

45

14

19

30

H7

H8

H9

H11

20

15

H6

9

H3

F16

H2

57

F15

3

56

F14

2

62

F13

H1

56a

F12

G2

63

F11

1

70

F10

G1

76

F9

59

52

F8

60

46

F7

F18

24

F6

F17

35

78

F5

26

59

E10

29

58

E9

F4

57

E8

F3

55

56

E7

72

70

E4

73

69

E3

E6

52

E2

E5

51

ITEM LINE

E1

DESCRIPTION

INDICATOR LIGHT, AUTO VIBRATION

INDICATOR LIGHT, HYDRAULIC FILTER

BACK UP ALARM

INDICATOR LIGHT, DIFFERENTIAL LOCK

INDICATOR LIGHT, ENG. OIL PSI.

INDICATOR LIGHT, ENG. TEMP.

HORN

INDICATOR LIGHT, BRAKE

INDICATOR LIGHT, NEUTRAL

INDICATOR LIGHT, ALTENATOR

ALTENATOR

BATTERY

FUSE, RIGHT DIM LIGHT

FUSE, LEFT DIM LIGHT

FUSE, RIGHT PARK LIGHTS

FUSE, LEFT PARK LIGHTS

FUSE, HAZARD LIGHTS

FUSE, LIGHTING

FUSE, DIRECTIONAL LIGHTS

FUSE, WORK LIGHTS

FUSE, PLUG SOCKET

FUSE, LIGHTING

FUSE, DIFFERENTIAL LOCK

FUSE, EMERGENCY OFF

FUSE, CAB FUNCTIONS

FUSE, TWO SPEED

FUSE, VIBRATION

FUSE, BRAKE

FUSE, ALTENATOR

FUSE, INSTRUMENTATION

LIGHT, RIGHT DIM

LIGHT, LEFT DIM

LIGHT, RIGHT TAIL

LIGHT, FRONT RIGHT PARK

LIGHT, LEFT TAIL

LIGHT, FRONT LEFT PARK

LIGHT, FRONT LEFT WORK

LIGHT, REAR LEFT WORK

LIGHT, FRONT RIGHT WORK

LIGHT, FRONT LEFT WORK

LIGHT, FUEL GAUGE

LIGHT, TEMPERATURE GAUGE

S5

S4

S3

S2

S1

R2

R1

P3

P2

P1

M7

M6

M5

M4

M3

M2

M1

K13

K12

K11

K10

K9

K6

K5

K4

K3

K2

K1

K0

H24

H23

H22

H21

H19

H18

H17

H16

H15

H14

H13

18

17

15

11

1

22

21

22

21

4

78a

78

82

81

80

79

2

64

28-29

13-14

54-56

24-25

32-33

16-26

8-11

10-16

5-16

2-8

0-2

66

65

64

63

77

74

71

68

65

64a

53

35

ITEM LINE H12

DESCRIPTION

SWITCH, HIGH ENGINE TEMP.

SWITCH, HORN BUTTON

SWITCH, BRAKE RELEASE PRESSURE

SWITCH, NEUTRAL POSITION

SWITCH, KEY

SENSOR, FUEL LEVEL

SENSOR, ENGINE TEMPERATURE

GAUGE, FUEL LEVEL

GAUGE, ENGINE TEMPERATURE

HOUR METER

MOTOR, HEATER PUMP

MOTOR, HEATER

MOTOR, FAN

MOTOR, WASHER PUMP

MOTOR, REAR WIPER

MOTOR, FRONT WIPER

MOTOR, STARTER

RELAY, DIRECTIONAL FLASHER

RELAY, AUTOMATIC VIBRATION

RELAY, BACK UP ALARM

RELAY, LIGHTING SYSTEM

RELAY, EMERGENCY OFF

RELAY, VIBRATION MANUAL CONTROL

RELAY, BRAKE RELEASE

RELAY, NEUTRAL POSITION

RELAY, BRAKE MONITOR, NEUTRAL

RELAY, BRAKE MONITOR, ALTENATOR

RELAY, ANTI-RESTART

RELAY, AUXILIARY START

LIGHT, REAR RIGHT DIRECTIONAL

LIGHT, FRONT RIGHT DIRECTIONAL

LIGHT, REAR LEFT DIRECTIONAL

LIGHT, FRONT LEFT DIRECTIONAL

INDICATOR LIGHT, HEATER

INDICATOR LIGHT, WORK LIGHT REAR

INDICATOR LIGHT, WORK LIGHT FRONT

INDICATOR LIGHT, DIRECTION ARROW

INDICATOR LIGHT, HAZARD LIGHTS

INDICATOR LIGHT, DIRECTIONALS

INDICATOR LIGHT, LIGHTS

INDICATOR LIGHT, 2 SPEED AXLE

V4

V3

V2

V1

Y6

Y5

Y4

Y3

Y2

Y1

S28A

S28

S27

S26

S25

S24

S23

S19

S18

S17

S16

S15

S13

S12

S11

S10

S9

S8

S7B

S7A

S7

46

7

16

17

6

26

46

35

30

29

73

70

65

65

56

33

24

13

19

26

77

82

80

79

52

46

46

35

29

29

29

20

ITEM LINE S6

DESCRIPTION

DIODE, ISOLATION

DIODE, ISOLATION

DIODE, ISOLATION

DIODE, ISOLATION

SOLENOID, ENGINE SHUT DOWN

SOLENOID, BRAKE/SERVO

SOLENOID, DIFFERENTIAL LOCK

SOLENOID, 2 SPEED AXLE

SOLENOID, VIBRATION LOW FREQ.

SOLENOID, VIBRATION HIGH FREQ.

SWITCH, REAR WORK LIGHTS

SWITCH, FRONT WORK LIGHTS

SWITCH, HAZARD LIGHTS

SWITCH, DIRECTIONAL LIGHTS

SWITCH, LIGHTING

SWITCH, THUMB,VIBRATION ON/OFF

SWITCH, EMERGENCY OFF

SWITCH, BACK UP ALARM

SWITCH, HYDRAULIC FILTER PSI.

SWITCH, HYDRAULIC BRAKE

SWITCH, HEATER

SWITCH, FAN

SWITCH, REAR WIPER

SWITCH, FRONT WIPER

SWITCH, LIGHTING SYSTEM

SWITCH, ARTICULATION POSITION

SWITCH, DIFFERENTIAL LOCK

SWITCH, TWO SPEED AXLE

SWITCH, AUTO/MANUAL VIBRATION

SWITCH, VIBRATION LOW FREQ.

SWITCH, VIBRATION HIGH FREQ.

SWITCH, ENGINE OIL PRESSURE

July 1998

3 - 39

3 - 40

July 1998

60

2

3

E11

E12

F1

F2

17

18

H4

H5

45

14

19

30

H7

H8

H9

H11

20

15

H6

9

H3

F16

H2

57

F15

3

56

F14

2

62

F13

H1

56a

F12

G2

63

F11

1

70

F10

G1

76

F9

59

52

F8

60

46

F7

F18

24

F6

F17

35

78

F5

26

59

E10

29

58

E9

F4

57

E8

F3

55

56

E7

72

70

E4

73

69

E3

E6

52

E2

E5

51

ITEM LINE

E1

DESCRIPTION

INDICATOR LIGHT, AUTO VIBRATION

INDICATOR LIGHT, HYDRAULIC FILTER

BACK UP ALARM

INDICATOR LIGHT, DIFFERENTIAL LOCK

INDICATOR LIGHT, ENG. OIL PSI.

INDICATOR LIGHT, ENG. TEMP.

HORN

INDICATOR LIGHT, BRAKE

INDICATOR LIGHT, NEUTRAL

INDICATOR LIGHT, ALTENATOR

ALTENATOR

BATTERY

FUSE, RIGHT DIM LIGHT

FUSE, LEFT DIM LIGHT

FUSE, RIGHT PARK LIGHTS

FUSE, LEFT PARK LIGHTS

FUSE, HAZARD LIGHTS

FUSE, LIGHTING

FUSE, DIRECTIONAL LIGHTS

FUSE, WORK LIGHTS

FUSE, PLUG SOCKET

FUSE, LIGHTING

FUSE, DIFFERENTIAL LOCK

FUSE, EMERGENCY OFF

FUSE, CAB FUNCTIONS

FUSE, TWO SPEED

FUSE, VIBRATION

FUSE, BRAKE

FUSE, ALTENATOR

FUSE, INSTRUMENTATION

LIGHT, RIGHT DIM

LIGHT, LEFT DIM

LIGHT, RIGHT TAIL

LIGHT, FRONT RIGHT PARK

LIGHT, LEFT TAIL

LIGHT, FRONT LEFT PARK

LIGHT, FRONT LEFT WORK

LIGHT, REAR LEFT WORK

LIGHT, FRONT RIGHT WORK

LIGHT, FRONT LEFT WORK

LIGHT, FUEL GAUGE

LIGHT, TEMPERATURE GAUGE

S5

S4

S3

S2

S1

R2

R1

P3

P2

P1

M7

M6

M5

M4

M3

M2

M1

K13

K12

K11

K10

K9

K6

K5

K4

K3

K2

K1

K0

H24

H23

H22

H21

H19

H18

H17

H16

H15

H14

H13

18

17

15

11

1

22

21

22

21

4

78a

78

82

81

80

79

2

64

28-29

13-14

54-56

24-25

32-33

16-26

8-11

10-16

5-16

2-8

0-2

66

65

64

63

77

74

71

68

65

64a

53

35

ITEM LINE H12

DESCRIPTION

SWITCH, HIGH ENGINE TEMP.

SWITCH, HORN BUTTON

SWITCH, BRAKE RELEASE PRESSURE

SWITCH, NEUTRAL POSITION

SWITCH, KEY

SENSOR, FUEL LEVEL

SENSOR, ENGINE TEMPERATURE

GAUGE, FUEL LEVEL

GAUGE, ENGINE TEMPERATURE

HOUR METER

MOTOR, HEATER PUMP

MOTOR, HEATER

MOTOR, FAN

MOTOR, WASHER PUMP

MOTOR, REAR WIPER

MOTOR, FRONT WIPER

MOTOR, STARTER

RELAY, DIRECTIONAL FLASHER

RELAY, AUTOMATIC VIBRATION

RELAY, BACK UP ALARM

RELAY, LIGHTING SYSTEM

RELAY, EMERGENCY OFF

RELAY, VIBRATION MANUAL CONTROL

RELAY, BRAKE RELEASE

RELAY, NEUTRAL POSITION

RELAY, BRAKE MONITOR, NEUTRAL

RELAY, BRAKE MONITOR, ALTENATOR

RELAY, ANTI-RESTART

RELAY, AUXILIARY START

LIGHT, REAR RIGHT DIRECTIONAL

LIGHT, FRONT RIGHT DIRECTIONAL

LIGHT, REAR LEFT DIRECTIONAL

LIGHT, FRONT LEFT DIRECTIONAL

INDICATOR LIGHT, HEATER

INDICATOR LIGHT, WORK LIGHT REAR

INDICATOR LIGHT, WORK LIGHT FRONT

INDICATOR LIGHT, DIRECTION ARROW

INDICATOR LIGHT, HAZARD LIGHTS

INDICATOR LIGHT, DIRECTIONALS

INDICATOR LIGHT, LIGHTS

INDICATOR LIGHT, 2 SPEED AXLE

V4

V3

V2

V1

Y6

Y5

Y4

Y3

Y2

Y1

S28A

S28

S27

S26

S25

S24

S23

S19

S18

S17

S16

S15

S13

S12

S11

S10

S9

S8

S7B

S7A

S7

46

7

16

17

6

26

46

35

30

29

73

70

65

65

56

33

24

13

19

26

77

82

80

79

52

46

46

35

29

29

29

20

ITEM LINE S6

DESCRIPTION

DIODE, ISOLATION

DIODE, ISOLATION

DIODE, ISOLATION

DIODE, ISOLATION

SOLENOID, ENGINE SHUT DOWN

SOLENOID, BRAKE/SERVO

SOLENOID, DIFFERENTIAL LOCK

SOLENOID, 2 SPEED AXLE

SOLENOID, VIBRATION LOW FREQ.

SOLENOID, VIBRATION HIGH FREQ.

SWITCH, REAR WORK LIGHTS

SWITCH, FRONT WORK LIGHTS

SWITCH, HAZARD LIGHTS

SWITCH, DIRECTIONAL LIGHTS

SWITCH, LIGHTING

SWITCH, THUMB,VIBRATION ON/OFF

SWITCH, EMERGENCY OFF

SWITCH, BACK UP ALARM

SWITCH, HYDRAULIC FILTER PSI.

SWITCH, HYDRAULIC BRAKE

SWITCH, HEATER

SWITCH, FAN

SWITCH, REAR WIPER

SWITCH, FRONT WIPER

SWITCH, LIGHTING SYSTEM

SWITCH, ARTICULATION POSITION

SWITCH, DIFFERENTIAL LOCK

SWITCH, TWO SPEED AXLE

SWITCH, AUTO/MANUAL VIBRATION

SWITCH, VIBRATION LOW FREQ.

SWITCH, VIBRATION HIGH FREQ.

SWITCH, ENGINE OIL PRESSURE

July 1998

3 - 41

3 - 42

July 1998

60

2

3

E11

E12

F1

F2

17

18

H4

H5

45

14

19

30

H7

H8

H9

H11

20

15

H6

9

H3

F16

H2

57

F15

3

56

F14

2

62

F13

H1

56a

F12

G2

63

F11

1

70

F10

G1

76

F9

59

52

F8

60

46

F7

F18

24

F6

F17

35

78

F5

26

59

E10

29

58

E9

F4

57

E8

F3

55

56

E7

72

70

E4

73

69

E3

E6

52

E2

E5

51

ITEM LINE

E1

DESCRIPTION

INDICATOR LIGHT, AUTO VIBRATION

INDICATOR LIGHT, HYDRAULIC FILTER

BACK UP ALARM

INDICATOR LIGHT, DIFFERENTIAL LOCK

INDICATOR LIGHT, ENG. OIL PSI.

INDICATOR LIGHT, ENG. TEMP.

HORN

INDICATOR LIGHT, BRAKE

INDICATOR LIGHT, NEUTRAL

INDICATOR LIGHT, ALTENATOR

ALTENATOR

BATTERY

FUSE, RIGHT DIM LIGHT

FUSE, LEFT DIM LIGHT

FUSE, RIGHT PARK LIGHTS

FUSE, LEFT PARK LIGHTS

FUSE, HAZARD LIGHTS

FUSE, LIGHTING

FUSE, DIRECTIONAL LIGHTS

FUSE, WORK LIGHTS

FUSE, PLUG SOCKET

FUSE, LIGHTING

FUSE, DIFFERENTIAL LOCK

FUSE, EMERGENCY OFF

FUSE, CAB FUNCTIONS

FUSE, TWO SPEED

FUSE, VIBRATION

FUSE, BRAKE

FUSE, ALTENATOR

FUSE, INSTRUMENTATION

LIGHT, RIGHT DIM

LIGHT, LEFT DIM

LIGHT, RIGHT TAIL

LIGHT, FRONT RIGHT PARK

LIGHT, LEFT TAIL

LIGHT, FRONT LEFT PARK

LIGHT, FRONT LEFT WORK

LIGHT, REAR LEFT WORK

LIGHT, FRONT RIGHT WORK

LIGHT, FRONT LEFT WORK

LIGHT, FUEL GAUGE

LIGHT, TEMPERATURE GAUGE

S5

S4

S3

S2

S1

R2

R1

P3

P2

P1

M7

M6

M5

M4

M3

M2

M1

K13

K12

K11

K10

K9

K6

K5

K4

K3

K2

K1

K0

H24

H23

H22

H21

H19

H18

H17

H16

H15

H14

H13

18

17

15

11

1

22

21

22

21

4

78a

78

82

81

80

79

2

64

28-29

13-14

54-56

24-25

32-33

16-26

8-11

10-16

5-16

2-8

0-2

66

65

64

63

77

74

71

68

65

64a

53

35

ITEM LINE H12

DESCRIPTION

SWITCH, HIGH ENGINE TEMP.

SWITCH, HORN BUTTON

SWITCH, BRAKE RELEASE PRESSURE

SWITCH, NEUTRAL POSITION

SWITCH, KEY

SENSOR, FUEL LEVEL

SENSOR, ENGINE TEMPERATURE

GAUGE, FUEL LEVEL

GAUGE, ENGINE TEMPERATURE

HOUR METER

MOTOR, HEATER PUMP

MOTOR, HEATER

MOTOR, FAN

MOTOR, WASHER PUMP

MOTOR, REAR WIPER

MOTOR, FRONT WIPER

MOTOR, STARTER

RELAY, DIRECTIONAL FLASHER

RELAY, AUTOMATIC VIBRATION

RELAY, BACK UP ALARM

RELAY, LIGHTING SYSTEM

RELAY, EMERGENCY OFF

RELAY, VIBRATION MANUAL CONTROL

RELAY, BRAKE RELEASE

RELAY, NEUTRAL POSITION

RELAY, BRAKE MONITOR, NEUTRAL

RELAY, BRAKE MONITOR, ALTENATOR

RELAY, ANTI-RESTART

RELAY, AUXILIARY START

LIGHT, REAR RIGHT DIRECTIONAL

LIGHT, FRONT RIGHT DIRECTIONAL

LIGHT, REAR LEFT DIRECTIONAL

LIGHT, FRONT LEFT DIRECTIONAL

INDICATOR LIGHT, HEATER

INDICATOR LIGHT, WORK LIGHT REAR

INDICATOR LIGHT, WORK LIGHT FRONT

INDICATOR LIGHT, DIRECTION ARROW

INDICATOR LIGHT, HAZARD LIGHTS

INDICATOR LIGHT, DIRECTIONALS

INDICATOR LIGHT, LIGHTS

INDICATOR LIGHT, 2 SPEED AXLE

V4

V3

V2

V1

Y6

Y5

Y4

Y3

Y2

Y1

S28A

S28

S27

S26

S25

S24

S23

S19

S18

S17

S16

S15

S13

S12

S11

S10

S9

S8

S7B

S7A

S7

46

7

16

17

6

26

46

35

30

29

73

70

65

65

56

33

24

13

19

26

77

82

80

79

52

46

46

35

29

29

29

20

ITEM LINE S6

DESCRIPTION

DIODE, ISOLATION

DIODE, ISOLATION

DIODE, ISOLATION

DIODE, ISOLATION

SOLENOID, ENGINE SHUT DOWN

SOLENOID, BRAKE/SERVO

SOLENOID, DIFFERENTIAL LOCK

SOLENOID, 2 SPEED AXLE

SOLENOID, VIBRATION LOW FREQ.

SOLENOID, VIBRATION HIGH FREQ.

SWITCH, REAR WORK LIGHTS

SWITCH, FRONT WORK LIGHTS

SWITCH, HAZARD LIGHTS

SWITCH, DIRECTIONAL LIGHTS

SWITCH, LIGHTING

SWITCH, THUMB,VIBRATION ON/OFF

SWITCH, EMERGENCY OFF

SWITCH, BACK UP ALARM

SWITCH, HYDRAULIC FILTER PSI.

SWITCH, HYDRAULIC BRAKE

SWITCH, HEATER

SWITCH, FAN

SWITCH, REAR WIPER

SWITCH, FRONT WIPER

SWITCH, LIGHTING SYSTEM

SWITCH, ARTICULATION POSITION

SWITCH, DIFFERENTIAL LOCK

SWITCH, TWO SPEED AXLE

SWITCH, AUTO/MANUAL VIBRATION

SWITCH, VIBRATION LOW FREQ.

SWITCH, VIBRATION HIGH FREQ.

SWITCH, ENGINE OIL PRESSURE

July 1998

3 - 43

3 - 44

July 1998

60

2

3

E11

E12

F1

F2

17

18

H4

H5

45

14

19

30

H7

H8

H9

H11

20

15

H6

9

H3

F16

H2

57

F15

3

56

F14

2

62

F13

H1

56a

F12

G2

63

F11

1

70

F10

G1

76

F9

59

52

F8

60

46

F7

F18

24

F6

F17

35

78

F5

26

59

E10

29

58

E9

F4

57

E8

F3

55

56

E7

72

70

E4

73

69

E3

E6

52

E2

E5

51

ITEM LINE

E1

DESCRIPTION

INDICATOR LIGHT, AUTO VIBRATION

INDICATOR LIGHT, HYDRAULIC FILTER

BACK UP ALARM

INDICATOR LIGHT, DIFFERENTIAL LOCK

INDICATOR LIGHT, ENG. OIL PSI.

INDICATOR LIGHT, ENG. TEMP.

HORN

INDICATOR LIGHT, BRAKE

INDICATOR LIGHT, NEUTRAL

INDICATOR LIGHT, ALTENATOR

ALTENATOR

BATTERY

FUSE, RIGHT DIM LIGHT

FUSE, LEFT DIM LIGHT

FUSE, RIGHT PARK LIGHTS

FUSE, LEFT PARK LIGHTS

FUSE, HAZARD LIGHTS

FUSE, LIGHTING

FUSE, DIRECTIONAL LIGHTS

FUSE, WORK LIGHTS

FUSE, PLUG SOCKET

FUSE, LIGHTING

FUSE, DIFFERENTIAL LOCK

FUSE, EMERGENCY OFF

FUSE, CAB FUNCTIONS

FUSE, TWO SPEED

FUSE, VIBRATION

FUSE, BRAKE

FUSE, ALTENATOR

FUSE, INSTRUMENTATION

LIGHT, RIGHT DIM

LIGHT, LEFT DIM

LIGHT, RIGHT TAIL

LIGHT, FRONT RIGHT PARK

LIGHT, LEFT TAIL

LIGHT, FRONT LEFT PARK

LIGHT, FRONT LEFT WORK

LIGHT, REAR LEFT WORK

LIGHT, FRONT RIGHT WORK

LIGHT, FRONT LEFT WORK

LIGHT, FUEL GAUGE

LIGHT, TEMPERATURE GAUGE

S5

S4

S3

S2

S1

R2

R1

P3

P2

P1

M7

M6

M5

M4

M3

M2

M1

K13

K12

K11

K10

K9

K6

K5

K4

K3

K2

K1

K0

H24

H23

H22

H21

H19

H18

H17

H16

H15

H14

H13

18

17

15

11

1

22

21

22

21

4

78a

78

82

81

80

79

2

64

28-29

13-14

54-56

24-25

32-33

16-26

8-11

10-16

5-16

2-8

0-2

66

65

64

63

77

74

71

68

65

64a

53

35

ITEM LINE H12

DESCRIPTION

SWITCH, HIGH ENGINE TEMP.

SWITCH, HORN BUTTON

SWITCH, BRAKE RELEASE PRESSURE

SWITCH, NEUTRAL POSITION

SWITCH, KEY

SENSOR, FUEL LEVEL

SENSOR, ENGINE TEMPERATURE

GAUGE, FUEL LEVEL

GAUGE, ENGINE TEMPERATURE

HOUR METER

MOTOR, HEATER PUMP

MOTOR, HEATER

MOTOR, FAN

MOTOR, WASHER PUMP

MOTOR, REAR WIPER

MOTOR, FRONT WIPER

MOTOR, STARTER

RELAY, DIRECTIONAL FLASHER

RELAY, AUTOMATIC VIBRATION

RELAY, BACK UP ALARM

RELAY, LIGHTING SYSTEM

RELAY, EMERGENCY OFF

RELAY, VIBRATION MANUAL CONTROL

RELAY, BRAKE RELEASE

RELAY, NEUTRAL POSITION

RELAY, BRAKE MONITOR, NEUTRAL

RELAY, BRAKE MONITOR, ALTENATOR

RELAY, ANTI-RESTART

RELAY, AUXILIARY START

LIGHT, REAR RIGHT DIRECTIONAL

LIGHT, FRONT RIGHT DIRECTIONAL

LIGHT, REAR LEFT DIRECTIONAL

LIGHT, FRONT LEFT DIRECTIONAL

INDICATOR LIGHT, HEATER

INDICATOR LIGHT, WORK LIGHT REAR

INDICATOR LIGHT, WORK LIGHT FRONT

INDICATOR LIGHT, DIRECTION ARROW

INDICATOR LIGHT, HAZARD LIGHTS

INDICATOR LIGHT, DIRECTIONALS

INDICATOR LIGHT, LIGHTS

INDICATOR LIGHT, 2 SPEED AXLE

V4

V3

V2

V1

Y6

Y5

Y4

Y3

Y2

Y1

S28A

S28

S27

S26

S25

S24

S23

S19

S18

S17

S16

S15

S13

S12

S11

S10

S9

S8

S7B

S7A

S7

46

7

16

17

6

26

46

35

30

29

73

70

65

65

56

33

24

13

19

26

77

82

80

79

52

46

46

35

29

29

29

20

ITEM LINE S6

DESCRIPTION

DIODE, ISOLATION

DIODE, ISOLATION

DIODE, ISOLATION

DIODE, ISOLATION

SOLENOID, ENGINE SHUT DOWN

SOLENOID, BRAKE/SERVO

SOLENOID, DIFFERENTIAL LOCK

SOLENOID, 2 SPEED AXLE

SOLENOID, VIBRATION LOW FREQ.

SOLENOID, VIBRATION HIGH FREQ.

SWITCH, REAR WORK LIGHTS

SWITCH, FRONT WORK LIGHTS

SWITCH, HAZARD LIGHTS

SWITCH, DIRECTIONAL LIGHTS

SWITCH, LIGHTING

SWITCH, THUMB,VIBRATION ON/OFF

SWITCH, EMERGENCY OFF

SWITCH, BACK UP ALARM

SWITCH, HYDRAULIC FILTER PSI.

SWITCH, HYDRAULIC BRAKE

SWITCH, HEATER

SWITCH, FAN

SWITCH, REAR WIPER

SWITCH, FRONT WIPER

SWITCH, LIGHTING SYSTEM

SWITCH, ARTICULATION POSITION

SWITCH, DIFFERENTIAL LOCK

SWITCH, TWO SPEED AXLE

SWITCH, AUTO/MANUAL VIBRATION

SWITCH, VIBRATION LOW FREQ.

SWITCH, VIBRATION HIGH FREQ.

SWITCH, ENGINE OIL PRESSURE

July 1998

3 - 45

SECTION THREE

ELECTRICAL

CAB WIRING

3 - 46

July 1998

WIRE HARNESS 7250/16315

July 1998

3 - 47

3 - 48

July 1998

July 1998

3 - 49

SECTION THREE

ELECTRICAL

3 - 50

July 1998

SECTION THREE

July 1998

ELECTRICAL

3 - 51

SECTION THREE

ELECTRICAL

WIRE CHART 7250/16315 WIRE

COLOR

FROM

TO

1

red

battery + terminal

key switch (S1) terminal 30

2

red

key switch (S1) terminal 30

fuse (F6) terminal 1

3

black/red

key switch (S1) terminal 15

fuse (F1) terminal 1

4

black/red

key switch (S1) terminal 54

fuse (F7) terminal 1

5

black

key switch (S1) terminal 50a

relay (K1) terminal 30

6

black

relay (K1) terminal 87

plug connector (X1) terminal 1

6a

black

relay (K1) terminal 87

plug connector (X1) terminal 2

7

black/red

fuse (F1) terminal 2

plug connector (X1) terminal 6

8

black/red

fuse (F1) terminal 2

relay (K4) terminal 30

9

black/red

relay (K4) terminal 30

relay (K5) terminal 86

10

black/red

relay (K5) terminal 86

relay (K11) terminal 30

11

black/red

relay (K11) terminal 30

horn (H4) + terminal

12

black/red

fuse (F1) terminal 2

fuel gauge (P3) + terminal

13

black/red

fuel gauge (P3) + terminal

engine temp. gauge (P2) + terminal

14

black/red

engine temp. gauge (P2) + terminal

plug connector (X14) terminal 13

15

black/red

fuse (F1) terminal 2

plug connector (X2) terminal 1

16

blue

plug connector (X1) terminal 3

fuse (F2) terminal 1

17

blue

fuse (F2) terminal 2

plug connector (X14) terminal 7

19

blue

fuse (F2) terminal 2

relay (K2) terminal 86

20

blue

relay (K2) terminal 86

diode (V3)

21

violet

diode (V3)

relay (K1) terminal 85

22

violet

relay (K1) terminal 86

relay (K3) terminal 86

23

violet

relay (K3) terminal 86

relay (K4) terminal 87

24

violet

relay (K4) terminal 87

relay (K12) terminal 86

25

violet

relay (K12) terminal 86

plug connector (X14) terminal 9

26

violet

relay (K4) terminal 86

plug connector (X2) terminal 2

27

brown/green

relay (K11) terminal 86

plug connector (X2) terminal 4

28

brown/white

relay (K11) terminal 87

plug connector (X1) terminal 4

29

black/yellow

relay (K3) terminal 30

plug connector (X14) terminal 6

30

black/yellow

relay (K3) terminal 30

brake switch (S3) terminal 3

31

black

relay (K5) terminal 85

relay (K3) terminal 87a

32

black

relay (K3) terminal 87a

diode (V2)

33

black

diode (V2)

relay (K2) terminal 30

34

brown/yellow

relay (K2) terminal 87

horn button switch (S4) terminal S

35

brown/yellow

horn (H4) - terminal

relay (K2) terminal 87

36

brown/yellow

horn button switch (S4) terminal S

diode (V1)

37

red/white

diode (V1)

plug connector (X14) terminal 3

3 - 52

July 1998

SECTION THREE

ELECTRICAL

WIRE

COLOR

FROM

TO

38

red/white

diode (V1)

plug connector (X1) terminal 7

39

green/red

plug connector (X14) terminal 12

plug connector (X4) terminal 1

40

green

plug connector (X14) terminal 8

plug connector (X1) terminal 8

41

black

engine temp gauge (P2) terminal G

plug connector (X1) terminal 9

42

white

fuel gauge (P3) terminal G

plug connector (X1) terminal 10

43

black/yellow

fuse (F7) terminal 2

plug connector (X6) terminal 1

44

black/yellow

relay (K9) terminal 86

plug connector (X6) terminal 2

45

black/red

fuse (F7) terminal 1

relay (K9) terminal 30

46

black/red

relay (K9) terminal 87

fuse (F3) terminal 1

47

black/yellow

fuse (F3) terminal 2

brake switch (S17) terminal 15

48

black/yellow

brake switch (S17) terminal 15

brake switch (S17) terminal 30

49

black/yellow

brake switch (S17) terminal 49

relay (K5) terminal 87a

50

black/yellow

relay (K5) terminal 30

plug connector (X1) terminal 16

51

yellow/white

diode (V6)

brake switch (S17) terminal 30b

52

yellow/white

brake switch (S17) terminal 30b

diff. lock solenoid (Y4) terminal 1

56

gray

fuse (F4) terminal 2

auto vib switch (S7B) + terminal

57

gray

auto vib switch (S7B) terminal S

relay (K6) terminal 85

58

gray

high freq. vib switch (S7) terminal 30

relay (K6) terminal 87

59

gray

high freq. vib switch (S7) terminal 30

low freq. vib switch (S7A) terminal 30

60

gray/green

relay (K6) terminal 87

relay (K12) terminal 30

61

gray/green

auto vib switch (S7B) terminal S2

relay (K12) terminal 87a

62

gray/white

low freq. vib switch (S7A) terminal 15

high freq. vib switch (S7) terminal 30b

63

gray/white

low freq. vib switch (S7A) terminal 49

plug connector (X1) terminal 11

64

gray/red

low freq. vib switch (S7A) terminal 30b

high freq. vib switch (S7) terminal 15

65

gray/red

high freq. vib switch (S7) terminal 49

plug connector (X1) terminal 12

67

gray

fuse (F4) terminal 2

plug connector (X2) terminal 5

73

gray

relay (K9) terminal 86

plug connector (X2) terminal 6

77

blue/yellow

fuse (F5) terminal 2

two speed switch (S8) + terminal

78

blue/yellow

two speed switch (S8) terminal S2

plug connector (X1) terminal 13

79

yellow

fuse (F8) terminal 2

diff. lock switch (S9) terminal S

80

yellow/white

diff. lock switch (S9) terminal S1

plug connector (X1) terminal 14

81

yellow/white

plug connector (X1) terminal 15

light (H7) + terminal

82

yellow/white

light (H7) + terminal

diode (V6)

83

black/gray

fuse (F9) terminal 2

light switch (S11) + terminal

84

black/gray

light switch (S11) terminal S2

temp. gauge light (E1) + terminal

85

black/gray

temp. gauge light (E1) + terminal

fuel gauge light (E2) + terminal

86

black/gray

light switch (S11) terminal S1

relay (K10) terminal 86

90

red

fuse (F6) terminal 1

fuse (F13) terminal 1

91

red

fuse (F13) terminal 2

relay (K10) terminal 30

July 1998

3 - 53

SECTION THREE

ELECTRICAL

WIRE

COLOR

FROM

TO

92

red

relay (K10) terminal 87

light switch (S25) + terminal

93

red

light switch (S25) terminal 1

fuse (F15) + terminal

94

yellow/white

fues (F15) terminal 2

plug connector (X7) terminal 1

95

yellow/white

fuse (F15) terminal 2

plug connector (X1) terminal 20

96

yellow

fuse (F16) terminal 2

plug connector (X7) terminal 2

97

yellow

fuse (F16) terminal 2

plug connector (X1) terminal 21

98

white/black

light switch (S25) terminal 3

fuse (F17) terminal 1

99

yellow/black

fuse (F17) terminal 2

plug connector (X7) terminal 3

100

yellow/red

fuse (F18) terminal 2

plug connector (X7) terminal 4

101

red

fuse (F14) terminal 2

hazard switch (S27) terminal 30

102

black/red

fuse (F12) terminal 2

hazard switch (S27) terminal 15

103

black

hazard switch (S27) terminal 49

relay (K13) terminal 49

104

black

hazard switch (S27) terminal 49

hazard switch (S27) terminal 30b

105

black/yellow

relay (K13) terminal C

plug connector (X14) terminal 5

106

black/yellow

relay (K13) terminal 49a

hazard switch (S27) terminal 49a

107

black/yellow

hazard switch (S27) terminal 49a

directional switch (S26) terminal A

108

black/white

hazard switch (S27) terminal L

directional switch (S26) terminal B

109

black/white

directional switch (S26) terminal B

directional switch (S26) terminal E

110

black/green

hazard switch (S27) terminal R

directional switch (S26) terminal C

111

black/green

directional switch (S26) terminal C

directional switch (S26) terminal F

112

black/white

hazard switch (S27) terminal L

plug connector (X7) terminal 5

113

black/white

hazard switch (S27) terminal L

plug connector (X1) terminal 22

114

black/green

hazard switch (S27) terminal R

plug connector (X7) terminal 6

115

black/green

hazard switch (S27) terminal R

plug connector (X1) terminal 23

120

gray/black

fuse (F11) terminal 2

light switch (S28) + terminal

121

gray/black

light switch (S28) + terminal

light switch (S28A) + terminal

122

gray/black

light switch (S28) terminal S2

plug connector (X9) terminal 1

123

gray/black

light switch (S28A) terminal S2

plug connector (X1) terminal 24

125

gray/black

fuse (F10) terminal 2

accessory plug (X3) + terminal

127

red

fuse (F6) terminal 2

plug connector (X5) terminal 1

160

brown

ground terminal

ground terminal

161

brown

fuel gauge (P3) - terminal

gound wire 160

162

brown

engine temp. gauge (P2) - terminal

fuel gauge (P3) - terminal

165

brown

plug connector (X14) terminal 15

engine temp. gauge (P2) - terminal

166

brown

light switch (S28A) terminal 31

ground wire 160

167

brown

light switch (S28) terminal 31

light switch (S28A) terminal 31

168

brown

horn switch (S4) terminal S1

light switch (S28) terminal 31

169

brown

indicator (H7) - terminal

ground wire 160

170

brown

light switch (S11) terminal 31

indicator (H7) - terminal

3 - 54

July 1998

SECTION THREE

ELECTRICAL

WIRE

COLOR

FROM

TO

171

brown

auto vib switch (S7B) terminal 31

light switch (S11) terminal 31

172

brown

two speed switch (S8) terminal 31

auto vib switch (S7B) terminal 31

173

brown

plug connector (X9) terminal 2

ground terminal

177

brown

plug connector (X1) terminal 31

ground terminal

178

brown

plug connector (X2) terminal 3

ground terminal

179

brown

brake switch (S3) terminal 4

ground terminal

180

brown

plug connector (X4) terminal 2

ground terminal

181

brown

relay (K2) terminal 85

ground terminal

182

brown

relay (K2) terminal 85

relay (K3) terminal 85

183

brown

relay (K3) terminal 85

relay (K4) terminal 85

186

brown

relay (K6) terminal 86

ground terminal

187

brown

relay (K6) terminal 86

relay (K9) terminal 85

188

brown

relay (K9) terminal 85

relay (K10) terminal 85

189

brown

relay (K10) terminal 85

relay (K11) terminal 85

190

brown

relay (K11) terminal 85

relay (K12) terminal 85

191

brown

relay (K12) terminal 85

relay (K13) terminal 85

193

brown

plug connector (X5) terminal 3

ground terminal

194

brown

plug connector (X7) terminal 8

ground terminal

195

brown

diff. lock solenoid (Y4) terminal 2

ground terminal

196

brown

plug connector (X7) terminal 7

plug connector (X7) terminal 8

200

yellow/white

fuse (F15) terminal 2

plug connector (X5) terminal 6

201

yellow

fuse (F16) terminal 2

plug connector (X5) terminal 7

202

yellow/black

fuse (F17) terminal 2

plug connector (X5) terminal 8

203

yellow/red

fuse (F18) terminal 2

plug connector (X5) terminal 9

204

black/white

plug connector (X7) terminal 5

plug connector (X5) terminal 10

205

black/green

plug connector (X7) terminal 6

plug connector (X5) terminal 11

206

gray/black

plug connector (X9) terminal 1

plug connector (X5) terminal 2

207

green

plug connector (X1) terminal 17

plug connector (X5) terminal 4

208

green

plug connector (X1) terminal 18

plug connector (X5) terminal 5

July 1998

3 - 55

SECTION THREE

ELECTRICAL

WIRE HARNESS 7250/16110

3 - 56

July 1998

July 1998

3 - 57

3 - 58

July 1998

SECTION THREE

ELECTRICAL

WIRE CHART 7250/16110 WIRE

COLOR

FROM

TO

1

red

starter motor (M1) terminal 30

altenator (G2) terminal B+

2

black

plug connector (X1) terminal 1

starter motor (M1) terminal 50

2a

black

plug connector (X1) terminal 2

starter motor (M1) terminal 50

3

blue

plug connector (X1) terminal 3

altenator (G2) terminal D+

4

white

plug connector (X1) terminal 10

fuel level sensor (R2)

5

gray

plug connector (X1) terminal 7

engine temp. switch (S5)

6

gray

plug connector (X1) terminal 6

engine shut off solenoid (Y6)

7

green

plug connector (X1) terminal 8

engine oil PSI switch (S6) terminal 4

8

black

plug connector (X1) terminal 9

engine temp. sensor

9

brown/white

plug connector (X1) terminal 4

backup alarm connector (X11) +

10

brown

plug connector (X1) ground terminal

backup alarm connector (X11) -

11

blue/yellow

plug connector (X1) terminal 13

two speed solenoid (Y3) terminal 1

12

brown

plug connector (X1) ground terminal

two speed solenoid (Y3) terminal 2

13

yellow/white

plug connector (X1) terminal 14

articulation switch (S10) terminal 3

14

yellow/white

plug connector (X1) terminal 15

articulation switch (S10) terminal 4

15

gray/white

plug connector (X1) terminal 11

high vib solenoid (Y1) terminal 1

16

brown

plug connector (X1) ground terminal

high vib solenoid (Y1) terminal 2

17

gray/red

plug connector (X1) terminal 12

low vib solenoid (Y2) terminal 1

18

brown

plug connector (X1) ground terminal

low vib solenoid (Y2) terminal 2

19

brown

plug connector (X1) ground terminal

plug connector (X10) terminal 2

20

black/gray

plug connector (X1) terminal 24

plug connector (X10) terminal 1

21

green

plug connector (X1) terminal 17

heater fuel motor (M7) terminal 1

22

green

plug connector (X1) terminal 18

heater fuel motor (M7) terminal 2

23

brown

plug connector (X1) ground terminal

engine oil PSI switch (S6) terminal 3

25

black/green

plug connector (X1) terminal 23

plug connector (X8) terminal 4

26

black/white

plug connector (X1) terminal 22

plug connector (X8) terminal 3

27

yellow

plug connector (X1) terminal 21

plug connector (X8) terminal 2

28

white

plug connector (X1) terminal 20

plug connector (X8) terminal 1

29

brown

plug connector (X1) ground terminal

brake solenoid (Y5) terminal 2

30

black/yellow

plug connector (X1) terminal 16

brake solenoid (Y5) terminal 1

31

brown

plug connector (X1) ground terminal

plug connector (X8) terminal 6

32

brown

plug connector (X8) terminal 6

plug connector (X8) terminal 5

July 1998

3 - 59

3 - 60

July 1998

SECTION FOUR

HYDRAULIC

July 1998

4-1

SECTION FOUR

HYDRAULICS

PUMP SUCTION LINES

4-2

July 1998

SECTION FOUR

July 1998

HYDRAULICS

4-3

HYDRAULIC COOLING SYSTEM

4-4

July 1998

SECTION FOUR

July 1998

HYDRAULICS

4-5

HYDRAULIC DRAIN LINES

4-6

July 1998

DRAIN LINES

July 1998

4-7

HYDRAULIC TEST SYSTEM

4-8

July 1998

SECTION FOUR

HYDRAULICS

HYDRAULIC TEST STATION

A hydraulic pressure test station is located on the right side of the machine, below the operator’s platform. All hydraulic pressures can be measured from this location by using either a VT8002 gauge set or a VT8004 adapter fitting.

July 1998

4-9

4 - 10

July 1998

SECTION FOUR

HYDRAULICS

CHARGE SYSTEM Charge oil is supplied by two separate pumps. A gerotor type charge pump is mounted inside the propulsion pump housing. Flow from the gerotor pump is combined with the return oil from the steering system to fill the necessary charge oil requirements. Supply oil for the propulsion charge pump is drawn from the reservoir. Charge pump output leaves the propulsion pump and joins the steering return oil at the inlet to the filter. Oil discharging from the hydraulic filter returns to the propulsion and vibratory pumps, pump and brake control systems, and the differential lock system.

Charge oil used for servo control of the propulsion pump swash plate, is controlled by a small solenoid valve on the propulsion pump. This valve is sometimes refered to as the brake release valve because of its dual functions of brake and servo control. When activated, this solenoid valve supplies oil to release the brakes and operate the pump servo system. When deactivated oil for brake release and pump servo control is blocked. This causes the brakes to be spring applied and the pump servo to return to neutral. Charge oil from the filter also feeds the vibratory pump and its servo control. Charge pressure can be checked at port #1 of the test station

July 1998

4 - 11

SECTION FOUR

HYDRAULICS

4 - 12

July 1998

SECTION FOUR

HYDRAULICS

PROPULSION SYSTEM The propulsion, or drive system, consists of an engine driven Sauer Sundstrand series 90 variable displacement axial piston pump with bi-directional flow. This pump supplies oil to a drum drive motor and an axle drive motor in a parallel flow path. The drum drive motor is a Poclain model MS25 radial piston type. Some early model 1103’s used a Rexroth MCR20 motor. The drum drive motor may also be equipped with an optional drum drive brake. The axle drive motor is a Sauer Sundstrand 51V axial piston type with a two speed feature.

Charge oil used for servo control of the propulsion pump swash plate, is controlled by a small solenoid valve on the propulsion pump. This valve is sometimes refered to as the brake release valve because of its dual functions of brake and servo control. When activated, this solenoid valve supplies oil to release the brakes and operate the pump servo system. When deactivated oil for brake release and pump servo control is blocked.

The oil from the propulsion pump flows to the front drum motor and the rear axle motor in a parallel path. The front drum motor is a fixed displacement motor while the rear axle motor is a variable displacement motor controlled by a solenoid valve to obtain two drive speeds for the machine. Multifunction valves, located on the bottom side of the pump and set at 450 bar (6500 psi), protect the system from overload.

July 1998

4 - 13

4 - 14

July 1998

SECTION FOUR

July 1998

HYDRAULICS

4 - 15

4 - 16

July 1998

SECTION FOUR

HYDRAULICS

MULTIFUNCTION VALVES Two multifunction valves are located in the high pressure circuit of the Series 90 propulsion pump. Each valve contains a charge check valve, high pressure relief valve, and an adjustable closed loop servo controlled pressure limiting feature. The pressure limiting feature destrokes the pump as pressure approaches the high pressure relief point.

Charge pressure enters the valve near the tip of the valve, passes through the check valve and discharges out the tip, provided the charge pressure is greater than system pressure.

This function maintains the charge pressure in the hydrostatic loop. As high pressure reaches the pressure limiting point, the pressure limiting valve opens and discharges oil to the displacement control valve. Pressure offsets the stroked position of the control valve, destroking the pump, maintaining the system pressure. Servo pressure relief valves limit the pressure of the discharging oil to 750 PSI. In the event of a cold oil start up, the pressure limiting functions in the control valve could see quite a delay. In that case, the main relief valve would open, discharging oil through the charge check port to the charge circuit.

Adjustments of the pressure limiter can be made by inserting a 5 mm Allen wrench into the end of the valve and loosening the jam nut. Rotating the Allen wrench clockwise will increase the point of pressure limiting while rotating the wrench counter clockwise will lower the point of pressure limiting. One revolution of the wrench is equal to approximately 1350 PSI. After adjustment is complete, retorque the jam nut to 12 ft./lbs. Do not over torque!

The by-pass function for towing is accomplished by unscrewing the middle section of the valve three full revolutions. Use a 1 5/8’’ wrench to hold the valve in place. Use a 1 1/16’’ wrench to unscrew the by-pass. After towing is completed, tighten the by-pass and torque to 30 ft./lbs. Do not over torque!

July 1998

4 - 17

SECTION FOUR

HYDRAULICS

PROPULSION SYSTEM DIAGNOSTICS INTERNAL LEAKAGE

All hydrostatic systems require charge pressure to function properly. This is because a hydrostatic system cannot operate at a negative pressure. The charge pump provides a positive pressure to the hydrostatic pump inlet. On the model 1103, normal charge pressure is about 290 PSI and can be checked at port #1 on the test station located in the right side of the machine. Hydrostatic systems are designed to leak a small amount of oil from the pumps and motors for lubrication of parts and cooling, and in some instances, leakage is strictly due to operating clearances. The greater the system pressure the higher this leakage rate. Fresh charge oil will make up for normal system losses.

When components fail, leakage under pressure increases tremendously and is noted by a drop in charge pressure (the charge pump is not capable of keeping up with the hydrostatic system leakage rate). The condition of a hydrostatic pump/motor circuit can be determined by a simple charge pressure test at maximum engine RPM and normal operating temperature. Under the previously mentioned conditions (RPM and temperature), compare the charge pressure readings with the hydrostatic system at no load and maximum load. If these two charge pressure readings show a difference of more than 10%, between the loaded and no load conditions, the hydrostatic system has higher than desired leakage.

After determining that the hydrostatic closed loop system has a higher than desired leakage rate, it is necessary to determine which component is leaking and causing the charge pressure to drop.

One method of isolating the component is to measure the motor case drain flows with the hydrostatic system at no load and maximum load at high engine idle. The component with high internal leakage will have a significantly higher case drain flow when the system is loaded. When using a flow meter in the case drain line, be sure it is properly sized to avoid excessive case drain pressure.

A second method is to cap the pressure lines to the front and rear motors and determine if charge pressure increases to normal. A normal charge pressure reading under these conditions would eliminate the pump as the problem. A low charge pressure reading with the motors blocked indicates a pump or charge relief problem. With the pump isolated and at a no stroke condition, there should be normal charge pressure. If the pressure is low, the first place to look is at the charge relief valve.

4 - 18

July 1998

SECTION FOUR

HYDRAULICS

The next step is to reconnect one drive motor and rerun the charge pressure test. A normal charge pressure reading would eliminate that motor as the source of leakage. A low charge pressure reading would indicate that the motor has high internal leakage. Reconnect the second drive motor and repeat the test. If a drive motor has a leakage problem, it should have been isolated by this test.

Remember, the failure of one component in a hydrostatic system can cause contamination throughout the entire system. Prior to installing the new or rebuilt component, the entire system must be disassembled and cleaned. This includes all pumps, motors, valves, coolers, hoses, and reservoirs.

PUMP SERVO CONTROL Charge system oil is supplied to the pump’s servo control through a solenoid valve located at the top rear of the pump assembly. A control cable to the operator’s platform is used to stroke the pump’s internal servo control valve. Small orifices are installed into the servo valve to help control the stroke rate.

If the machine moves in the neutral position, check the adjustment of the control cable. If the cable is adjusted properly the machine could be having brake problems.

If the machine does not move in forward or reverse when the operator’s control lever is moved, check for a problem (possibly electrical) in the solenoid valve. As a quick check, see if the brake release pressure, which is also controlled by this solenoid valve, is at 290 PSI. For more information on troubleshooting electrical problems refer to the electrical section of this manual.

If the machine does not move or moves slowly and charge pressure is at its normal level, it is possible that leakage in the servo control cylinder is greater than the amount of oil allowed through the servo valve orifices. Servo gauge ports M4 and M5 on the pump can be used to test the servo pressure at the servo cylinder.

July 1998

4 - 19

4 - 20

July 1998

SECTION FOUR

HYDRAULICS

VIBRATION SYSTEM The vibration circuit consists of a Sunstrand Sauer Series 90 pump providing oil to a Sunstrand Sauer SF4 vibration motor. The pump is a variable displacement axial piston design with bi-directional flow, while the motor is a fixed displacement, bi-directional, axial piston style.

Machines with smooth drums have two frequency ranges while the padfoot drum operates with just the lower frequency. When high frequency is desired, the solenoid controlled pump is stroked to provide oil at a 42 cc per revolution rate to the vibration motor. This results in a vibration frequency of 2160 vibrations per minute, rotating the vibration shaft in a clockwise direction with a centrifugal force of 24053 lbs. When low frequency is desired, the solenoid controlled pump is stroked in the opposite direction, to provide oil at a 32 cc per revolution rate to the vibration motor. This results in a vibration frequency of 1680 vibrations per minute, rotating the shaft in a counter clockwise direction with a centrifugal force of 47211 lbs.

July 1998

4 - 21

SECTION FOUR

HYDRAULICS

4 - 22

July 1998

SECTION FOUR

HYDRAULICS

Push button switches on the operators control panel provides the options of frequency as well as automatic vibration off in neutral. A thumb switch at the top of the forward reverse control handle enables the operator to start and stop vibration.

Two multifunction valves in the vibration pump, set at 350 bar (5075 PSI), protect the vibration circuit from excessive pressure, in the same manner as in the propulsion circuit. The top valve controls the pressure when operating at the 2160 VPM frequency, low amplitude. The 1680 VPM low frequency, high amplitude pressure is controlled through the bottom valve.

Start up pressure may be as high as 350 bar (5075 PSI) but will drop between 100 bar (1450 PSI) and 150 bar (2200 PSI) once the operating speed of vibration is obtained.

VIBRATION FREQUENCY

This drawing illustrates a typical exciter shaft and the two overturning weights used to change the amplitude on a vibratory roller.

The shaft rotation can be faster in one direction and slower in the other direction. These two speeds create the two frequencies available on some models. The amplitude is changed by the use of overturning weights. In one direction the overturning weights are opposite the shaft counterweight and create a low amplitude vibration. When the shaft is rotated in the opposite direction the overturning weights are transferred to the same side as the shaft counterweight causing an increase in amplitude. This design allows for a LOW amplitude when the frequency is HIGH and a HIGH amplitude when the frequency is LOW.

July 1998

4 - 23

SECTION FOUR

HYDRAULICS

The models which offer only one frequency do not reverse the direction of shaft rotation nor do they use the overturning weight design. For additional information on this subject contact your Vibromax dealer. model

freq#1

freq#2

ampl#1

ampl#2

1103D

28Hz

36Hz

1.6mm

0.6mm

1103PD

28Hz

N/A

1.6mm

N/A

1103HD

28Hz

36Hz

1.6mm

0.6mm

1103HPD

28Hz

N/A

1.6mm

N/A

LOW FREQUENCY

HIGH FREQUENCY

4 - 24

July 1998

SECTION FOUR

HYDRAULICS

VIBRATION AMPLITUDE

HIGH AMPLITUDE LOW FREQUENCY

AMPLITUDE

h1

TIME in seconds

h2

LOW AMPLITUDE HIGH FREQUENCY

h1 and h2 above = Jumping Height 1/2 of h1 or h2 = Amplitude

JUMPING HEIGHT

July 1998

AMPLITUDE

4 - 25

One half the vertical distance that the drum travels is called the amplitude. The amplitude for any given machine will vary depending on the soil conditions. The amplitude and the height the machine lifts itself off the ground will gradually increase as the soil becomes more dense or compacted.

SECTION FOUR

HYDRAULICS

VIBRATORY SYSTEM DIAGNOSTICS The 1103PD (padfoot) models have one vibration frequency of 1680 vibrations per minute (28 Hz). Padfoot models also use a single offset shaft without overturning weights. The vibration motor will only rotate in one direction due to machine control configuration.

The 1103D (smooth drum) models are equipped with two overturning weights. The vibration shaft is bi-directionally rotated to obtain a vibration frequency of 1680 vibrations per minute (28 Hz) in one rotational direction and 2160 vibrations per minute (36 Hz) with the opposite direction of rotation.

Vibration frequency is related to the speed at which the vibration shaft is rotated and can be measured with a frequency meter. Low frequency problems will normally show up as a rough riding machine (often referred to as bucking). Operation at higher than recommended frequency will manifest itself as a shortened vibratory bearing life.

Vibromax Part No. VT9013

To increase or decrease the shaft speed requires more or less flow from the vibration pump.

Before making adjustments on the pump displacement controls always check that the engine operating speed is set to maximum (2500 rpm) and pressure test the system to insure that the system is functioning properly. Hydraulic pressures can be tested at taps #3 and #4 of the hydraulic test station. Start up pressure may be as high as 350 bar (5075 PSI) but should drop between 100 and 150 bar (1400 and 2200 PSI) once operating speed has been obtained.

Two multifunction valves in the vibration pump, set at 350 bar (5075 PSI), protect the vibration system from excessive pressure. The top valve controls the pressure when operating at high frequency and low amplitude. The low frequency high amplitude circuit is controlled through the bottom valve.

4 - 26

July 1998

SECTION FOUR

HYDRAULICS

STEERING SYSTEM

The steering circuit consists of a fixed displacement gear pump mounted onto the back of the vibration pump, a steering control valve (steering orbitrol) and two steering cylinders at the articulation joint. Oil is supplied from the reservoir to the steering pump. The oil from the pump is directed to the steering control valve at Port P. If a steering correction is not required, oil will pass through the valve and discharge out Port T, flow through the filter and enter the propulsion and vibration circuits as charge oil. Oil in the L and R passages as well as the oil in the steering cylinders is trapped and cannot flow, thus the machine maintains its steering direction. When a steering correction is required as dictated by rotation of the steering wheel, the control valve meters a portion of the oil from the P port to the L or R port (dependent on the direction the wheel is rotated) and to the steering cylinders. The resultant stroking of the cylinders causes the machine to turn. As oil is admitted into one end of the cylinders, oil discharges from the opposite end and returns to the valve, discharges out port T to the filter and on as charge pressure.

Three relief valves are designed into the steering system. Working pressure is controlled at 140 bar (2030 PSI) by the relief in port P. This pressure can be checked at port #2 of the hydraulic test station. Two port safety reliefs, set at 200 bar (2900 PSI), are built into cylinder ports L and R. These port relief valves protect the steering cylinder and work lines from being over pressurized while the oil is trapped by the steering hand valve (orbital motor).

July 1998

4 - 27

4 - 28

July 1998

SECTION FOUR

HYDRAULICS

STEERING SYSTEM

July 1998

4 - 29

SECTION FOUR

HYDRAULICS

PARKING BRAKE SYSTEM

A spring applied, hydraulically released, multi-disc brake is built into the drum drive motor.

Pilot pressure is used to release the brake. Without pilot pressure, the spring keeps the brake applied.

The standard rear axle uses a band brake at the intermediate gear box which is activated by a spring loaded cylinder. The cylinder is stroked by the application of pilot pressure, releasing the brake. The heavy duty rear axle has a shoe and drum brake at each axle end, or a multidisc brake at the intermediate gear box.

The brakes are controlled by a push button on the dash or by the emergency stop button on the direction console. When the brake switch on the dash is depressed, hydraulic pressure is removed from the brake circuit and the brakes become applied through spring force. The brake switch also activates the differential lock solenoid for improved brake holding. When the emergency stop switch is activated, the brake pressure is removed and the springs apply the brakes, the vibration circuit is turned off, the two speed motor is placed in low range, the differential lock is applied and the drive system stops.

4 - 30

July 1998

SECTION FOUR

HYDRAULICS

TOWING YOUR MACHINE A tow valve, located under the operators seat, is used to release the brakes on a machine that must be moved when the engine will not run. Place the valve in the tow position and turn the steering wheel to the right. The mechanical effort of turning the steering wheel will create sufficient pressure to release the brakes. That, in conjunction with unscrewing the multifunction valves will allow the machine to be towed. WARNING! Operating the machine with the tow valve in the tow position will cause brake system damage.

Multifunction valves

PARKING BRAKE DIAGNOSTICS The parking brake is spring applied and hydraulic pressure released. When the brake/servo valve is activated pressure is applied to release the brake and operate the pump controls.

When the pump control is engaged the brake should release. If the machine makes an effort to move after engaging the forward/reverse lever (engine seems to load down), the solenoid valve must be working. This would be an indication of a mechanical hang up in the brake. If you are able to drive the machine but the parking brake does not engage with the brake button activated this could indicate a mechanical hang up, or worn brake discs. To get the actual brake pressure reading requires teeing into the line to the pressure switch located on the tow valve. It should be mentioned here that this pressure switch is used to control the brake indicator light on the instrument panel.

July 1998

4 - 31

4 - 32

July 1998

July 1998

4 - 33

SECTION FOUR

HYDRAULICS

4 - 34

July 1998

SECTION FOUR

HYDRAULICS

DIFFERENTIAL LOCK SYSTEM

The differential lock is a spring applied, hydraulically released clutch that allows the operator to lock the differential. This results in both wheels rotating as a unit, which provides an improvement in machine traction.

Normal operation of the machine is conducted with the differential lock in the hydraulically released position. This allows for a differential action on the axle when turning the machine.

When increased traction is required, depressing the push button on the instrument panel, activates a solenoid which removes hydraulic pressure from the differential lock, allowing the lock to engage.

A zero angle switch, mounted at the articulation joint, disables the solenoid if the machine is not travelling in a straight ahead direction. The differential lock can not engage if the machine is turning.

July 1998

4 - 35

4 - 36

July 1998

SECTION FOUR

July 1998

HYDRAULICS

4 - 37

HYDRAULIC SCHEMATIC

SECTION FIVE

FINAL DRIVES

July 1998

5-1

SECTION FIVE

FINAL DRIVES

GENERAL INFORMATION The rear drive axle consists of a hydraulic drive motor, intermediate gear box, differential gears, differential lock, and planetary gear drive. Three types of axles have been used on the model 1103. The standard axle in the 1103 is the same Speth design used in the last model 1102. This axle is common to 1103D and 1103PD. The 1103HD and 1103HPD are equipped with a heavy duty Speth or a heavy duty Kessler axle. The Speth heavy duty is new to the model 1103 but the Kessler design has been previously used by Vibromax on the model 1402.

To identify a Speth axle look for the Speth name cast into the planetary end covers. The visible differences between the standard and heavy duty Speth axles are the larger drive motor on the heavy duty axle and the change in the brakes. The standard Speth axle is equipped with a band type brake on the intermediate gearbox input shaft which is actuated by a small hydraulic cylinder. The heavy duty Speth axle brake is a self contained hydraulic disc type also on the intermediate gearbox input shaft.

The Kessler heavy duty axle is easily identified by the large wheel brakes at the axle ends.

The major housing is also made of welded pieces while the Speth axles uses cast pieces.

All 1103 models use a Sauer Sundstrand series 51 bent axis hydraulic drive motor however, the heavy duty models have a larger displacement motor for added torque and better gradeabilty. These drive motors come with a standard two speed feature which allows the machine to have two travel speeds. The normal position for the two speed feature is low range. A switch on the instrument panel is used to activate high range.

5-2

July 1998

SECTION FIVE

FINAL DRIVES

OPERATION The axle drive motor is driven in a parallel flow path with the front drum motor. The output shaft of the axle drive motor is connected to the input shaft of the rear axle intermediate gear box. The intermediate gear box drives the differential through the differential pinion shaft.

Torque is transferred via the axle shaft and axle shaft gear to the planetary gears.

The three planetary gears turn in a fixed internal ring gear and drive the wheel hub.

The left hand axle tube is equipped with a differential lock mechanism. This mechanism is a spring applied and hydraulic pressure released device. As soon as the engine is started hydraulic charge pressure is ported to the differential lock cylinder to release the lock. The differential lock can be engaged by means of a switch on the instrument panel which shifts a valve to block the charge pressure and port the differential lock cylinder to tank. Once the hydraulic pressure is removed spring force is allowed to lock the differential. It should be noted that the differential will not lock if the machine is turning.

July 1998

5-3

SECTION FIVE

FINAL DRIVES

KESSLER AXLE

This manual will not go into detail on the disassembly or assembly procedures for the Kessler heavy duty axle. Very few model 1103H machines were produced with this axle. The repair procedures for these units are available in sections 6001 and 7001 of the 1402 service manual. Copies of these sections of the 1402 service manual are available through Vibromax.

5-4

July 1998

SECTION FIVE

FINAL DRIVES

SPETH STANDARD AXLE

The remainder of this section of the manual will deal with the disassembly and assembly of the standard Speth axle. The main items of concern are also applicable to the Speth heavy duty axle.

July 1998

5-5

SECTION FIVE

FINAL DRIVES

REAR AXLE REMOVAL 1. Place the machine on a level surface, lock the articulation joint, and block the front drum.

2. Drain the hydraulic reservoir by removing the return hose from the bottom of the vibration drive motor and catching the oil in a clean container. The hydraulic tank capacity is approximately 18.5 gallons (70 liters).

3. Loosen the lock nut and turn the parking brake adjustment screw out as far as possible.

4. Remove the split pin from the brake cylinder rod pin and pull the pin out of the cylinder yoke. NOTE: The cylinder is under spring load.

5. Remove the electrical connector from the axle drive motor two speed valve.

6. Tag, remove, and cap the hydraulic lines from the axle drive motor and differential lock.

7. Loosen the rear wheel lug nuts.

8. Lift the rear of the machine until the rear wheels are clear of the ground.

9. Support the machine rear frame with jack stands.

10. Remove the wheel lug nuts and pull the wheels from the axle.

CAUTION: tires are liquid filled and approximate weight is 1294 lbs. (587 kg.). Use proper lifting equipment to remove the tires.

11. Support the axle at the center with a floor jack and remove the axle mounting bolts from both sides of the frame. Lower the axle to the ground.

5-6

July 1998

SECTION FIVE

FINAL DRIVES

REAR AXLE INSTALLATION 1. Position the axle under the machine frame rails. Install and tighten the axle bolts to 295 ft lbs. (400 Nm.).

2. Install both wheels with snug wheel lug nuts.

3. Remove the jack support stands from under the machine and allow the machine to sit on the ground.

4. Tighten and torque the wheel nuts to 288 ft lbs. (390 Nm.).

NOTE: Re-tighten the wheel nuts every 8 hours until nut torque stabilizes.

5. Reconnect the hydraulic lines to the axle drive motor. Use tie straps to group the hoses.

NOTE: Be sure to fill the hydraulic motor case with oil!

6. Reconnect the electrical plug on the two speed valve.

7. Install the brake lever into the brake cylinder yoke and install the pin. Secure the pin with a new split pin.

8. Adjust the brake using the setting screw. The proper setting is measured between the cylinder end cap and the end of the cylinder rod. This measurement should be 1.0 inch (25.4 mm).

9. Refill the hydraulic reservoir with 18.5 gallons (70 liters) of filtered hydraulic fluid.

10. Fill the planetary drives with SAE 90 API GL-5 oil until it flows from the filler plug hole in the planetary drive hub. Be certain that the drain plug in the hub is located at the bottom of rotation during filling.

July 1998

5-7

SECTION FIVE

FINAL DRIVES

11. Remove the axle tube breather and fill with SAE 90 API GL-5 oil until it flows from the plug hole in the differential housing.

12. Remove the breather from the intermediate gear box and fill with SAE 90 API GL-5 oil until it flows from the plug hole in the intermediate gear box cover.

AXLE TUBE DISASSEMBLY NOTE: The wheel hub and planetary can be removed and serviced without axle removal but the following instructions assume the final drive is removed from the machine.

1. Mark the axle tubes and differential housing to ensure correct alignment during assembly.

2. Remove the bolts holding the axle tubes to the differential housing and remove the tube and planetary assemblies from the differential. Note that the left axle tube contains the differential lock mechanism.

3. Remove the differential lock compression spring, shifting ring, and shifting ring washer from the left axle tube assembly.

4. Place the tube and hub assembly on a support with the planetary facing up.

5-8

July 1998

July 1998

5-9

SECTION FIVE

FINAL DRIVES

PLANETARY DISSASSEMBLY 1. Remove the planetary cover bolts (32) and remove the cover (30).

2. Pull out the axle shaft. The axle shaft gear and bearing can now be removed from the shaft by removal of the retaining ring (29) and supporting ring (26). An external puller is required to remove the bearing (28).

3. Remove the planetary carrier capscrews (14). Use two M12 jacking bolts in the two holes provided in the planetary carrier (22) to loosen and remove the planetary carrier.

4. After removal of the planetary carrier (22), press the planetary gear pins (18) out of the gears (21).

5. Move each planetary gear into the center opening and remove it downward out of the carrier.

6. Remove the two planetary gear thrust washers (17), needle bearing rollers (19), and separating washers (20) from the planetary gears.

7. Returning to the wheel hub and axle tube assembly remove the old o-ring (7) from the wheel hub (6).

8. Remove the locking screw (12) from the large slotted nut (11) which holds the wheel hub to the axle tube (1). Loosen the slotted nut and remove the internal ring gear (16) with the drive gear (10) still installed.

9. Remove the snap rings (9) from the internal gear and remove the drive gear (10).

10. An external gear puller can now be used to remove the tapered roller bearing (8) from the drive gear.

11. Install two 12mm eye bolts into the wheel hub 180 degrees apart. Install a puller into the eye bolts and pull the wheel hub off the axle tube.

12. The bearing cup, bearing cone (5), and seal (4) can now be driven out of the wheel hub.

13. Remove any damaged wheel lug bolts (2) from the hub (6).

5 - 10

July 1998

July 1998

5 - 11

SECTION FIVE

FINAL DRIVES

DIFFERENTIAL LOCK REMOVAL

1. Remove the differential lock hydraulic fitting.

2. Using the appropriate tooling compress the piston (9) and inside compression spring (6).

3. Remove the snap ring (3) with an internal snap ring pliers.

4. Carefully remove the pressure applied by the compression spring allowing the piston to push outward.

5. Use an internal puller to pull the differential lock cylinder bushing (8) out of the axle tube.

6. The piston can now be removed for replacement of seals.

7. Remove the inner compression spring (6).

8. Remove the flanged bushing (5)

5 - 12

July 1998

SECTION FIVE

FINAL DRIVES

DIFFERENTIAL LOCK ASSEMBLY 1. Install new inner and outer seals in the differential lock cylinder bushing (8).

2. Install new seals on the piston (9).

3. Lubricate the piston seal and install the piston into the cylinder bushing so that the notch in the piston is aligned exactly in the center of the hole in the cylinder bushing.

4. Install the flanged bushing (5) into the axle tube.

5. Install the inner compression spring (6).

6. Lubricate the cylinder seals and install the cylinder unit into the axle tube making sure that the hole in the cylinder, which shows the piston groove, is aligned with the threaded fitting hole in the axle tube.

7. Using proper tooling apply a force to the piston so as to compress spring (6) while maintaining the alignment of the piston notch in the threaded hole.

8. Install the hydraulic fitting (10).

9. Install the snap ring (3).

10. Remove the force against the piston and allow the snap ring to seat properly.

11. Conduct an air leak down test at 85 PSI (6 bar) by applying air pressure to the hydraulic fitting port. The trapped pressure in the cylinder should not decay from the 85 PSI level during a one minute decay test.

12. With air pressure still applied to the piston you should be able to easily push the piston in with hand pressure applied to the piston.

13. Remove the air line.

July 1998

5 - 13

SECTION FIVE

FINAL DRIVES

AXLE TUBE AND PLANETARY ASSEMBLY 1. Install the bearing cup for the tapered roller bearing (6) into the wheel hub (5). Press the bearing cup into the shoulder in the hub.

2. Install the tapered roller bearing cone (6) into the wheel hub.

3. Apply Permatex sealant to the outer edge of seal ring (7) and press the seal into the wheel hub.

4. Turn the wheel hub over. Install the bearing cup for tapered roller bearing (4) into the wheel hub (5). Press the bearing cup into the shoulder in the wheel hub.

5. Coat the bearing surface on the axle tube (8) with Molycote grease.

6. Guide the wheel hub over the axle tube.

7. Press the wheel hub onto the axle tube until bearing (6) is seated on the axle tube. Use of a bearing driving tool is recommended. Rotating the hub during installation will help to seat the tapered bearing.

8. Pour some SAE 90 oil into the wheel hub to lubricate the bearing.

9. Press the bearing cone for the tapered roller bearing (4) onto the drive ring gear (10).

10. Install the drive ring gear (10) into the internal ring gear (11) and retain it with the two large snap rings.

11. Install the internal ring gear and drive ring gear assembly onto the axle tube splines.

12. Apply Loctite 592 to the threads of the slotted nut and axle tube.

13. Install the slotted nut (3) and tighten it to 140 ft lbs (190 Nm). After tightening, back off the slotted nut approximately 22 degrees and install the locking screw to 7.5 ft lbs (10 Nm.)

5 - 14

July 1998

SECTION FIVE

July 1998

FINAL DRIVES

5 - 15

5 - 16

July 1998

SECTION FIVE

FINAL DRIVES

14. Install o-ring (7) on the wheel hub.

15. Coat the inside of the planetary gear (21) with grease and install the needle bearings (19) into one side of the planetary gear.

16. Install the two separating rings (20) into the planetary gear from the opposite side. Coat the remainder of the inside of the planetary gear with grease and install the needle bearings.

17. After preparing the three planetary gears apply grease to the thrust washers (17) and install onto the planetary gear.

18. Carefully install the planetary gear into the planetary carrier (22) from bottom side of the carrier moving it upward in the center position then sliding it into the side position. Make sure the thrust washers and needle bearings stay in position.

19. Align the planetary gears with the holes in the carrier. Install the planetary pins with the tapped holes facing upwards toward the cover plate (30). The threaded holes should be facing the outside of the carrier.

Note: The threaded holes in the pins are used to secure the cover (bolt 34) and must be aligned with the bolt pattern of the other cover holes tapped into the carrier.

20. Install the planetary carrier assembly over the axle tube. Install the planetary bolts (14) and washers (13) and tighten to 89 ft. lbs (120 Nm).

21. Install the bushing (24) over the axle shaft.

22. Install the axle gear (25) over the axle shaft.

23. Install two spacer washers (26) onto the axle shaft.

24. Install the snap ring (27) onto the axle bearing (28). Heat the bearing to 1450F and install onto the shaft with the snap ring facing outwards. Make sure the bearing is against the shoulder and allow to cool.

25. Install one spacer washer (26) onto the shaft and install the snap ring (29).

26. Install the axle shaft into the axle tube.

27. Install a new cover o-ring. Apply Permatex 300 to the outer carrier surface. Install the cover. Apply Permatex 300 to the cover bolts. Tighten 12mm bolts to 88 ft lbs (120 Nm) and the 10mm bolts into the planetary pins to 51 ft lbs (69 Nm).

July 1998

5 - 17

SECTION FIVE

FINAL DRIVES

INTERMEDIATE GEARBOX DISASSEMBLY 1. Disconnect the axle drive motor from the intermediate gearbox.

2. Remove the brake drum retaining capscrew (10) and remove the brake drum with an external puller.

3. Disconnect the brake release springs from the brake shoes and remove the brake shoes.

4. Remove the snap ring and washer from the brake lever and remove the brake lever from the lever pin.

5. Remove the capscrews from the intermediate gearbox cover. Use two 10x80mm jack screws to force the cover off the gearbox housing.

6. Remove the intermediate gear shaft lock plate (31).

7. Using a piece of wood or hard plastic, lock the gears and remove the collar nut on the spur gear. The spur gear is the large gear mounted on the differential input shaft.

8. Using a soft driving pin drive out the intermediate gear shaft and the input pinion shaft.

You must work alternately between the two shafts as you are driving them out. As you pull the two shafts watch for any shims which might be installed.

9. Remove the spur gear from the differential input pinion shaft with an internal puller.

10. Press the inner and outer bearings off of the intermediate gearbox input pinion shaft.

11. Press the intermediate gear off the intermediate gear shaft.

12. Remove the intermediate gear bearing cones and shim spacer.

13. Remove both bearing cups from the intermediate gear with an internal puller.

14. Remove the snap ring from the intermediate gear.

5 - 18

July 1998

July 1998

5 - 19

SECTION FIVE

FINAL DRIVES

INTERMEDIATE GEARBOX ASSEMBLY 1. Press the two new ball bearings onto the intermediate gearbox input pinion shaft.

Remember to install the snap ring on the outboard bearing (8) and press the bearing on so as to have snap ring toward the gear teeth.

2. Install the snap ring into the intermediate gear and press in the two bearing cups.

3. Install the two bearing cones into the intermediate gear with the spacer shim between the two cones. These parts are offered as a matched set under part number V40128.

4. Press the intermediate gear shaft into the gear with the shaft’s grooved end up.

Press the shaft in until it protudes 0.8 inch (2cm) through the gear. This measurement is from the gear face to the end of the shaft.

5. Apply pressure to the inner bearing race of the intermediate gear bearings and check that the intermediate gear turns freely. The end play of the intermediate gear should be 0.0008 inch (0.02 mm). End play is set by grinding the spacer shim to size.

6. After seating the intermediate gear shaft and bearings, install a new o-ring in the groove of the intermediate gear shaft.

5 - 20

July 1998

SECTION FIVE

FINAL DRIVES

7. Replace the old input pinion shaft seal in the gearbox housing.

8. Install the large output shaft gear driving it onto the shaft with a plastic hammer.

9. It is necessary to check the input pinion gear for proper end play of 0.008 to 0.012 inch (0.2 to 0.3 mm). To check end play measure the distance from the housing seal surface to the pinion shaft bearing contact surface in the housing (measurement “a”). Measure the distance from the sealing face of the intermediate gearbox cover to the contact surface of the pinion bearing snap ring (measurement “b”). Using a calipers measure the length of the pinion shaft from the bottom of one pinion bearing to the outside edge of the second bearing’s snap ring (measurement “c”).

Pinion shaft clearance = (a + b) - c If needed, shims can be added under the pinion bearing which seats into the intermediate gearbox housing.

10. Install the pinion and intermediate gears making sure that the gear teeth are meshed.

Care must be taken not to damage the input pinion shaft seal or the intermediate shaft o-ring.

NOTE: Make sure the orientation of the intermediate gear shaft is correct. The slot in the shaft must be aligned for the lock plate to be installed.

11. Use a suitable tube driver on the bearing inner race to seat the intermediate gear shaft then seat the pinion shaft with a plastic hammer.

12. Install the lock plate in the groove in the intermediate gear shaft.

13. Install the collar nut onto the output shaft using Loctite 271. Use a piece of wood or plastic to hold the gear and tighten the collar nut to 332 ft lbs (450 Nm). Secure the collar nut by driving the edge of the nut into the shaft groove.

14. Apply Permatex 300 sealer to the sealing surfaces of the intermediate gearbox and install the cover using a plastic hammer to seat the cover. Install the cover capscrews and tighten to 51 ft lbs (69 Nm).

15. Install the brake lever and washer. Secure with the snap ring.

16. Install the brake shoes and shoe return springs.

17. Install the parallel key into the pinion shaft and install the brake drum. Secure the drum with the washer, lock washer, and retaining capscrew. Torque the capscrew to 93 -112 ft lbs (125 - 150 Nm).

18. Install a new o-ring on the drive motor flange and install the drive motor.

July 1998

5 - 21

SECTION FIVE

FINAL DRIVES

DIFFERENTIAL DISASSEMBLY 1. Remove the axle tubes.

2. Remove the intermediate gears.

3. Make an alignment marking between the axle housing (19) and the intermediate gearbox housing. Remove the capscrews that attach the intermediate gearbox housing to the axle housing and remove the intermediate gearbox.

4. Remove the old shaft seals from the intermediate gearbox housing.

5. Press the bearing flange (27) out of the axle housing (19) using two 12x120 mm jacking screws in the threaded holes provided in the flange.

6. Remove the shims (26) from the bearing flange.

NOTE: Write down the number and size of these shims. Install the same amount of shims during assembly.

7. Press the differential pinion shaft out of the tapered roller bearings (22) in the bearing flange (27). Press the bearing cone off the pinion shaft. Watch for the spacer (24) and any shims (23) during disassembly.

NOTE: The pinion shaft and ring gear are matched sets and must be replaced as such.

8. Remove the outer bearing cup and shaft seal from the bearing flange.

9. Remove the capscrews (11) from the gear cover (15) and remove the gear cover.

10. Remove the bearing cup and shims from the gear cover.

NOTE: Write down the number and size of these shims. Install the same amount of shims during assembly.

11. Install two 12mm eyebolts into the tapped holes provided in the differential housing (1) and remove the differential.

12. Remove the remaining snap ring (33), ring (32), shims (16), and bearing cup from the axle housing. NOTE: Write down the number and size of these shims. Install the same amount of shims during assembly.

13. Use an external puller to remove the two bearing cones from the differential housing.

14. Remove the capscrews holding the ring gear (20) to the differential housing. Use two 12x40mm jacking screws to separate the ring gear from the housing.

NOTE: Only disassemble the differential if repairs are needed.

5 - 22

July 1998

July 1998

5 - 23

SECTION FIVE

FINAL DRIVES

15. Remove the capscrews which hold the two parts of the differential housing together.

Before separating the two housing parts note that there should be alignment markings on the parts.

16. Remove the differential bevel gears and thrust washers.

DIFFERENTIAL ASSEMBLY 1. Apply oil to the contact area for the thrust washers in the differential housing halves (1) and install the thrust washers (2).

2. Install the bevel gears (3) in the differential halves.

3. Install the bevel spider gears (6) on the bevel gear shafts (4) with thrust washers (6).

4. Install the first set of bevel spider gears and shaft into the housing.

5. Install the second set of bevel spider gears with shaft onto the first set.

6. Assemble the second half of the differential housing to the half containing the spider gears. NOTE: Align the housing markings.

7. Install the differential capscrews using Loctite 271 and tighten to 51 ft lbs (69 Nm).

8. Install the ring gear insuring alignment of the capscrew and roll pin holes. NOTE: If a new ring gear is installed the pinion shaft must also be replaced. Make sure the ring and pinion have the same identification numbers.

9. Install the two roll pins (9 and 10) with the small fitting into the larger.

10. Install the ring gear capscrews using Loctite 271 and tighten to 88 ft lbs (120 Nm).

11. Preheat the differential bearing cones to 1750F (800C) and install on the differential halves.

12. Install the snap ring (33) into the groove in the axle housing (19).

13. Install the support ring (32) and the same amount of shims (16) that were removed during disassembly.

14. Install the outer bearing cup.

15. Apply a marking agent to three areas of the ring gear and install the differential assembly into the axle housing using two 12mm eyebolts.

16. Install the shims and bearing cup into the gear cover (15).

5 - 24

July 1998

July 1998

5 - 25

SECTION FIVE

FINAL DRIVES

17. Install the gear cover and tighten the capscrews to 50 ft lbs (69 Nm). NOTE: Do not apply any sealant until the shimming has been set.

18. Press the new tapered bearing cone (22) onto the pinion shaft (21).

NOTE: If a new pinion gear is installed the ring gear must also be replaced. Make sure the ring and pinion have the same identification numbers.

19. Install the spacer bushing (24) and shim (23) onto the pinion shaft.

20. Install lip seal (25) into the bearing flange (27) until it is seated 1.9 inch (49mm) below the face of the flange. Apply a sealant to the bearing flange prior to installation of the seal.

21. Install the outer and inner bearing cups into the bearing flange.

22. Install the pinion shaft into the bearing flange and install the outer bearing cone. With a 10 ton load applied to the bearing cone the rolling torque of the bearing flange should be 7 ft lbs (10 Nm). A thicker shim will lower rolling torque and a thinner shim will increase rolling torque. A new spacer shim (23) will normally have to be ground to size.

23. Install a suitable spacer over the pinion shaft ( in place of spur gear 28) and secure in place with collar nut (29). In preparation for differential set up torque the collar nut to 327 ft lbs (450 Nm).

24. Install two 12x20mm guide screws into the axle housing and install the shims (26) and the pinion assembly. Secure the bearing flange with four capscrews torqued to 88 ft lbs (120 Nm).

25. Rotate the pinion shaft several rotations in both directions then remove the bearing flange and note the contact area on the ring gear.

5 - 26

July 1998

July 1998

5 - 27

SECTION FIVE

FINAL DRIVES

26. Change shims (16) on the left or right side of the differential or shim (23) on the input pinion shaft to make corrections in the tooth contact area.

27. When differential setup is complete apply a sealing medium to the sealing surfaces of the gear cover (15) and the axle housing (19) and finish installation of the gear cover.

Tighten the capscrews to 50 ft lbs (69 Nm).

28. When differential setup is complete apply a sealing medium to the contact surfaces of the bearing flange (27), shims (26), and axle housing (19) and finish installation of the bearing flange.

29. Apply sealant to the shaft seal (25) and install in the intermediate gearbox housing.

30. Install the intermediate gearbox housing using the alignment marks previously made.

Tighten the capscrews to 88 ft lbs (120 Nm).

5 - 28

July 1998

SECTION FIVE

FINAL DRIVES

DRUM REMOVAL 1. Disconnect, tag, and cap the hydraulic lines for the drum drive motor on the left side of the machine. Plug the motor ports.

2. Disconnect, tag, and cap the hydraulic lines for the vibration motor on the right side of the machine. Plug the motor ports.

3. Block and support the front frame of the machine.

4. Remove the drive motor adapter (89) to frame bolts (102) on the left side of the machine.

5. Remove the front and rear buffer brackets (10) on the rights side of the machine.

6. Remove the front scraper bar from the machine.

7. Roll or lift the drum out of the front frame. Smooth drum weight = 9372 lbs (4250 kg) Padfoot drum weight = 10,197 lbs (4625 kg)

DRUM INSTALLATION 1. Roll or lift the drum into position in the machine’s front frame. The drum must be positioned for alignment of the drive motor bracket to the left side frame bolt holes.

2. Install the bolts in the front and rear buffer brackets on the right side of the machine. This will allow the machine frame to be lowered or raised as needed to complete alignment of the drive motor bracket on the left side of the machine.

3. Install the front scraper bar and torque the bolts to 313 ft lbs (425 Nm).

4. Tighten and torque the motor bracket and buffer bracket bolts to 313 ft lbs (425 Nm).

5. Install the hydraulic hoses on both the vibration and drive motors. NOTE: Fill all motor ports with clean hydraulic oil prior to hose installation.

6. Start the machine engine and allow the hydraulic systems to develop charge pressure.

Allow the engine to run at low idle for several minutes without loading to fill and flush the system.

7. On machines which have a brake in the drum drive motor it may be necessary to bleed the brake system at the motor brake port.

July 1998

5 - 29

DRUM DRIVE

LEFT SIDE

5 - 30

July 1998

July 1998

5 - 31

RIGHT SIDE

5 - 32

July 1998

July 1998

5 - 33

SECTION FIVE

FINAL DRIVES

DRUM DRIVE BEARING REMOVAL 1. Remove the drum from the machine and drain the exciter shaft oil.

2. Stand the drum on its end with the vibration motor facing upward. Note: The drive bearings can not be removed without standing the drum on end. This is necessary to avoid damage to the exciter shaft and exciter bearings.

3. Remove the vibration motor (21) and motor coupling (33).

4. Remove plate (9) from bearing flange (8).

5. Remove capscrews (44) from the bearing housing (7) and use two jacking screws to remove the housing from the drum. NOTE: Care should be taken not to damage the exciter shaft. The exciter bearing cone will come out with the housing.

6. Remove snap ring (31) and pull the exciter bearing cone (5) with an external puller.

7. Remove snap ring (29) from the bearing flange shaft (8) and press the bearing shaft out of the housing.

8. Use an external bearing puller to remove the inner drum drive bearing (25) and spacer (28) from the housing.

9. Remove the old face seal (26) then remove the retaining snap ring (27) for the outer drum drive bearing (24).

10. Use an external bearing puller to remove the drum drive bearing (24).

5 - 34

July 1998

July 1998

5 - 35

SECTION FIVE

FINAL DRIVES

DRUM DRIVE BEARING INSTALLATION 1. Press drive bearing (24) into the bearing housing (7) and install snap ring (27).

2. Install seal halves (26) into the bearing housing (7) and bearing flange (8).

3. Press the bearing flange (8) into the bearing housing (7).

4. Turn the bearing housing over and install the spacer (28).

5. Press drum drive bearing (25) onto the flange shaft (8) and install snap ring (29).

6. Press the exciter shaft bearing cone into the bearing housing (7) and install snap ring (31).

7. Replace o-ring seal (64) on the bearing housing.

8. If the exciter oil was drained prior to disassembly pour the proper amount and type of oil into the exciter shaft tube (refer to the oil specification chart in section one).

9. Install the drive bearing housing onto the drum and install capscrews (44) using Loctite 271 and torque to 471 ft lbs (640 Nm).

10. Install plate (9) using capscrews (58), washers (59), and Loctite 271. Torque capscrews to 155 ft lbs (210 Nm).

11. Install vibration motor drive coupling (33).

12. Install a new vibration motor o-ring (23) and mount the vibration motor using capscrew (56) and washer (57).

DRUM DRIVE MOTOR REPAIRS This manual is not intended to supersede or replace Poclain Hydraulic’s repair instructions for the model MS25 drum drive motor. We strongly recommend that those wanting to rebuild the drive motor, obtain a copy of Poclain Hydraulic’s repair manual IMG4 / 25125 (677777 666R) from their local Poclain distributor or from Vibromax under part number V40108.

NOTE: During the machine warranty period, the Poclain drum drive motor must be serviced by a certified Poclain repair center to receive warranty claim reimbursment.

5 - 36

July 1998

SECTION SIX

PARKING BRAKE SYSTEM

July 1998

6-1

SECTION SIX

PARKING BRAKE SYSTEM

DESCRIPTION The model 1103 comes standard with a parking brake on the rear axle. The 1103D with the standard Speth axle will have a hydraulic deactivated drum type brake on the intermediate gearbox input shaft. The heavy duty Speth axle is equipped with a hydraulic disc type brake on the intermediate gearbox input shaft. Some early production 1103’s were equipped with a Kessler heavy duty axle which had hydraulic deactivated drum brakes on the axle shaft.

These Kessler axles were also common to the model 1402.

As an option the model 1103 also offers a disk type brake incorporated into the drum drive motor. Both the axle and drum motor brakes are designed as parking brakes but do have enough braking power to stop the machine in emergency situations. It is important to note that after such emergency power stops the brakes must be inspected for serviceability.

Both the axle and the drum motor brakes are spring applied and hydraulic pressure released. The brake solenoid valve is located on the propulsion pump and is deactivated by a push button on the instrument control panel. This solenoid valve has a dual function of releasing the brake and supplying hydraulic power to the propulsion pump’s servo control system. Pushing the brake button will actuate the brake, but will also deactivate the pump servo system.

The brake system is equipped with a pressure switch and horn arrangement which provides a warning if the parking brake and the propulsion system are engaged at the same time.

More detail on the parking brake systems can be found in the hydraulic and electrical sections of this manual.

6-2

July 1998

July 1998

6-3

SECTION SIX

PARKING BRAKE SYSTEM

BRAKE RELEASE AND TOWING When the machine is shut down the brakes will spring apply, therefore, it is necessary to release the hydraulic actuated brakes prior to towing the machine. The machine is designed with a brake tow valve, located under the operator seat box, and can be used in conjunction with the steering hand pump to release the machines brakes. The towing valve is turned to the tow position and the brakes are released by turning the steering wheel (hand pump) to the right to generate the parking brake release pressure. NOTE: Prior to towing it is also necessary to back out the multifunction valves located on the propulsion pump port block.

multifunction valves

NOTE: Do not tow the machine faster than 1.9 miles per hour (3 km/h).

NOTE: Do not tow the machine farther than 0.6 mile (1 km). If a disabled machine must be moved beyond this distance use another means of transport.

NOTE: Running the engine with the tow valve in the tow position can cause brake system damage.

6-4

July 1998

SECTION SIX

PARKING BRAKE SYSTEM

DRUM MOTOR BRAKE The Poclain drive motor uses a type P35 brake system.

Brake disc wear can be determined before disassembly by measuring the piston stroke.

1) 2) 3) 4)

Remove the cover plug (142).

Supply oil pressure to the brake at 250 to 435 psi (17 to 30 bar).

Use a dial indicator to measure the piston stroke through the cover plug hole.

Piston stroke should measure between .031 and .055 inch (0.8 to 1.40mm).

July 1998

6-5

SECTION SIX

PARKING BRAKE SYSTEM

DISASSEMBLY OF MOTOR BRAKE

1.

Remove the motor.

2.

Place the motor on the bearing support with brake up.

3.

Extract the plug (142), discard the cover (141) and the o-ring (143).

4.

Compress the spring washer (108) by means of a mandel and press.

5.

Remove the snap ring (109) using an internal snap ring pliers.

6.

Remove the spring washer (108), the brake piston (107), the shims (105), and the brake discs (103) (104).

7.

Remove and discard o-ring (106).

ASSEMBLY OF MOTOR BRAKE

1.

Check the condition of the brake shaft splines and the brake body. These parts must be clean and free of burrs.

2.

Measure the total height of the disc stack ( 103 + 104).

3.

Add shims (105) to the disc stack as needed to increase the total height to 2.362 inch (60mm) minimum.

4.

Lubricate the discs and install alternately one friction disc (104) then one smooth disc (103). In all cases the last disc must be smooth (103).

5.

Clean all brake assembly parts including the snap ring and seal grooves.

6.

Install the shim stack determined in step #3 above.

6-6

July 1998

SECTION SIX

PARKING BRAKE SYSTEM

7.

Proceed with the brake adjustment. Install brake piston (107) without o-ring (106) and the snap ring (109).

8.

Compress the brakes discs. (force F = 22,500 lbs or 100,000 Newtons)

Measure dimension X. The amount of shims needed should equal X-X1.

9.

Remove the snap ring and piston and install the additional shims (105). Install the shims with the thickest shim towards the piston.

10. Grease and install the o-ring (106) on the piston (107). The seal must fit tightly on the piston.

11. Use anti-oxidizing grease to coat the snap ring and cover grooves, under side of the brake piston, snap ring, spring washer, and the sealing surface in the brake body.

12. Install the brake piston. Take care when passing the seal over the snap ring groove.

13. Install the spring washer and compress the washer using a mandrel and a press.

14. Install the snap ring (109) using and internal snap ring pliers.

15. Supply oil pressure to the brake at 250 to 435 psi (17 to 30 bar).

16. Use a dial indicator to measure the piston stroke.

17. Piston stroke should measure between .031 and .055 inch (0.8 to 1.40mm).

18. Install a new cover o-ring (143) and the cover (141). Place the cover on the housing and click into place using a mandrel. Make sure the outer edge of the cover is properly seated in the groove.

19. Install the motor.

July 1998

6-7

SECTION SIX

PARKING BRAKE SYSTEM

STANDARD AXLE BRAKE The standard axle brake is a band type located on the intermediate gearbox input shaft and controlled by a hydraulic cylinder with a spring return.

6-8

July 1998

SECTION SIX

PARKING BRAKE SYSTEM

BAND BRAKE ADJUSTMENT The band brake is adjusted by set screw (24) on brake lever (21). Turn the set screw until the dimension between the cylinder and rod end is 1.0 inch (25mm).

NOTE: The brake cylinder is assembled under a spring load!

July 1998

6-9

SECTION SIX

PARKING BRAKE SYSTEM

BAND BRAKE CYLINDER

WARNING! The steering cylinder is assembled under a spring load. Care must be taken during disassembly to avoid injury.

6 - 10

July 1998

SECTION SIX

PARKING BRAKE SYSTEM

HEAVY DUTY AXLE BRAKE

Brake Assembly

Gearbox

The heavy duty Speth axle brake is located on the input shaft of the intermediate gearbox. It is a disc type spring applied and hydraulic pressure released.

CAUTION: Brake assembled under a spring load.

July 1998

6 - 11

6 - 12

July 1998

SECTION SEVEN

VIBRATION SYSTEM

July 1998

7-1

SECTION SEVEN

VIBRATION SYSTEM

VIBRATION SYSTEM The vibration circuit consists of a Sunstrand Sauer Series 90 pump providing oil to a Sunstrand Sauer SF4 vibration motor. The pump is a variable displacement axial piston design with bidirectional flow, while the motor is a fixed displacement, bidirectional, axial piston style.

Machines with smooth drums have two frequency ranges while the padfoot drum operates with just the lower frequency. When high frequency is desired, the solenoid controlled pump is stroked to provide oil at a 42 cc per revolution rate to the vibration motor. This results in a vibration frequency of 2160 vibrations per minute, rotating the vibration shaft in a clockwise direction with a centrifugal force of 24053 lbs. When low frequency is desired, the solenoid controlled pump is stroked in the opposite direction, to provide oil at a 32 cc per revolution rate to the vibration motor. This results in a vibration frequency of 1680 vibrations per minute, rotating the shaft in a counter clockwise direction with a centrifugal force of 47211 lbs.

7-2

July 1998

SECTION SEVEN

VIBRATION SYSTEM

Push button switches on the operators control panel provides the options of frequency as well as automatic vibration off in neutral. A thumb switch at the top of the forward reverse control handle enables the operator to start and stop vibration.

Two multifunction valves in the vibration pump, set at 350 bar (5075 PSI), protect the vibration circuit from excessive pressure, in the same manner as in the propulsion circuit. The top valve controls the pressure when operating at the 2160 VPM frequency, low amplitude. The 1680 VPM low frequency, high amplitude pressure is controlled through the bottom valve.

Start up pressure may be as high as 350 bar (5075 PSI) but will drop between 100 bar (1450 PSI) and 150 bar (2200 PSI) once the operating speed of vibration is obtained.

VIBRATION FREQUENCY

This drawing illustrates a typical exciter shaft and the two overturning weights used to change the amplitude on a vibratory roller.

The shaft rotation can be faster in one direction and slower in the other direction. These two speeds create the two frequencies available on some models. The amplitude is changed by the use of overturning weights. In one direction the overturning weights are opposite the shaft counterweight and create a low amplitude vibration. When the shaft is rotated in the opposite direction the overturning weights are transferred to the same side as the shaft counterweight causing an increase in amplitude. This design allows for a LOW amplitude when the frequency is HIGH and a HIGH amplitude when the frequency is LOW.

July 1998

7-3

SECTION SEVEN

VIBRATION SYSTEM

The models which offer only one frequency do not reverse the direction of shaft rotation nor do they use the overturning weight design. For additional information on this subject contact your Vibromax dealer. model

freq#1

freq#2

ampl#1

ampl#2

1103D

28Hz

36Hz

1.6mm

0.6mm

1103PD

28Hz

N/A

1.6mm

N/A

1103HD

28Hz

36Hz

1.6mm

0.6mm

1103HPD

28Hz

N/A

1.6mm

N/A

LOW FREQUENCY

HIGH FREQUENCY

7-4

July 1998

SECTION SEVEN

VIBRATION SYSTEM

VIBRATION AMPLITUDE

HIGH AMPLITUDE LOW FREQUENCY

AMPLITUDE

h1

TIME in seconds

h2

LOW AMPLITUDE HIGH FREQUENCY

h1 and h2 above = Jumping Height 1/2 of h1 or h2 = Amplitude

JUMPING HEIGHT

July 1998

AMPLITUDE

7-5

One half the vertical distance that the drum travels is called the amplitude. The amplitude for any given machine will vary depending on the soil conditions. The amplitude and the height the machine lifts itself off the ground will gradually increase as the soil becomes more dense or compacted.

SECTION SEVEN

VIBRATION SYSTEM

VIBRATORY SYSTEM DIAGNOSTICS The 1103PD (padfoot) models have one vibration frequency of 1680 vibrations per minute (28 Hz). Padfoot models also use a single offset shaft without overturning weights. The vibration motor will only rotate in one direction due to machine control configuration.

The 1103D (smooth drum) models are equipped with two overturning weights. The vibration shaft is bi-directionally rotated to obtain a vibration frequency of 1680 vibrations per minute (28 Hz) in one rotational direction and 2160 vibrations per minute (36 Hz) with the opposite direction of rotation.

Vibration frequency is related to the speed at which the vibration shaft is rotated and can be measured with a frequency meter. Low frequency problems will normally show up as a rough riding machine (often referred to as bucking). Operation at higher than recommended frequency will manifest itself as a shortened vibratory bearing life.

Vibromax Part No. VT9013

To increase or decrease the shaft speed requires more or less flow from the vibration pump.

Before making adjustments on the pump displacement controls always check that the engine operating speed is set to maximum (2500 rpm) and pressure test the system to insure that the system is functioning properly. Hydraulic pressures can be tested at taps #3 and #4 of the hydraulic test station. Start up pressure may be as high as 350 bar (5075 PSI) but should drop between 100 and 150 bar (1400 and 2200 PSI) once operating speed has been obtained.

Two multifunction valves in the vibration pump, set at 350 bar (5075 PSI), protect the vibration system from excessive pressure. The top valve controls the pressure when operating at high frequency and low amplitude. The low frequency high amplitude circuit is controlled through the bottom valve.

7-6

July 1998

LIFTING DEVICE

July 1998

7-7

SECTION SEVEN

VIBRATION SYSTEM

DRUM REMOVAL 1. Disconnect, tag, and cap the hydraulic lines for the drum drive motor on the left side of the machine. Plug the motor ports.

2. Disconnect, tag, and cap the hydraulic lines for the vibration motor on the right side of the machine. Plug the motor ports.

3. Block and support the front frame of the machine.

4. Remove the drive motor adapter to frame bolts on the left side of the machine.

5. Remove the front and rear buffer brackets on the right side of the machine.

6. Remove the front scraper bar from the machine.

7. Roll or lift the drum out of the front frame. Smooth drum weight = 9372 lbs (4250 kg) Padfoot drum weight = 10,197 lbs (4625 kg)

DRUM INSTALLATION 1. Roll or lift the drum into position in the machine’s front frame. The drum must be positioned for alignment of the drive motor bracket to the left side frame bolt holes.

2. Install the bolts in the front and rear buffer brackets on the right side of the machine. This will allow the machine frame to be lowered or raised as needed to complete alignment of the drive motor bracket on the left side of the machine.

3. Install the front scraper bar and torque the bolts to 313 ft. lbs (425 Nm).

4. Tighten and torque the motor bracket and buffer bracket bolts to 313 ft. lbs (425 Nm).

5. Install the hydraulic hoses on both the vibration and drive motors. NOTE: Fill all motor ports with clean hydraulic oil prior to hose installation.

6. Start the machine engine and allow the hydraulic systems to develop charge pressure.

Allow the engine to run at low idle for several minutes without loading to fill and flush the system.

7. On machines which have a brake in the drum drive motor it may be necessary to bleed the brake system at the motor brake port.

7-8

July 1998

SECTION SEVEN

VIBRATION SYSTEM

EXCITER BEARING REMOVAL 1. Remove the drum from the machine and drain the exciter shaft oil.

2. Remove the drum drive motor and drive plate from the left side of the drum.

3. Stand the drum on its end with the vibration motor facing upward.

Note: Smooth drum = 9372 lbs (4250 kg) Padfoot drum = 10,197 lbs (4625 kg) 4. Remove the vibration motor (21) and motor coupling (33).

5. Remove plate (9) from bearing flange (8).

6. Remove capscrews (44) from the bearing housing (7) and use two jacking screws to remove the housing from the drum. NOTE: Care should be taken not to damage the exciter shaft. The exciter bearing cone will come out with the housing.

7. Remove snap ring (31) and pull the exciter bearing cone (5) with an internal puller.

8. Remove snap ring (29) from the bearing flange shaft (8) and press the bearing shaft out of the housing.

9. Use an external bearing puller to remove the inner drum drive bearing (25) and spacer (28) from the housing.

10. Remove the old face seal (26) then remove the retaining snap ring (27) for the outer drum drive bearing (24).

11. Use an external bearing puller to remove the drum drive bearing (24).

12. Use the exciter shaft lifting device to secure and remove the exciter shaft from the drum.

13. Lay the drum back on its side and remove the exciter bearing housing from the left side of the drum.

14. Use the appropriate bearing pullers to remove the exciter bearing parts from the exciter shaft and housing.

July 1998

7-9

7 - 10

July 1998

July 1998

7 - 11

7 - 12

July 1998

July 1998

7 - 13

SECTION SEVEN

VIBRATION SYSTEM

EXCITER BEARING ASSEMBLY 1. Clean the exciter shaft housing in the drum.

2. Heat the inner bearing races and press onto the exciter shaft.

3. Install a new bearing race into the left side housing and install the housing using a new oring seal.

4. Install the M24x80 capscrews using Loctite 271 and torque to 471 ft lbs. (640 Nm).

5. Stand the drum on end with the vibration motor side up.

6. Install the exciter shaft using the proper lifting device to avoid shaft or bearing damage.

7. Add 12.7 quarts (12 liter) oil to the exciter housing. CLP DIN 51517/3 (Mobil Gear 629) 8. Press drive bearing (24) into the bearing housing (7) and install snap ring (27).

9. Install seal halves (26) into the bearing housing (7) and bearing flange (8).

10. Press the bearing flange (8) into the bearing housing (7).

11. Turn the bearing housing over and install the spacer (28).

12. Press drum drive bearing (25) onto the flange shaft (8) and install snap ring (29).

13. Press the exciter shaft bearing cone into the bearing housing (7) and install snap ring (31).

14. Replace o-ring seal (64) on the bearing housing.

15. Install the drive bearing housing onto the drum and install capscrews (44) using Loctite 271 and torque to 471 ft lbs (640 Nm).

16. Install plate (9) using capscrews (58), washers (59), and Loctite 271. Torque capscrews to 155 ft lbs (210 Nm).

17. Install vibration motor drive coupling (33).

18. Install a new vibration motor o-ring (23) and mount the vibration motor using capscrew (56) and washer (57).

7 - 14

July 1998

SECTION SEVEN

VIBRATION SYSTEM

SMOOTH DRUM SHAFT

July 1998

7 - 15

SECTION SEVEN

VIBRATION SYSTEM

PADFOOT DRUM SHAFT

7 - 16

July 1998

SECTION EIGHT

STEERING SYSTEM

July 1998

8-1

SECTION EIGHT

STEERING SYSTEM

SPECIAL TOOLS

8-2

July 1998

SECTION EIGHT

STEERING SYSTEM

ARTICULATION JOINTS

July 1998

8-3

SECTION EIGHT

STEERING SYSTEM

8-4

July 1998

SECTION EIGHT

STEERING SYSTEM

JOINT DISASSEMBLY 1.

Support the rear end of the machine’s rear frame with the proper jack stands.

2.

Support the front part of the machine’s rear frame with the proper jack stands.

3.

Support the machine’s front roller frame with the proper jack stands.

4.

Remove the roller drum. Remember to tag and cap all hydraulic lines.

5.

Remove the hose clamps and hoses from the front drum frame.

6.

Remove the split pins (#10) and washers (#9) from the two steering cylinder pivot pins.

7.

Remove the cylinder pivot pins (#7).

8.

Sling the front roller frame in preparation for removal. The roller frame weight is 4697 lbs (2130 Kg).

9.

Remove the 16mm capscrews (#21) from the bearing cover (#22).

10. Remove the bearing cover (#22), spring washer (#23), and the thrust collar (#24).

11. Install a 12mm lifting eyebolt in the tapped hole provided in the link plate (#28) and support the plate for removal.

12. Remove the ten 20mm capscrews (#25) which secure the plate (#28) to the steering link (#31) and remove the link plate (#28).

13. Remove bearing cup (#26) from the link plate (#28) with an internal bearing puller.

14. Remove the machine’s front roller frame from the steering link (#31).

15. Remove the sealing rings (#14) and pull the bearing cones (#27) from the roller frame lugs by use of an external bearing puller.

16. Remove capscrew (#30) from the steering link and install a 16mm lifting eyebolt and support the link for removal. The steering link weight is 420 lbs (190 Kg).

17. Remove the lower bearing cover (#19), spring washer (#18), and thrust collar (#17) by removing capscrews (#20).

18. Remove the shift plate (#2) and bearing cover (#3) by removing capscrews (#1).

19. Install the service bushing (see special tools) into the upper steering link bearing bore.

20. Install the bearing cover (#3) over the special bushing using two M16x120 capscrews.

21. Tighten the capscrews alternately until the bearing cover is drawn down to the steering link. This will force the link upward and expose the lower bearing cone (#15).

July 1998

8-5

SECTION EIGHT

STEERING SYSTEM

8-6

July 1998

SECTION EIGHT

STEERING SYSTEM

22. Remove the sealing ring from the lower bearing and use an external bearing puller to remove the bearing cone (#15) from the lower rear frame lug.

23. Support the steering link (#31) from the bottom with a floor jack.

24. Remove the upper bearing cover (#3) and the special service bushing.

25. Allow the steering link (#31) to drop downward by lowering the jack under the link. Drop the link down until the upper bearing cone (#5) is fully exposed.

26. Remove the sealing ring (#6) and the bearing cone (#5) from the top rear frame lug.

27. With the steering link fully lowered and the bearing cones removed pull the link clear of the lower rear frame lug.

28. Lift the steering link upward and off the upper rear frame lug.

29. Remove the bearing cup (#29) from the steering link (#31).

July 1998

8-7

SECTION EIGHT

STEERING SYSTEM

8-8

July 1998

SECTION EIGHT

STEERING SYSTEM

JOINT ASSEMBLY NOTE: The bearings in the steering articulation joints are designed to be assembled without grease or other lubricants. Lubrication of these bearings will actually shorten bearing life.

1.

Install bearing cup (#28) into the steering link (#31) until it is fully seated.

2.

With the eyebolt inserted in place of capscrew (#30) lift the steering link up and over the upper rear frame lug.

3.

Lower the link and guide it over the lower rear frame lug.

4.

Lift the link upward and evenly space the link between the upper and lower lugs.

5.

Install a new sealing ring (#6) into the upper link bearing bore. Make sure it is pressed into place.

6.

Install the new bearing cone (#5) onto the upper rear frame lug.

7.

Install the new bearing cup (#4) into the bearing bore and make sure it is fully seated.

8.

Install the upper bearing cover (#3) and shift plate (#2) using Loctite 271 and capscrews (#1). Torque the capscrews to 182 ft lbs (247 Nm).

9.

Install a new sealing ring into the lower bearing bore and press into place.

10. Install a new bearing cone (#15) onto the lower rear frame lug.

11. Install the new bearing cup (#16) into the bearing bore and make sure it is fully seated.

12. Install the spring washer (#18) and thrust collar (#17) into the lower bearing cover (#19). The spring washer’s outer diameter should contact the thrust collar.

13. Install the lower bearing cover using Loctite 271 on capscrews (#20) and torque the capscrews to 182 ft lbs (247 Nm).

14. Remove the lifting eyebolt from the steering link and install capscrew (#30).

15. Install new front and rear sealing rings (#14) onto the roller frame lugs.

16. Install new front and rear bearing cones (#27) onto the roller frame lugs.

17. Move the roller frame into position in the steering link. Roller frame weight = 4697 lbs (2130 Kg). Be careful not to damage the bearing parts.

18. Install link plate (#28) with the ten capscrews (#25) using Loctite 271 and torque the capscrews to 297 ft lbs (402 Nm).

19. Install the bearing cup (#26) into the link plate (#28) bore and make sure it is fully seated.

July 1998

8-9

SECTION EIGHT

STEERING SYSTEM

8 - 10

July 1998

SECTION EIGHT

STEERING SYSTEM

20. Install the spring washer (#23) and the thrust collar (#24) into the bearing cover (#22).

The spring washer’s outer diameter must contact the thrust collar.

21. Secure the bearing cover (#22) using Loctite 271 and capscrews (#21). Torque the capscrews to 182 ft lbs (247 Nm).

22. Install the steering cylinder pivot pins (#7) and secure with washer (#9) and split pin (#10).

23. Position and clamp the hydraulic hoses into the proper locations on the frame.

24. Install the front drum.

25. Remove all jack stands.

July 1998

8 - 11

SECTION EIGHT

STEERING SYSTEM

STEERING CYLINDER

8 - 12

July 1998

SECTION NINE

CHASSIS

July 1998

9-1

SECTION NINE

CHASSIS

DRUM FRAME

9-2

July 1998

SECTION NINE

CHASSIS

REAR FRAME

July 1998

9-3

SECTION NINE

CHASSIS

SIDE FRAME

9-4

July 1998

SECTION NINE

CHASSIS

ENGINE COMPARTMENT PANELS

July 1998

9-5

SECTION NINE

CHASSIS

OPERATOR PLATFORM

9-6

July 1998

SECTION NINE

CHASSIS

ROLLOVER PROTECTION STRUCTURE

Torque to 303 ft lbs.

(410 Nm.)

Torque to 738 ft lbs.

(1000 Nm.)

NOTE: The fasteners used for mounting the ROPS are special for this application.

Use only the recommended replacement parts.

NOTE: Never modify or repair ROPS parts. Always replace damaged parts with the proper new parts!

July 1998

9-7

SECTION NINE

CHASSIS

9-8

July 1998

SECTION TEN

ATTACHMENTS

July 1998

10 - 1

SECTION TEN

ATTACHMENTS

LEVELING BLADE

10 - 2

July 1998

SECTION TEN

ATTACHMENTS

BLADE CONTROL

July 1998

10 - 3

SECTION TEN

ATTACHMENTS

BLADE HYDRAULIC LINES

10 - 4

July 1998

index A

E

accessory plug..................................... 3 - 35 alternator voltage checks ................... 3 - 19 alternators explained .......................... 3 - 17 axle information ..................................... 5 - 2 axle installation ...................................... 5 - 7 axle removal........................................... 5 - 6 axle tube disassembly .......................... 5 - 8 axles ........................................................ 1 - 3

emergency stop switch....................... 3 - 27 engine...................................................... 1 - 3 engine oil specification ....................... 1 - 19 engine specifications.................. 1 - 16, 2 - 3 engine warranty ..................................... 2 - 3

F fluid specifications ............................... 1 - 17 fuse location ........................................... 3 - 3

B batteries explained .............................. 3 - 15 battery diagnostics ............................... 3 - 16 bolt torque chart................................... 1 - 13 brake adjustment................................... 6 - 9 brake cylinder....................................... 6 - 10 brake switch ......................................... 3 - 27 brake, heavy duty ................................ 6 - 11 brakes ..................................................... 1 - 4

H heater .................................................... 3 - 35 hydraulic charge system..................... 4 - 11 hydraulic cooling system ...................... 4 - 4 hydraulic drain lines .............................. 4 - 6 hydraulic schematic............................. 4 - 38 hydraulic suction lines........................... 4 - 2 hydraulic test fittings ............................. 4 - 9 hydraulic test station ............................. 4 - 8 hydrostatic pump ................................... 1 - 3

C California Proposition 65 .................. 2, 1 - 1 charge system diagnostics ................ 3 - 18 cleaning parts....................................... 1 - 12

I

D

instrument panel ......................... 3 - 4, 3 - 25 intermediate gearbox .......................... 5 - 18

diesel fuel specification ...................... 1 - 18 differential disassembly ...................... 5 - 22 differential lock removal ..................... 5 - 12 differential lock system ....................... 4 - 35 drive motor ............................................. 1 - 3 drive motor repairs .............................. 5 - 36 drive motor types................................. 4 - 13 drive system specifications................ 1 - 16 drum drive............................................. 5 - 30 drum motor brake .................................. 6 - 5 drum removal ....................................... 5 - 29

L leveling blade ....................................... 10 - 2 lighting circuit ....................................... 3 - 33

M machine components............................ 1 - 6 machine specifications ....................... 1 - 15 multifunction valves............................. 4 - 17

1

index O

towing your machine ........................... 4 - 31

operating data ...................................... 1 - 16

U

P

understanding electrical schematics .. 3 - 7

parking brake system.......................... 4 - 30 parking brakes ....................................... 6 - 2 planetary assembly ............................. 5 - 14 planetary disassembly ........................ 5 - 10 propulsion system diagnostics .......... 4 - 18 pump servo control.............................. 4 - 19

V

R relay location .......................................... 3 - 3 relays, understanding ........................... 3 - 9 relays, Vibromax types ....................... 3 - 11 ROPS ................................................. 9 - 7

S

vibration amplitude explained ... 4 - 25, 7 - 5 vibration circuit ............................ 3 - 29, 7 - 2 vibration diagnostics.............................. 7 - 6 vibration frequency .............................. 4 - 23 vibration pump........................................ 1 - 3 vibration shaft bearings ........................ 7 - 9 vibration shaft, padfoot drum ............. 7 - 16 vibration shaft, smooth drum ............. 7 - 15 vibration system ................................... 4 - 21

W wipers .................................................... 3 - 35 work lights............................................. 3 - 35

safety, electrical rules ........................... 1 - 9 safety, general ....................................... 1 - 7 safety, machine operation.................... 1 - 8 safety, maintenance.............................. 1 - 9 safety, personal ..................................... 1 - 7 serial numbers ....................................... 1 - 5 spark arrester ......................................... 1 - 7 starter diagnostics ............................... 3 - 21 starter motor test ................................. 3 - 23 starter/charging circuit ........................ 3 - 13 starters explained ................................ 3 - 20 steering cylinder .................................. 8 - 12 steering joints......................................... 8 - 3 steering pump ........................................ 1 - 4 steering system.................................... 4 - 27

T tire ballast ............................................. 1 - 20 torque data ........................................... 1 - 13 tow valve ............................................... 4 - 31

2

VIBROMAX AMERICA INC. 2823 Carlisle Avenue Racine, WI 53404 USA Phone: 1-262-637-8111 Fax: 1-262-637-8211

VIBROMAX GmbH Erkrather Str. 343 40231 Dusseldorf, GERMANY Phone: (49) 211-9866-402 Fax: (49) 211-9866-555

VIBROMAX COMPACTION EQUIPMENT GmbH Schaeferberg 1 06466 Gatersleben, GERMANY Phone: (49) 39482-9331 Fax: (49) 39482-9102

VIBROMAX COMPACTION EQUIPMENT GmbH 72, Pasir Ris Heights SINGAPORE 519279 Phone: (65) 5838297 Fax: (65) 5838301