JCB Vibromax 752C Tandem Drum Roller Service Repair Manual - PDF Download

TANDEM DRUM ROLLER SERVICE MANUAL SM71001 May 2000

Model 752C

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.

SECTION ONE GENERAL INFORMATION .............................................................. 1 - 1 MACHINE DESCRIPTION .............................................................................. 1 - 3 MACHINE SERIAL NUMBERS ....................................................................... 1 - 5 IDENTIFYING MACHINE COMPONENTS ..................................................... 1 - 6 MACHINE SPECIFICATIONS.......................................................................... 1 - 8 STANDARD TORQUE DATA ....................................................................... 1 - 10 FLUID CAPACITY - 752C ............................................................................. 1 - 12 DIESEL FUEL SPECIFICATION ................................................................... 1 - 13 ENGINE OIL SPECIFICATION ..................................................................... 1 - 14 ROLLOVER PROTECTION STRUCTURE .................................................. 1 - 15 SAFETY, GENERAL ..................................................................................... 1 - 16 SPARK ARRESTER ................................................................................ 1 - 16 SAFETY, PERSONAL ................................................................................... 1 - 17 SAFETY, MACHINE OPERATION ............................................................... 1 - 19 SAFETY, MAINTENANCE ............................................................................ 1 - 22 SAFETY, DECALS........................................................................................ 1 - 23

SECTION TWO ENGINE ............................................................................................. 2 - 1 ENGINE DATA ................................................................................................ 2 - 2 CUMMINS ENGINE WARRANTY................................................................... 2 - 3 ENGINE REMOVAL ........................................................................................ 2 - 4

SECTION THREE ELECTRICAL.................................................................................... 3 - 1 INSTRUMENT PANEL, RIGHT....................................................................... 3 - 2 INSTRUMENT PANEL, LEFT ......................................................................... 3 - 4 INSTRUMENT PANEL COVER ...................................................................... 3 - 5 COMBINATION INDICATOR .......................................................................... 3 - 6 SPEED RANGE CONTROL............................................................................ 3 - 7 UNDERSTANDING ELECTRICAL SCHEMATICS ....................................... 3 - 11 UNDERSTANDING RELAYS ........................................................................ 3 - 14 VIBROMAX RELAYS ............................................................................... 3 - 15 STARTER/CHARGING CIRCUIT ................................................................. 3 - 17 UNDERSTANDING BATTERIES.................................................................. 3 - 17 BATTERY DIAGNOSTICS ...................................................................... 3 - 18 UNDERSTANDING ALTERNATORS ........................................................... 3 - 19

CHARGING SYSTEM DIAGNOSTICS .................................................... 3 - 20 VOLTAGE CHECKS AT ALTERNATOR ................................................. 3 - 21 SYSTEM LEAKAGE ................................................................................. 3 - 21 CIRCUIT WIRING TEST .......................................................................... 3 - 21 MEASURING ALTERNATOR OUTPUT .................................................. 3 - 22 UNDERSTANDING STARTERS ................................................................... 3 - 22 STARTER SOLENOID ............................................................................ 3 - 23 STARTER SYSTEM DIAGNOSTICS ...................................................... 3 - 23 SOLENOID CIRCUIT TEST .................................................................... 3 - 23 STARTER CIRCUIT WIRING TEST ........................................................ 3 - 24 STARTER MOTOR TEST ........................................................................ 3 - 25 INSTRUMENTATION PANEL....................................................................... 3 - 27 LIGHTING CIRCUIT ...................................................................................... 3 - 29 WATER SPRINKLER CIRCUIT .................................................................... 3 - 31 VIBRATION/DRUM SELECTION CIRCUITS................................................ 3 - 33 VIBRATION CONTROL CIRCUIT................................................................. 3 - 35 TWO SPEED PROPULSION MOTOR CIRCUITS........................................ 3 - 37 WIRE CHART, RIGHT PANEL & HARNESS 4010/67455 ............................ 3 - 44 WIRE CHART, LEFT PANEL & HARNESS 4010/67413 .............................. 3 - 46 WIRE CHART, FRONT HARNESS 4010/67336 ........................................... 3 - 48 WIRE CHART, REAR HARNESS 4010/68335 ............................................. 3 - 49

SECTION FOUR HYDRAULIC ..................................................................................... 4 - 1 PROPULSION SYSTEM ................................................................................. 4 - 5 VIBRATION SYSTEM ..................................................................................... 4 - 9 STEERING SYSTEM .................................................................................... 4 - 13 BRAKE CIRCUIT .......................................................................................... 4 - 17 HYDRAULIC AND COOLING LINES ............................................................ 4 - 18 HYDRAULIC DRAIN SYSTEM ..................................................................... 4 - 20 HYDRAULIC SYSTEM COMPONENTS ....................................................... 4 - 22 PRESSURE TEST POINTS .......................................................................... 4 - 22 HYDRAULIC SCHEMATIC ........................................................................... 4 - 23

SECTION FIVE POWER TRAIN................................................................................. 5 - 1 752C DRUM ASSEMBLY ............................................................................... 5 - 3 DRUM REMOVAL........................................................................................... 5 - 8 DRUM INSTALLATION ................................................................................... 5 - 9 RIGHT SIDE BEARING COVER ................................................................... 5 - 10 DRUM DRIVE BEARING REMOVAL ............................................................ 5 - 11 DRUM DRIVE BEARING ASSEMBLY........................................................... 5 - 12 DRUM DRIVE MOTOR REPAIRS ................................................................ 5 - 13 DRUM DRIVE GEARBOX............................................................................. 5 - 14 GFT 17 T2/312 2 GEARBOX ........................................................................ 5 - 16

SECTION SIX PARKING BRAKE SYSTEM ............................................................ 6 - 1 BRAKE CIRCUIT ............................................................................................ 6 - 6 TOWING YOUR MACHINE ............................................................................ 6 - 7

SECTION SEVEN VIBRATION SYSTEM ....................................................................... 7 - 1 LIFTING DEVICE ............................................................................................ 7 - 2 DRUM EXCITER SHAFT ................................................................................ 7 - 3 752C VIBRATION SYSTEM ........................................................................... 7 - 4 VIBRATION SYSTEM ..................................................................................... 7 - 7 VIBRATION FREQUENCY ............................................................................. 7 - 8 VIBRATION AMPLITUDE ............................................................................... 7 - 9 VIBRATORY SYSTEM DIAGNOSTICS........................................................ 7 - 10 752C DRUM DRAWING ............................................................................... 7 - 11 DRUM - LEFT SIDE ...................................................................................... 7 - 12 DRUM - RIGHT SIDE .................................................................................... 7 - 15 DRUM REMOVAL......................................................................................... 7 - 18 DRUM INSTALLATION ................................................................................. 7 - 19 RIGHT SIDE BEARING COVER ................................................................... 7 - 20 EXCITER BEARING REMOVAL ................................................................... 7 - 21 EXCITER BEARING ASSEMBLY ................................................................. 7 - 23

SECTION EIGHT STEERING SYSTEM ........................................................................ 8 - 1 STEERING SYSTEM ...................................................................................... 8 - 5 STEERING PIVOT REMOVAL ....................................................................... 8 - 6 STEERING CYLINDER ................................................................................. 8 - 10

SECTION NINE CHASSIS .......................................................................................... 9 - 1 REAR ENGINE/ROLLER FRAME .................................................................. 9 - 2 FRONT ROLLER FRAME............................................................................... 9 - 3 STEERING LINK.............................................................................................. 9 - 4 FRONT WATER/DIESEL TANK ..................................................................... 9 - 5 REAR WATER/HYDRAULIC TANK ................................................................ 9 - 6 INSTRUMENT CONSOLE .............................................................................. 9 - 7 SEAT RACK.................................................................................................... 9 - 8 ROLLOVER PROTECTION STRUCTURE (ROPS) ....................................... 9 - 9

SECTION TEN ATTACHMENTS ............................................................................. 10 - 1

SECTION ONE

GENERAL INFORMATION

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SM71001 - SECTION ONE

GENERAL INFORMATION

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SM71001 - SECTION ONE

GENERAL INFORMATION

MACHINE DESCRIPTION In the fall of 1999 Vibromax introduced the new 752 series “C� tandem drum vibratory roller. The 752C has a significant increase in engine power to 110 hp (82 kW). The operating weight was increased to 23,300 lbs. (10568 kg) while keeping the same 66 inch (1675mm) drum size.

The new roller uses the Cummins 3.9 liter 4 cylinder turbo charged engine. The new engine is tuned to meet the latest EPA emissions standards.

A Mannesman Rexroth variable displacement, axial piston hydrostatic pump, used for machine propulsion, is mounted to the flywheel end of the engine. It provides oil to the front and rear drum drive motors in a parallel path. The Rexroth 2 speed drum drive motors are mounted on the left side of the drums, drive through L&S planetary gearboxes, and are isolated from the drum by rubber buffers. This arrangement is used in the heavy roller models with a great deal of success. These machines come standard with parking brakes at both the front drum and the rear drum. A spring applied-hydraulically released multi disc brake is part of the drum drive gearbox.

The vibration system on the 752C uses a Rexroth hydrostatic pump mounted directly behind the propulsion pump. It is similar in design to the propulsion pump. The vibratory pump supplies oil to a Rexroth hydrostatic motor mounted at the right side of the drum. The new model 752C operates at frequencies of 1980 or 2520 vibrations per minute. Vibratory operations can be done with front drum only, both drums together, or rear drum only.

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SM71001 - SECTION ONE

GENERAL INFORMATION

A steering/charge pump, mounted to the auxiliary drive at the front of the engine, provides the oil needed for steering. The steering pump also acts as the 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 electrical system consists of a 12 volt battery, starter, alternator system, optional lighting and standard instrumentation.

The model 752C comes standard with: Beveled drums - Dual scrapers on each drum - Automatic vibration off in neutral - Pressurized intermittent sprinkler system - Lockable instrument panel cover - Deluxe adjustable, 3 position operator’s seat - Fuel level & engine temperature gauges - Hourmeter - Horn - Indicator lights for alternator charge, engine oil pressure, low water tank level and neutral position Backup alarm - 4 post ROPS with canopy.

Option equipment available: Gravity water sprinkler - Road lights - Front & rear halogen work lights - Speed limiter - Water level indicator gauge.

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SM71001 - SECTION ONE

GENERAL INFORMATION

MACHINE SERIAL NUMBERS

Enter the machine and component serial numbers highlighted in the above drawing. When ordering spare parts or requesting information on the machine, have these numbers available for your dealer. Make a copy of these numbers and keep it in a safe place. If the machine is stolen, these numbers should be made available to the investigating authorities.

1

Model / Serial Number

2

Engine Serial Number

3

ROPS Serial Number

4

Front Drive Motor Serial Number

5

Rear Drive Motor Serial Number

6

Drive Pump Serial Number

7

Vibration Pump Serial Number

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SM71001 - SECTION ONE

GENERAL INFORMATION

IDENTIFYING MACHINE COMPONENTS

1

rollover protection structure

6

dry air cleaner

2

front water tank

7

rear drive motor & gearbox

3

scraper

8

rear drum

4

front drive motor & gearbox

9

lifting and towing eye

5

front drum

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GENERAL INFORMATION

1

hydraulic tank

6

fuel tank

2

rear water tank

7

front vibration motor

3

rear vibration motor

8

lifting and towing eye

4

engine

9

front water tank

5

radiator and oil cooler

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SM71001 - SECTION ONE

GENERAL INFORMATION

MACHINE SPECIFICATIONS MODEL 752C

in.

1-8

mm

A

106

2690

B

77.6

1970

C

30.3

770

D

48

1220

H1

117

2970

H2

87

2210

K

10.6

270

L

166.5

4230

M

15.9

405

O

5.8

147.5

S

1.45

37

W

66

1675

E

40o

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SM71001 - SECTION ONE

GENERAL INFORMATION

ENGINE Make/Model/Type/Cooling Displacement - cu. in. (cc) HP, SAE net (kW) @2500 rpm Air Cleaner Fuel Consumption- gal/hr (l/hr) Fuel capacity - gal (ltr) Electrical system Battery, amp hours/Alternator, amps

Cummins 4BT3.9 C110, 4 cylinder diesel, water cooled 240 cu.in. (3920cc) 110 (82) Dual replaceable elements 3.0 (11.5) 37 (140) 12-volt 120/65

Drive Propulsion Travel speed, 1st/2nd/3rd - mph (km/hr) Theoretical gradeability, forward -% Brakes, operating Brakes, parking Steering Articulation/Oscillation

Infinitely variable hydrostatic drive to both drums 0-2.4 (0-4) / 0-3.9 (0-6.3) / 0-7.4 (0-12) 35 Hydrostatic braking thru ground drive Spring applied hydraulic release on drum gearboxes Articulated, hydraulic powered 25/10

Operating Data Operating weight - lb (kg) Turning radius, inside - in (mm) Static linear drum load - lb/in (kg/cm) Frequency - vpm (Hz) Nominal amplitude - in (mm) Centrifugal force per drum - lbf (kN) Centrifugal force/rolling width - lbf/in. (N/cm) Drum shell thickness - in (mm) Water tank capacity - gal (L)

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23,300 (10568) 200 (5080) front 168.6 (30) / rear 184.5 (33) Low frequency High frequency 1980 (33) 2520 (42) .041 (1.05) .014 (.36) 26,412 (117) 14,668 (65) 400 (700) 222 (389) 1.45 (37) front 121.5 (460) / rear 95.1 (360)

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SM71001 - 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 SIZE

ft-lbs

Nm

GRADE 10.9 ft-lbs

GRADE 12.9

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 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

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

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SM71001 - SECTION ONE

GENERAL INFORMATION

FITTINGS, CONNECTIONS AND PLUGS DIAMETER & PITCH

NEWTONS/METER

POUNDS/FOOT

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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SM71001 - SECTION ONE

GENERAL INFORMATION

FLUID CAPACITY - 752C MACHINE PART

CAPACITY USA (metric)

SPECIFICATIONS

Fuel tank

37 gal (140 l)

see diesel fuel

Engine crankcase

11.5 qts(10.9 l)

engine oil API classification API-CD MIL-L-2104C multigrade engine oil single grade engine oil

Hydraulic system

(see oil chart) (see oil chart)

47.6 gal (180 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

Drum gearbox (each drum)

1.4 qts (1.3 l)

CPL 220 LS 2 DIN 51517/3 Mobilgear 630 Mobilgear SHC 220 Texaco Syngear 220

Vibration system (each drum)

2.6 qts (2.5 l)

CLP DIN 51517/3 Mobil Gear 627 Shell Omala 100 Texaco Meropa 100

Battery

as required

Distilled water

Grease

as required

Molydisulfide grease

Engine coolant

20 qts (19 l)

50% ethylene glycol and 50% water -34 degrees F (-37 degrees C)

Reservoir refill

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SM71001 - 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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SM71001 - 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

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SM71001 - SECTION ONE

GENERAL INFORMATION

ROLLOVER PROTECTION STRUCTURE

There are 16 bolts, nuts, and washers (4 each post) that hold the ROPS to the machine. The bolts are located at the base of each leg of the ROPS. The torque specifications for each bolt is 195 foot pounds (265 Nm.).

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SM71001 - SECTION ONE

GENERAL INFORMATION

SAFETY, GENERAL The information in this manual does not replace any safety rules and laws used in your area. Before operating 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. Before starting the engine study the operator’s manual.

•

Know the location and function of all machine controls.

•

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

•

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 times.

The following decal is located on the right side of the instrument panel. Check the decal daily. Clean or replace as needed.

SPARK ARRESTER NOTE: Rules or laws in some areas may require that this machine be equipped with a spark arrester or spark arrester muffler. Check the rules or laws in your area.

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GENERAL INFORMATION

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.

Foreign materials and loose objects on the steps, hand rails, and in the operators compartment can cause accidents and injury. Keep the steps, hand rails, and operator’s compartment clear at all times.

Make sure cab windows are clean and unobstructed.

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.

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

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.

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.

Lack of, or incomplete, machine inspection and maintenance can cause accidents.

Always follow the instructions in this manual for machine inspection and maintenance.

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SM71001 - SECTION ONE

GENERAL INFORMATION

Always use the seat belt when operating the machine. Make sure the buckle is fully secured.

The following decal is located on the upper right hand corner of the instrument panel. Check the decal daily. Clean or replace as needed.

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

The following decal is located on the instrument panel to the left side of the main gauge cluster.

Check the decal daily. Clean or replace as needed.

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SM71001 - SECTION ONE

GENERAL INFORMATION

SAFETY, MACHINE OPERATION

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

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

The following decal is located on the left side of the operator seat box. Check the decal daily. Clean or replace as needed.

Do not permit other people to ride on the machine as passengers.

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.

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.

The vibrations from this machine can cause the walls of a trench or high bank to collapse. 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.

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.

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SM71001 - SECTION ONE

GENERAL INFORMATION

The following decal is located in two places on each side of the machine’s front and rear frames in the articulation joint area. Check the decals daily. Clean or replace as needed.

The following decal is also located on both sides of the rear frame in the area of the articulation joint and symbolizes the danger of the pinch point. Check the decals daily. Clean or replace as needed.

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.

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GENERAL INFORMATION

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! Table 1: Electrical Safety Rules 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)

Cable Voltage

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SM71001 - SECTION ONE

GENERAL INFORMATION

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.

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

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

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

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

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.).

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.

Batteries produce explosive gases. Keep away from flames. Ventilate when charging.

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

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.

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

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GENERAL INFORMATION

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

SAFETY, DECALS Damaged, missing or dirty warning decals can lead to incorrect operation which could result in injury or death.

Replace all missing or damaged decals and keep all warning decals clean. The warning decals are available from your Vibromax dealer.

Inspect all instruction decals and warning decals every 10 operating hours or daily, which ever occurs first.

Clean all illegible decals with water, soap and a cloth. Do not use solvents or fuels to clean decals.

Damaged, missing or illegible decals must be replaced. If a decal is located on a component that must be replaced, be certain to apply a new decal on the replaced component.

DECAL 2751/10002

DECAL 4003/32220

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SM71001 - SECTION ONE

GENERAL INFORMATION

DECAL 4003/32221

DECAL 4003/32222

DECAL 4003/22002

DECAL 4003/07055

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SECTION TWO

ENGINE

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SM71001 - SECTION TWO

ENGINE

ENGINE DATA ENGINE DATA TURBO Make / Model / Type Cummins 4BT3.9-C110, 4 cylinder Cooling Water Displacement - cu.in. (cc) 240 (3920) HP, SAE net (kW) @ 2500 rpm 110 (82) Air Cleaner Dual replacement elements Fuel filter Spin-on Cartridge Fuel consumption gal/hr (l/hr) 3.0 (11.5) Fuel Capacity - gal (liter) 37 (140) Electrical system 12 volt Injection sequence 1-3-4-2 Operating speed 2200 Idle speed 675 - 725 Inlet valve clearance (cold) .010 inch (.25mm) Exhaust valve clearance (cold) .020 inch (.51mm)

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SM71001 - 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, in the USA call the Cummins Customer Relations Department at 1-800-343-7357.

It is not the intent or purpose of this manual to supersede the manufacturer’s 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.

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SM71001 - SECTION TWO

ENGINE

ENGINE REMOVAL The following procedure is written for engine removal in the upward direction through the machine’s floor opening.

1.

Place the machine on a hard level surface and block the front and rear drums.

2.

Unlock the battery box cover.

3.

Disconnect the battery’s negative (-) cable from the battery.

4.

Disconnect the battery’s positive (+) cable from the battery.

5.

Remove the battery from the battery box.

6.

Remove the seat frame and battery box.

7.

Remove all floor panels.

8.

Remove all floor panel support frames.

9.

Unlock and remove the machine’s left side door.

10. Remove the machine’s front access panel.

11. Remove the machine’s right side access panel.

12. Disconnect the exhaust pipe from the exhaust manifold.

13. Remove the air intake hoses.

14. Remove the capscrews holding the steering/charge pump adapter to the engine. Disengage the pump from the engine drive and move the pump clear of the engine. Leave the hoses connected to the pump.

15. Tag and disconnect the electrical wires from the engine temperature sensor.

16. Drain the engine coolant system.

17. Remove the upper and lower radiator hoses.

18. Remove the capscrews holding the radiator cowling. Lift the cowling toward the engine to access the fan capscrews.

19. Remove the fan and fan spacer. NOTE THE DIRECTION OF THE FAN PITCH PRIOR TO REMOVAL. Remove the radiator cowling.

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SM71001 - SECTION TWO

ENGINE

20. Remove the pin securing the throttle linkage to the injection pump.

21. Loosen the nuts securing the throttle linkage to the engine bracket and remove the linkage from the bracket.

22. Shut off both fuel valves at the fuel tank.

23. Disconnect the fuel line from the lift pump and cap the line.

24. Disconnect and tag the electrical wires for the fuel shut off solenoid.

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ENGINE

25. Disconnect and cap the fuel return line at the pump.

26. Disconnect and tag the electrical wires from the engine oil pressure switch.

27. Disconnect and tag the electrical wires from the starter and solenoid.

28. Remove the ground strap from the starter motor flange.

29. Disconnect and tag the wires to the alternator.

30. Disconnect and remove the coolant recovery bottle.

31. Disconnect the engine ground strap from the engine block.

32. Disconnect the pump control cable from the drive pump cable bracket.

33. Support the drive and vibratory pumps. Remove the capscrews from the pump mounting plate and slide the pumps back away from the engine.

34. Drain the engine oil and disconnect the drain hose from the bulkhead fitting through the bottom plate.

35. Remove the hose clamp holding the oil drain hose.

36. Connect a suitable lifting device to the engine lifting eyes.

37. Remove the capscrews and washers from the three engine mounts (two mounts at the rear of the engine and one at the front).

38. Raise the engine and slide it toward the radiator until the engine is clear of other components, then lift the engine from the machine.

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SM71001 - SECTION TWO

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ENGINE

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ENGINE

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SECTION THREE

ELECTRICAL

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ELECTRICAL

INSTRUMENT PANEL, RIGHT

X7

ELECTRICAL SOCKET: This socket provides an external 12 volt power source.

F1

FUSE #1: Fuse (8 amp.) for warning lamps on neutral start, alternator, engine oil pressure, parking brake, hydraulic filter, horn switch, backup alarm switch, engine temperature, and engine temperature gauge.

F2

FUSE #2: Fuse (8 amp.) for backup lights and electrical socket.

F3

FUSE #3: Fuse (8 amp.) for the turn signal switch circuit.

F4

FUSE #4: Fuse (8 amp.) for the front and rear light circuits.

P1

COMBINATION INDICATOR GAUGE:

P3

ENGINE TEMPERATURE GAUGE: This gauge indicates the temperature of the engine when the engine is running and the key switch is in the “ON” position. Normal engine temperature is indicated by the “GREEN” zone. If the gauge pointer moves into the “RED” zone during operation, stop the engine and check for the problem.

S1

KEY SWITCH: circuits.

see page 6

This switch is used to start and stop the engine and energize the electrical

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SM71001 - SECTION THREE S3

ELECTRICAL

HORN SWITCH: Push this switch to sound the horn

NOTE: You will hear a warning sound from the horn if the engine temperature is too high.

You will also hear a warning sound from the horn if the propulsion system is engaged while the parking brake is on.

S13 HEAD & TAIL LIGHT SWITCH: and “HIGH BEAM”.

S4

This is a three position rotary switch: “OFF”, “LOW BEAM”,

TURN SIGNAL SWITCH: This is a three position rotary switch. “OFF” is in the center position.

“LEFT” and “RIGHT” turn correspond to the direction the switch is rotated.

S14 BACKUP LIGHT SWITCH: This switch controls the backup lights. Push the button in to the “ON” position to illuminate the backup lights. The switch button will illuminate and lock into the “ON” position until the button is pushed again to release the switch.

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ELECTRICAL

INSTRUMENT PANEL, LEFT

P4

WATER LEVEL INDICATOR: (optional equipment) Shows the water tank level.

S9

WATER PUMP SWITCH: This switch has three positions “MANUAL”, “OFF”, and “AUTOMATIC”. Rotate the switch left to the “MAN” position for continuous water sprinkler operation. Rotate the switch right to the “AUTO” position for intermittent sprinkler operation.

D1

SPRINKLING INTERVAL SWITCH: This is a 10 position switch which controls the water sprinkler OFF time when switch S9 is in the “AUTO” mode. The sprinkler ON time is set at 3 seconds while the OFF time is variable from 3 to 30 seconds in 3 second intervals

S12 VIBRATION FREQUENCY SWITCH: This switch has six positions: two “0” (OFF) positions, a “MAN” (MANUAL) and an “AUTO” (AUTOMATIC) position for 33 Hz (1980 vpm), and a “MAN” (MANUAL) and an “AUTO” (AUTOMATIC) position for 42 Hz (2520 vpm). The high amplitude / low frequency positions are on the left side of the switch and the low amplitude / high frequency positions are on the right side of the switch.

In either of the MANUAL positions, vibration will start when switch S18 or S19 or S20 has been selected and VIBRATION CONTROL SWITCH S11 is in the ON position. Vibration will stop when S11 is in the OFF position.

In either of the AUTOMATIC positions, vibration will start when switch S18 or S19 or S20 has been selected and VIBRATION CONTROL SWITCH S11 is in the ON position and the machine propulsion control is moved out of neutral. Vibration will stop when the propulsion control is moved back to neutral or switch S11 is turned to OFF.

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ELECTRICAL

NOTE: Do not change vibration speed with the machine moving. If you need to change vibration speed, stop the machine and change the vibration speed.

S18 FRONT DRUM VIBRATION SWITCH: Selecting this switch after setting switch S12 to MAN or AUTO will turn ON front drum only vibration when switch S11 is turned ON. The switch button will illuminate when selected. The drum selection is canceled when switch S12 is returned to the OFF position.

S19 FRONT & REAR DRUM VIBRATION SWITCH: Selecting this switch after setting switch S12 to MAN or AUTO will turn ON both front and rear drum vibration when switch S11 is turned ON. The switch button will illuminate when selected. The drum selection is canceled when switch S12 is returned to the OFF position.

S20 REAR DRUM VIBRATION SWITCH: Selecting this switch after setting switch S12 to MAN or AUTO will turn ON rear drum only vibration when switch S11 is turned ON. The switch button will illuminate when selected. The drum selection is canceled when switch S12 is returned to the OFF position.

S11 VIBRATION CONTROL SWITCH: This switch has two positions, ON and OFF. There is a lamp in the switch knob that will illuminate when the switch is ON. After selecting MAN or AUTO on switch S12 and selecting the desired drum configuration with switch S18 or S19 or S20, turn the knob to the right to start vibratory operation. Turn the knob to the left to stop vibratory operation.

F5

FUSE #5 This is a fuse (8 amp.) for the vibration circuit.

F6

FUSE #6 This is a fuse (8 amp.) for the sprinkler circuit.

F7

FUSE #7 This is a fuse (20 amp.) for the water pump circuit.

F8

FUSE #8 This is a fuse (8 amp.) for the ether cold start and other (optional equipment).

INSTRUMENT PANEL COVER

Instrument panel covers are provided for both the left and right sections of the instrument panel.They can be secured using padlocks. These covers are stored under the right side of the seat rail.

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ELECTRICAL

COMBINATION INDICATOR

INDICATOR LAMPS: 1 2 3 4 5 6 7 8 9 10 11 12

Water level indicator light Hydraulic filter indicator light Brake “ON” warning light Alternator indicator light Engine oil pressure indicator light Engine coolant temperature indicator light Engine oil temperature indicator (not used) Sprinkler pump “ON” indicator light Air filter indicator light (not used) Fuel level indicator light (not used) Neutral position indicator light Directional light indicator (not used)

When the key switch is turned to the ON position indicator lamps #3, #4, and #5, will illuminate. Additionally lamps #1 and #11 will illuminate if the water tank level is low and if the propulsion control lever is in the neutral position.

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ELECTRICAL

SPEED RANGE CONTROL

Low range, mid range, and high range travel speeds are controlled by two blue push button switches on the operator’s center column. The left side switch operates the speed control on the front drum motor and the right side switch operates the speed control on the rear drum motor. Low = 0-2.4 mph (0-4 km/hr), mid = 0-3.9 mph (0-6.3 km/hr), high = 0-7.4 mph (0-12 km/hr). Note that mid range travel has two possible switch combinations.

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Relays are located inside the instrument panel. The following is a listing identifying the relays as seen on the above drawings.

K1 K2 K3 K5 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16

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RELAY RELAY RELAY RELAY RELAY RELAY RELAY RELAY RELAY RELAY RELAY RELAY RELAY RELAY

Flasher unit Neutral start Anti-restarting lock (early model only) Water pump Front exciter Front and rear exciter Rear exciter Exciter locking Exciter locking Exciter ON/OFF Front exciter Rear exciter Neutral brake warning Brake warning

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ELECTRICAL

UNDERSTANDING ELECTRICAL SCHEMATICS

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UNDERSTANDING ELECTRICAL SCHEMATICS European electrical schematics differ somewhat from USA schematics in that the European schematic is drawn in the 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 non-crossing 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.

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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, port #2. X2/4 on line 13 means it is the X2 connector, port #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 line 10 an arrowhead indicates the wire will reconnect at relay K12 terminal 86 on line 28 (the component number is shown, followed by the line number).

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:

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ELECTRICAL

UNDERSTANDING ELECTRICAL SCHEMATICS

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ELECTRICAL Other items which may help you understand the diagram:

D

Delay relay

E

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

All drawings are shown without power

F

Fuse

All components are shown in the OFF position

G

Battery, alternator

All relay contacts #87 are normally open contacts

H

Indicator (panel indicator light, horn, alarm)

All relay contacts #87a are normally closed contacts

K

Relay

M

Motor

Relay terminal #30 is power to the contacts (when possible)

P

Gauges (hour meter, temperature gauge, etc.)

Relay terminal #87 or #87a is power from the contacts (when possible)

R

Resistor

Power to control the relay is always terminal #86

S

Switch

V

Diode

X

Connector

Y

Solenoid control valve

Ground is always terminal #85

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.

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ELECTRICAL

UNDERSTANDING RELAYS

sprinkler pump, emergency flashers, etc.

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).

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.

In the next example, the part of the relay that is connected to the control circuit consist of the windings of an electromagnet and a simple switch. When the control circuit switch is closed, a magnetic field is produced by the electromagnet. This magnetic force is used to pull 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

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ELECTRICAL

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

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.

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.

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.

Relay terminal #85 is always ground.

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ELECTRICAL

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ELECTRICAL

STARTER/CHARGING CIRCUIT

UNDERSTANDING BATTERIES

The key switch (S1) receives power from the battery (G1) at terminal 30 [line 1]. When the key switch is placed in the ON position, power is connected to switch terminals 15 and 54, energizing all key controlled components. The alternator indicator light (H3) will illuminate, indicating the key switch is on but there is no alternator output. The ground for H3 is in the regulator of the alternator [line 3]. The P1 hour meter [line 4] and the K16 brake warning relay [line 4a] will not function because battery ground occurs on both sides of these components. After the engine has been started and the alternator provides output current, the regulator output is 12 volts in place of ground.

With 12 volts to the hour meter and the brake warning relay, these components can now function. The H3 indicator light will extinguish as a result of the 12 volt potential on both sides of the lamp. P1 hour meter [line 4] and the K16 brake warning relay coil [line 4a] become energized.

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.

To start the machine, S17 neutral start switch [line 6] must be closed, providing power to the H13 neutral position indicator light, the K2 neutral start relay and the K15 brake warning in neutral relay. With K2 energized, the contacts [line 2] are closed allowing current to flow from terminal 50a on the key switch to the starter solenoid relay K0 [line 2a] coil and on to ground. K0 relay contacts close, providing a current path from battery (+) to the M1 starter motor [line 2] and the engagement coil of fuel solenoid Y0 [line 5a].

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.

When the engine starts and the alternator provides current, the regulator produces 12 volts in place of ground. Without ground on the K2 relay coil [line 5] K2 contacts [line 2] open, preventing a restart of the running engine.

Contacts on the K0 relay open when power is removed from the K0 relay coil removing power to the starter motor and the fuel solenoid engagement coil of Y0. Holding power for the Y0 fuel solenoid is provided through fuse F1.

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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.

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ELECTRICAL

STATE OF CHARGE VOLTAGE READING

SPECIFIC GRAVITY

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

Measure the voltage just before removing the load.

% CHARGE

12.66

1.260

100

12.60

1.250

91

12.54

1.240

83

12.48

1.230

75

12.42

1.220

62*

Temp C

21

16

10

4

-1

12.36

1.210

58

Temp F

70

60

50

40

30

12.30

1.200

0**

Min-voltage

9.6

9.5

9.4

9.3

9.1

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

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

UNDERSTANDING ALTERNATORS 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.

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.

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

Wait 30 seconds for the battery to recover.

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

On a machine the sequence will be as follows: when the key switch 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.

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.

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

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 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.

Normal warning lamp operation.

KEY

ENGINE

LAMP

OFF

OFF

OFF

ON

OFF

ON

ON

ON

OFF

Examples of abnormal warning lamp operation and probable causes are: Key [OFF], Engine [OFF], Lamp [ON]: short in wiring to excite rotor Key [ON], Engine [OFF], Lamp [OFF]: bad alternator diode 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+ terminal to the positive terminal of the starter solenoid.

Key [ON], Engine [ON], Lamp [ON]: regulator problem

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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’s voltage (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.

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.

SYSTEM LEAKAGE Remove the ground cable from the battery.

Make sure the key 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

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ELECTRICAL

MEASURING ALTERNATOR OUTPUT

UNDERSTANDING STARTERS

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 12 volt system.

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.

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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 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.

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 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.

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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.

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 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.

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

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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.

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INSTRUMENTATION PANEL The instrumentation panel components receive power from terminal 15/54, through Fuse F1, provided the key switch is in the ON position.

The P3 engine temperature indicator [line 8] is controlled by the variable resistor R1. Engine oil pressure indicator light H5 [line 9] will illuminate provided the normally closed engine oil pressure switch S6 is closed [line 9]. The hydraulic oil filter indicator light H6 [line 9a] will illuminate if the normally open S5 pressure switch [line9a] is closed. The H4 brake on indicator light will illuminate until brake release pressure becomes great enough to open the normally closed switch S8 [line 10].

5/21/2000

The H1 horn will sound if the normally open switch S3 is depressed. The H1 horn is also a warning indicator for the brake circuit, sounding if the running machine is placed in forward or reverse while the S8 pressure switch [line 10] is closed (K15 is controlled by the neutral start switch while K16 closes when the engine is running and the alternator is producing current [line 10a]). Diode V6 prevents the brake on indicator lamp from illuminating when the horn switch is depressed. Diode V7 performs the same function for the engine temperature indicator light. The engine temperature light (H9) illuminates if pressure switch S2 is closed due to high engine temperature.

The H2 back up alarm [line 12] receives power from fuse F1 at the neutral start switch [line 6] through the back up alarm pressure switch S10 [line 12]. The S10 pressure switch is located on the propulsion pump reverse travel control.

3 - 27

SM71001 - SECTION THREE

ELECTRICAL

3 - 28

5/21/2000

SM71001 - SECTION THREE

ELECTRICAL

LIGHTING CIRCUIT All lighting equipment is key switch controlled with separate fuses for each of the three major circuits.

F3 provides powers for the directional light circuit [lines 13 through 14b]. K1 is the flasher relay while S4 is the directional light control switch. Intermittent output at terminal 49a of the relay supplies power to the direction control switch. Output through terminal B or C is dependent upon the placement of the selector switch. Terminal C of the relay provides power to the indicator light on the control switch through terminal E. Elements E1 through E4 illuminate when the selector switch is activated.

E1 = left rear directional light E2 = left front directional light E3 = right rear directional light E4 = right front directional light

5/21/2000

Fuse F2 protects the back up light circuit as well as the accessory socket. The back up lights are controlled by a manual on-off switch S14 on the control panel. Output terminal S2 powers E5 and E6 lights.

E5 = left backup light E6 = right backup light

Fuse F4 protects the main lighting circuit which consists of the main switch S13 and the eight lights. The switch is a three position switch.

E7 = right tail light E8 = left tail light E9 = right low headlight E10 = left low headlight E11 = right high headlight E12 = left high headlight E15 = engine temp gauge lamp E16 = water level gauge lamp

3 - 29

SM71001 - SECTION THREE

ELECTRICAL

3 - 30

5/21/2000

SM71001 - SECTION THREE

ELECTRICAL

WATER SPRINKLER CIRCUIT The sprinkler system consists of a switch for manual or automatic timed operation, a low water level indicator light, an optional water level gauge, and the sprinkler pump with shut off valve. Power for the circuit is supplied through Fuse F6.

Placing switch S9 in the manual position allows current to flow from terminal 3 to the H7 indicator light and to the K5 relay [line 22]. The K5 relay contacts [line 25] close, allowing current to flow from fuse F7 to the M2 sprinkler pump and Y5 shut off solenoid.

Placing the switch in the automatic position allows current to flow from terminal 1 to the D1 delay relay [line 21] where sprinkler off time is adjustable by variable resistor R2 [line 21]. When the delay relay contacts [line 22a] close, current is made available at K5 relay, providing power to the sprinkler pump and shut off solenoid. Indicator light H7 will also illuminate.

When the low level switch S7 [line 23] is closed, current passes through the H8 water level indicator light from fuse F1. The P2 water level gauge receives power through fuse F6 and indicates the water level based on the position of variable resistor R3 [line 24].

5/21/2000

The delay relay D1 [line 21] located behind the left side panel and the sprinkler potentiometer on the left instrument panel control the sprinkler interval. The delay relay has two adjustments (T1 and T2) for control of the "OFF" and "ON" times of the sprinkler pump. T1 controls "OFF" time and T2 controls "ON" time. Turning either adjustment clockwise increases the "OFF" or "ON" time. The potentiometer on the instrument panel will control the "OFF" time only. Turn the potentiometer counter clockwise to get the minimum "OFF" time and clockwise for maximum "OFF" time. The potentiometer has no control of the "ON" time. When first starting with fresh asphalt, maximum water usage is required so the potentiometer would be set fully counter clockwise. As the drum warms up, less water is required and can be controlled by increasing the sprinkler "OFF" time by turning the potentiometer clockwise.

Adjust the sprinkler controls as follows: Place the potentiometer at minimum (fully counter clockwise). Set delay relay T1 to minimum desired "OFF" time. Set delay relay T2 to maximum desired "ON" time. The factory settings are 10 seconds "OFF" and 10 seconds "ON".

3 - 31

SM71001 - SECTION THREE

ELECTRICAL

3 - 32

5/21/2000

SM71001 - SECTION THREE VIBRATION/DRUM CIRCUITS

ELECTRICAL

SELECTION

The machine is designed to provide vibration to either the front or the rear drums, or both drums, dependent upon the selection of the three momentary push button switches S18, S19, or S20 on the left control panel. The selection of vibration with switch S11, as well as the selection of frequency with switch S12 must be made for activation of vibration. The circuit is designed so that once a drum selection switch has been depressed, the depression of a second drum selection switch will be electrically ignored.

It will be necessary to stop vibration before another selection can be made.

The circuit is powered by fuse F5 and requires the closing of switch S12 for circuit power. As shown, current cannot flow beyond the three selector switches S18, S19, or S20. One of the switches must be closed to allow the current to flow. Momentary closure of switch S18 (front drum) provides power to relay K7 [line 27 and 33] bringing power to V4 diode, K7 relay, K10 relay and

5/21/2000

K12 relay [line 37 and 40]. At this point, K7 relay remains powered even though switch S18 has opened. The switched contacts of relay K7 prevents current flow if switch S20 were depressed. Relay contacts K10 [line 31] open to prevent current flow from switch S19 if depressed. Relay K13 [line 29] activates the front exciter (shown later). Diodes V2 and V3 prevent the flow of current into the rest of the circuit.

The momentary closure of switch S20 causes a similar function, providing power to relay K9, K11, K12 as well as K14 which activates the rear exciter (shown later). Diodes V1 and V2 prevent the flow of current into the rest of the circuit.

When momentary switch S19 is depressed, relay K8 is activated as well as relay K12.

Diodes V1 and V2 prevent current flow to the rest of the circuit. With the K8 contacts open [line 27] the S18 and S19 circuits become diabled.

3 - 33

SM71001 - SECTION THREE

ELECTRICAL

3 - 34

5/21/2000

SM71001 - SECTION THREE

ELECTRICAL

VIBRATION CONTROL CIRCUIT As mentioned on the previous page, the selector push buttons provide vibration to the front or rear or both drums by providing power to relay K13 or K14 or neither relay.

If relay K13 is activated, the closing of the contacts [line 38] would provide power to solenoid Y3 resulting in vibration to the front drum only. If relay K14 is activated, the closing of contacts [line 39] would provide power to solenoid Y4 resulting in vibration in the rear drum only. When the selection is made for both front and rear vibration, neither K13 or K14 relays are activated and both drums vibrate.

Indicator lights H14 (previous drawing), H15 and H16 are located in the push buttons on the left instrument panel indicating which circuit is active.

The selection of frequency as well as manual or automatic control must also be made

5/21/2000

prior to starting the vibrator. This is done by the rotation of switch S12 to one of six positions. Placing the switch in low frequency (33 Hz) manual, closes switch contacts 11 and 12 and provides current to solenoid Y1.

Placing the switch in high frequency (50 Hz) manual, closes switch contacts 5 and 6 and provides current to solenoid Y2. Selecting high frequency automatic closes switch contacts 9 and 10 and provides power to solenoid Y2 if neutral switch S21 is closed (machine in forward or reverse). Selecting low frequency automatic closes switch contacts 7 and 8 and provides power to solenoid Y1 if switch S21 is closed. The remaining two switch positions are OFF. Switch S11 is the start/stop switch for the vibration circuit. After all selections of vibration are made, this switch can be turned on.

Turning the switch back will stop vibration.

NOTE: This switch overrides the automatic function of switch S12.

3 - 35

SM71001 - SECTION THREE

ELECTRICAL

3 - 36

5/21/2000

SM71001 - SECTION THREE

ELECTRICAL

TWO SPEED PROPULSION MOTOR CIRCUITS Each drum on the model 752C is equipped with a two speed hydraulic drive motor.

With this design the machine will actually have the capability of three drive speeds.

Low range is obtained by running both drum drive motors at maximum displacement.

Mid range is activated when one drum drive motor is operated at maximum displacement and the other drum motor is operated at minimum displacement. For high range operation both front and rear drum motors are operated at minimum displacement.

5/21/2000

Power for the 2-speed circuit is supplied from terminal 2 of fuse F8. When switch S22 [line 73] is actuated, power is supplied to solenoid valve Y6 [line 73] shifting the front drum drive motor to minimum displacement (high range). When switch S23 [line 75] is actuated, power is supplied to solenoid valve Y7 [line 75] shifting the rear drum drive motor to minimum displacement (high range).

3 - 37

3 - 38

5/21/2000

18A

19

16A

17

18

17A

2A

15

13

17

27

22

25

26

26A

1

3

11

12

3

10

E8

E9

E10

E11

E12

E15

E16

F1

F2

F3

F4

F5

F6

F7

F8

G

G1

G2

H1

H2

H3

H4

6A

31A

37A

39A

H13

H14

H15

H16

11A

20

E7

23

19A

E6

H9

15

E5

H8

15A

E4

22A

14A

E3

H7

14

E2

9

13A

E1

9A

13

D1

H6

21A

C2

H5

29A

35A

C1

ITEM LINE

S1

R3

R2

R1

P4

P3

P2

P1

M2

M1

K16

K15

K14

K13

K12

K11

K10

K9

K8

K7

K5

K2

K1

K0

INDICATOR LIGHT, REAR ONLY VIB.

INDICATOR LIGHT, FRONT ONLY VIB.

INDICATOR LIGHT, FRONT/REAR VIB.

INDICATOR LIGHT, NEUTRAL POSITION

INDICATOR LIGHT, ENGINE TEMP.

INDICATOR LIGHT, WATER LEVEL

INDICATOR LIGHT, WATER PUMP

INDICATOR LIGHT, HYDRAULIC FILTER

INDICATOR LIGHT, ENG. OIL.

INDICATOR LIGHT, BRAKE ON

INDICATOR LIGHT, ALTERNATOR

BACKUP ALARM

HORN

ALTERNATOR

BATTERY

PICKUP, SPEEDOMETER

S20

S19

S18

S17

S14

S13

S12

S11

S10

S9

S8

S7

S6

S5

S4

S3

RELAY, VIBRATION REAR DRUM

RELAY, VIBRATION FRONT DRUM

RELAY, VIBRATION ON/OFF

RELAY, VIBRATION LOCKING ON

RELAY, VIBRATION LOCKING ON

RELAY, REAR DRUM VIBRATION

25

33

31

27

6

15

17

40-27

40

12

22

10

23A

9

9A

14

11

11A

1

24

21

8

26

8

24

4

SWITCH, REAR VIBRATION

SWITCH, FRONT & REAR VIBRATION

SWITCH, FRONT VIBRATION

SWITCH, NEUTRAL START

SWITCH, BACKUP LIGHT

SWITCH, LIGHT

SWITCH, VIB. FREQUENCY & MODE

SWITCH, VIBRATION CONTROL

SWITCH, BACKUP ALARM

SWITCH, WATER SPRINKLER

SWITCH, PARKING BRAKE

SWITCH, WATER LEVEL

SWITCH, ENGINE OIL PRESSURE

SWITCH, HYDRAULIC OIL FILTER

SWITCH, DIRECTIONAL LIGHTS

SWITCH, HORN PUSH BUTTON

SWITCH, ENGINE TEMPERATURE

SWITCH, KEY

SENSOR, WATER LEVEL

POTENTIOMETER, SPRINKLER DELAY

SENSOR, ENGINE TEMPERATURE

GAUGE, SPEEDOMETER OPTION

GAUGE, ENGINE TEMPERATURE

GAUGE, WATER LEVEL

HOUR METER

MOTOR, SPRINKLER PUMP

MOTOR, STARTER

5-10A RELAY, BRAKE CONTROL 2

V2

V1

S23

S22

S21

Y7

Y6

Y5

Y4

Y3

Y2

Y1

Y0

V8

V7

V6

V5

V4

75

73

25A

39

38

41

40

5A

5A

11A

10A

35

29

36

31A

29A

75

73

41

ITEM LINE

RELAY, FRONT & REAR DRUM VIBRATION V3

RELAY, FRONT DRUM VIBRATION

RELAY, WATER PUMP

RELAY, NEUTRAL START, ANTI RESTART

RELAY, FLASHER

RELAY, AUXILIARY START

DESCRIPTION

7-10A RELAY, NEUTRAL POSTION MONITOR

35-39

29-38

37-40

34-31

28-31

33-27

31-27

27-33

22-25

6-2

14

0-2

ITEM LINE

FUSE, 20 AMP. ETHER/SPEEDOMETER OP S2

FUSE, 20 AMP. WATER PUMP CIRCUIT

FUSE, 20 AMP. SPRINKLER CIRCUIT

FUSE, 8 AMP. VIBRATION

FUSE, 8 AMP. LIGHTING

FUSE, 8 AMP. TURN SIGNALS

FUSE, 8 AMP. BACKUP LIGHT & SOCKET

FUSE, 8 AMP. MAIN INSTRUMENTATION

LIGHT, WATER LEVEL GAUGE

LIGHT, ENGINE TEMP. GAUGE

LIGHT, LEFT HIGH BEAM HEADLIGHT

LIGHT, RIGHT HIGH BEAM HEADLIGHT

LIGHT, LEFT LOW BEAM HEADLIGHT

LIGHT, RIGHT LOW BEAM HEADLIGHT

LIGHT, LEFT TAIL

LIGHT, RIGHT TAIL

LIGHT, RIGHT BACK UP

LIGHT, LEFT BACK UP

LIGHT, RIGHT FRONT TURN SIGNAL

LIGHT, RIGHT REAR TURN SIGNAL

LIGHT, LEFT FRONT TURN SIGNAL

LIGHT, LEFT REAR TURN SIGNAL

DELAY RELAY, SPRINKLER SYSTEM

CAPACITOR, REAR VIB. RELAY

CAPACITOR, FRONT VIB. RELAY

DESCRIPTION

SOLENOID, REAR DRUM 2-SPEED

SOLENOID, FRONT DRUM 2-SPEED

SOLENOID, WATER SPRINKLER

SOLENOID, REAR DRUM VIBRATION

SOLENOID, FRONT DRUM VIBRATION

SOLENOID, VIBRATION HIGH FREQ.

SOLENOID, VIBRATION LOW FREQ.

SOLENOID, FUEL SHUT OFF

DIODE, ANTI-RESTART RELAY

DIODE, HORN & ENGINE TEMP

DIODE, BRAKE CONTROL RELAY

DIODE, REAR VIB. RELAY

DIODE, FRONT VIB. RELAY

DIODE, REAR VIB. ON/OFF

DIODE, FRONT/REAR VIB. ON/OFF

DIODE, FRONT VIB. ON/OFF

SWITCH, REAR DRUM 2-SPD.

SWITCH, FRONT DRUM 2-SPD.

SWITCH, VIBRATION OFF IN NEUTRAL

DESCRIPTION

3 - 40

5/21/2000

31A

37A

39A

H15

H16

H13

H14

11A

6A

H9

23

H8

22A

10

H4

H7

3

H3

9

12

H2

9A

11

H1

H6

3

G2

H5

1

25

F7

G1

22

F6

26

27

F5

26A

17

F4

G

13

F3

F8

15

2A

F1

F2

17A

E16

E11

17

16A

E10

18

19

E9

E15

18A

E8

E12

19A

20

E7

15

14

E3

E6

13A

E2

14A

13

E1

15A

21A

D1

E5

35A

C2

E4

29A

ITEM LINE

C1

DESCRIPTION K1

S1

R3

R2

R1

P4

P3

P2

P1

M2

M1

K16

K15

K14

K13

K12

K11

K10

K9

K8

K7

K5

K2

INDICATOR LIGHT, REAR ONLY VIB.

INDICATOR LIGHT, FRONT ONLY VIB.

INDICATOR LIGHT, FRONT/REAR VIB.

INDICATOR LIGHT, NEUTRAL POSITION

INDICATOR LIGHT, ENGINE TEMP.

INDICATOR LIGHT, WATER LEVEL

INDICATOR LIGHT, WATER PUMP

INDICATOR LIGHT, HYDRAULIC FILTER

INDICATOR LIGHT, ENG. OIL.

INDICATOR LIGHT, BRAKE ON

INDICATOR LIGHT, ALTERNATOR

BACKUP ALARM

HORN

ALTERNATOR

BATTERY

PICKUP, SPEEDOMETER

S20

S19

S18

S17

S14

S13

S12

S11

S10

S9

S8

S7

S6

S5

S4

S3

DESCRIPTION

RELAY, VIBRATION REAR DRUM

RELAY, VIBRATION FRONT DRUM

RELAY, VIBRATION ON/OFF

RELAY, VIBRATION LOCKING ON

RELAY, VIBRATION LOCKING ON

RELAY, REAR DRUM VIBRATION

RELAY, FRONT & REAR DRUM VIBRATION

RELAY, FRONT DRUM VIBRATION

RELAY, WATER PUMP

RELAY, NEUTRAL START, ANTI RESTART

RELAY, FLASHER

RELAY, AUXILIARY START

33

31

27

6

15

17

40-27

40

12

22

10

23A

9

9A

14

11

11A

1

24

21

8

26

8

24

4

25

2

SWITCH, REAR VIBRATION

SWITCH, FRONT & REAR VIBRATION

SWITCH, FRONT VIBRATION

SWITCH, NEUTRAL START

SWITCH, BACKUP LIGHT

SWITCH, LIGHT

SWITCH, VIB. FREQUENCY & MODE

SWITCH, VIBRATION CONTROL

SWITCH, BACKUP ALARM

SWITCH, WATER SPRINKLER

SWITCH, PARKING BRAKE

SWITCH, WATER LEVEL

SWITCH, ENGINE OIL PRESSURE

SWITCH, HYDRAULIC OIL FILTER

SWITCH, DIRECTIONAL LIGHTS

SWITCH, HORN PUSH BUTTON

SWITCH, ENGINE TEMPERATURE

SWITCH, KEY

SENSOR, WATER LEVEL

POTENTIOMETER, SPRINKLER DELAY

SENSOR, ENGINE TEMPERATURE

GAUGE, SPEEDOMETER OPTION

GAUGE, ENGINE TEMPERATURE

GAUGE, WATER LEVEL

HOUR METER

MOTOR, SPRINKLER PUMP

MOTOR, STARTER

5-10A RELAY, BRAKE CONTROL

7-10A RELAY, NEUTRAL POSTION MONITOR

35-39

29-38

37-40

34-31

28-31

33-27

31-27

27-33

22-25

6-2

14

0-2

ITEM LINE K0

FUSE, 20 AMP. ETHER/SPEEDOMETER OP S2

FUSE, 20 AMP. WATER PUMP CIRCUIT

FUSE, 20 AMP. SPRINKLER CIRCUIT

FUSE, 8 AMP. VIBRATION

FUSE, 8 AMP. LIGHTING

FUSE, 8 AMP. TURN SIGNALS

FUSE, 8 AMP. BACKUP LIGHT & SOCKET

FUSE, 8 AMP. MAIN INSTRUMENTATION

LIGHT, WATER LEVEL GAUGE

LIGHT, ENGINE TEMP. GAUGE

LIGHT, LEFT HIGH BEAM HEADLIGHT

LIGHT, RIGHT HIGH BEAM HEADLIGHT

LIGHT, LEFT LOW BEAM HEADLIGHT

LIGHT, RIGHT LOW BEAM HEADLIGHT

LIGHT, LEFT TAIL

LIGHT, RIGHT TAIL

LIGHT, RIGHT BACK UP

LIGHT, LEFT BACK UP

LIGHT, RIGHT FRONT TURN SIGNAL

LIGHT, RIGHT REAR TURN SIGNAL

LIGHT, LEFT FRONT TURN SIGNAL

LIGHT, LEFT REAR TURN SIGNAL

DELAY RELAY, SPRINKLER SYSTEM

CAPACITOR, REAR VIB. RELAY

CAPACITOR, FRONT VIB. RELAY S22

Y7

Y6

Y5

Y4

Y3

Y2

Y1

Y0

V8

V7

V6

V5

V4

V3

V2

V1

S23

75

73

25A

39

38

41

40

5A

5A

11A

10A

35

29

36

31A

29A

75

73

41

ITEM LINE S21

DESCRIPTION

SOLENOID, REAR DRUM 2-SPEED

SOLENOID, FRONT DRUM 2-SPEED

SOLENOID, WATER SPRINKLER

SOLENOID, REAR DRUM VIBRATION

SOLENOID, FRONT DRUM VIBRATION

SOLENOID, VIBRATION HIGH FREQ.

SOLENOID, VIBRATION LOW FREQ.

SOLENOID, FUEL SHUT OFF

DIODE, ANTI-RESTART RELAY

DIODE, HORN & ENGINE TEMP

DIODE, BRAKE CONTROL RELAY

DIODE, REAR VIB. RELAY

DIODE, FRONT VIB. RELAY

DIODE, REAR VIB. ON/OFF

DIODE, FRONT/REAR VIB. ON/OFF

DIODE, FRONT VIB. ON/OFF

SWITCH, REAR DRUM 2-SPD.

SWITCH, FRONT DRUM 2-SPD.

SWITCH, VIBRATION OFF IN NEUTRAL

3 - 42

5/21/2000

31A

37A

39A

H16

6A

H13

H15

11A

H14

23

H7

H9

22A

H6

H8

9

9A

H5

3

10

12

H2

H4

11

H1

H3

3

G2

26

F8

26A

25

F7

1

22

F6

G1

27

F5

G

17

2A

F1

13

17A

E16

F4

18

E15

F3

17

E12

15

16A

E11

F2

18A

19

E10

E8

E9

19A

20

E7

15

E3

E6

14

E2

14A

13A

E1

15A

13

D1

E5

21A

C2

E4

29A

35A

C1

ITEM LINE

S1

R3

R2

R1

P4

P3

P2

P1

M2

M1

K16

K15

K14

K13

K12

K11

K10

K9

K8

K7

K5

K2

K1

K0

PICKUP, SPEEDOMETER

INDICATOR LIGHT, REAR ONLY VIB.

INDICATOR LIGHT, FRONT ONLY VIB.

INDICATOR LIGHT, FRONT/REAR VIB.

INDICATOR LIGHT, NEUTRAL POSITION

INDICATOR LIGHT, ENGINE TEMP.

INDICATOR LIGHT, WATER LEVEL

INDICATOR LIGHT, WATER PUMP

INDICATOR LIGHT, HYDRAULIC FILTER

INDICATOR LIGHT, ENG. OIL.

INDICATOR LIGHT, BRAKE ON

INDICATOR LIGHT, ALTERNATOR

BACKUP ALARM

HORN

ALTERNATOR

BATTERY

S3

S20

S19

S18

S17

S14

S13

S12

S11

S10

S9

S8

S7

S6

S5

S4

RELAY, VIBRATION REAR DRUM

RELAY, VIBRATION FRONT DRUM

RELAY, VIBRATION ON/OFF

RELAY, VIBRATION LOCKING ON

RELAY, VIBRATION LOCKING ON

RELAY, REAR DRUM VIBRATION

RELAY, FRONT & REAR DRUM VIBRATION

RELAY, FRONT DRUM VIBRATION

RELAY, WATER PUMP

RELAY, NEUTRAL START, ANTI RESTART

RELAY, FLASHER

RELAY, AUXILIARY START

DESCRIPTION

33

31

27

6

15

17

40-27

40

12

22

10

23A

9

9A

14

11

11A

1

24

21

8

26

8

24

4

25

2

SWITCH, REAR VIBRATION

SWITCH, FRONT & REAR VIBRATION

SWITCH, FRONT VIBRATION

SWITCH, NEUTRAL START

SWITCH, BACKUP LIGHT

SWITCH, LIGHT

SWITCH, VIB. FREQUENCY & MODE

SWITCH, VIBRATION CONTROL

SWITCH, BACKUP ALARM

SWITCH, WATER SPRINKLER

SWITCH, PARKING BRAKE

SWITCH, WATER LEVEL

SWITCH, ENGINE OIL PRESSURE

SWITCH, HYDRAULIC OIL FILTER

SWITCH, DIRECTIONAL LIGHTS

SWITCH, HORN PUSH BUTTON

SWITCH, ENGINE TEMPERATURE

SWITCH, KEY

SENSOR, WATER LEVEL

POTENTIOMETER, SPRINKLER DELAY

SENSOR, ENGINE TEMPERATURE

GAUGE, SPEEDOMETER OPTION

GAUGE, ENGINE TEMPERATURE

GAUGE, WATER LEVEL

HOUR METER

MOTOR, SPRINKLER PUMP

MOTOR, STARTER

5-10A RELAY, BRAKE CONTROL

7-10A RELAY, NEUTRAL POSTION MONITOR

35-39

29-38

37-40

34-31

28-31

33-27

31-27

27-33

22-25

6-2

14

0-2

ITEM LINE

FUSE, 20 AMP. ETHER/SPEEDOMETER OP S2

FUSE, 20 AMP. WATER PUMP CIRCUIT

FUSE, 20 AMP. SPRINKLER CIRCUIT

FUSE, 8 AMP. VIBRATION

FUSE, 8 AMP. LIGHTING

FUSE, 8 AMP. TURN SIGNALS

FUSE, 8 AMP. BACKUP LIGHT & SOCKET

FUSE, 8 AMP. MAIN INSTRUMENTATION

LIGHT, WATER LEVEL GAUGE

LIGHT, ENGINE TEMP. GAUGE

LIGHT, LEFT HIGH BEAM HEADLIGHT

LIGHT, RIGHT HIGH BEAM HEADLIGHT

LIGHT, LEFT LOW BEAM HEADLIGHT

LIGHT, RIGHT LOW BEAM HEADLIGHT

LIGHT, LEFT TAIL

LIGHT, RIGHT TAIL

LIGHT, RIGHT BACK UP

LIGHT, LEFT BACK UP

LIGHT, RIGHT FRONT TURN SIGNAL

LIGHT, RIGHT REAR TURN SIGNAL

LIGHT, LEFT FRONT TURN SIGNAL

LIGHT, LEFT REAR TURN SIGNAL

DELAY RELAY, SPRINKLER SYSTEM

CAPACITOR, REAR VIB. RELAY

CAPACITOR, FRONT VIB. RELAY

DESCRIPTION

Y7

Y6

Y5

Y4

Y3

Y2

Y1

Y0

V8

V7

V6

V5

V4

V3

V2

V1

S23

S22

S21

75

73

25A

39

38

41

40

5A

5A

11A

10A

35

29

36

31A

29A

75

73

41

ITEM LINE

SOLENOID, REAR DRUM 2-SPEED

SOLENOID, FRONT DRUM 2-SPEED

SOLENOID, WATER SPRINKLER

SOLENOID, REAR DRUM VIBRATION

SOLENOID, FRONT DRUM VIBRATION

SOLENOID, VIBRATION HIGH FREQ.

SOLENOID, VIBRATION LOW FREQ.

SOLENOID, FUEL SHUT OFF

DIODE, ANTI-RESTART RELAY

DIODE, HORN & ENGINE TEMP

DIODE, BRAKE CONTROL RELAY

DIODE, REAR VIB. RELAY

DIODE, FRONT VIB. RELAY

DIODE, REAR VIB. ON/OFF

DIODE, FRONT/REAR VIB. ON/OFF

DIODE, FRONT VIB. ON/OFF

SWITCH, REAR DRUM 2-SPD.

SWITCH, FRONT DRUM 2-SPD.

SWITCH, VIBRATION OFF IN NEUTRAL

DESCRIPTION

SM71001 - SECTION THREE

ELECTRICAL

WIRE CHART, RIGHT PANEL & HARNESS 4010/67455 WIRE

COLOR

FROM

TO

31

red

connector X1 port #1

switch S1 terminal #30

32

black

connector X1 port #2

switch S1 terminal #15

33

black

switch S1 terminal #15

fuse F1 terminal #1

34

black-red

fuse F1 terminal #1

fuse F2 terminal #1

35

black-red

fuse F2 terminal #1

fuse F3 terminal #1

36

black-red

fuse F3 terminal #1

fuse F4 terminal #1

37

black-red

fuse F1 terminal #2

connector X0 port #13 +

38

black

switch S3 terminal S1

relay K15 terminal #87a

38a

black

relay K15 terminal #87a

diode V7

39

blue

reserve

reserve

40

black-red

fuse F1 terminal #2

gauge P3 terminal +

41

black-red

connector x2 port #2

gauge P3 terminal +

42

blue

relay K16 terminal #86

connector X0 port #7 - H3

43

blue

connector X2 port #3

relay K16 terminal #86

43a

blue

relay K16 terminal #86

diode V8

43b

blue

diode V8

relay K2 terminal #85

44

blue-yellow

connector X2 port #4

gauge P3 terminal G

45

green

connector X2 port #5

connector X0 port #8 - H5

46

black-yellow

connector X2 port #6

relay K16 terminal #87

46a

black-yellow

relay K16 terminal #87

connector X0 port #6 - H3

47

black-red

connector X2 port #7

relay K2 terminal #86

48

black-red

relay K2 terminal #86

relay K15 terminal #86

48a

black-red

relay K15 terminal #86

connector X0 port #9 - H13

49

black

fuse F2 terminal #2

auxiliary socket X7

50

black

fuse F2 terminal #2

switch S14 terminal +

51

black

connector X2 port #15

connector X0 port #12 - H6

52

black

connector X2 port #8

wire tee for 52a and 85

52a

black

line 52 wire tee

diode V7

53

black

connector X3 port #1

switch S3 terminal S1

54

yellow

connector X2 port #9

switch S14 terminal S2

55

yellow

connector X2 port #9

connector X2 port #10

56

black

switch S1 terminal #50a

relay K2 terminal #87

57

black

connector X1 port #3

relay K2 terminal #30

58

black-yellow

fuse F3 terminal #2

relay K1 terminal #49

59

black-yellow

switch S4 terminal A

relay K1 terminal #49a

60

black-white

connector X2 port #11

switch S4 terminal B

61

blue

connector X6 port #4

connector X0 port #4 - H7

3 - 44

5/21/2000

SM71001 - SECTION THREE

ELECTRICAL

WIRE

COLOR

FROM

TO

61a

black-yellow

switch S4 terminal E

relay K1 terminal C

62

black-white

connector X3 port #7

switch S4 terminal B

63

black-green

connector X2 port #12

switch S4 terminal C

64

blue

connector X6 port #5

connector X0 port #11 - H8

65

black-green

connector X3 port #2

switch S4 terminal C

66

black-gray

fuse F4 terminal #2

switch S13 terminal +

67

yellow

connector X3 port #5

connector X3 port #4

68

yellow

connector X3 port #4

gauge P3 - E15

69

gray

gauge P3 - E15

switch S13 terminal #1

69a

gray

connector X6 port #3

gauge P3 - E15

70

gray

connector X2 port #13

switch S13 terminal #1

71

gray

connector X2 port #13

connector X2 port #14

72

white

connector X3 port #3

switch S13 terminal #3

72a

white

switch S13 terminal #3

switch S13 terminal #4

73

white

connector X3 port #3

connector X3 port #6

74

brown

relay K16 terminal #85

wire #74a

74a

brown

wire #74

relay K1 terminal #31

75

brown

relay K1 terminal #31

relay K15 terminal #85

75a

brown

relay K15 terminal #85

wire #76

76

brown

wire #75a

wire #76a

76a

brown

wire #76

wire #77

77

brown

wire #76a

switch S3 terminal S

77a

brown

switch S3 terminal S

switch S4 terminal F

78

brown

switch S4 terminal F

relay K15 terminal #85

79

brown

relay K15 terminal #85

switch S14 terminal #31

80

brown

connector X2 port #1

switch S14 terminal #31

81

brown

relay K16 terminal #85

wire #82

82

brown

wire #81

wire #90

83

blue-brown

connector X2 port #16

connector X6 port #1

84

blue-brown

connector X2 port #17

connector X6 port #2

85

black

wire #52 tee

connector X0 port #3 - H9

90

brown

wire #82

connector X0 port #15 +

108

black-red

connector X2 port #2

connector X3 port #8

5/21/2000

3 - 45

SM71001 - SECTION THREE

ELECTRICAL

WIRE CHART, LEFT PANEL & HARNESS 4010/67413 WIRE

COLOR

FROM

TO

81

black

fuse F8 terminal #1

fuse F7 terminal #1

82

black

fuse F7 terminal #1

fuse F6 terminal #1

83

black

fuse F6 terminal #1

fuse F5 terminal #1

84

gray-red

switch S11 terminal B

switch S12 terminal #11

85

gray-red

connector X5 port #3

switch S11 terminal E

85a

gray-red

switch S11 terminal B

switch S11 terminal E

86

gray-red

connector X5 port #2

switch S12 terminal #7

87

gray-red

switch S12 terminal #7

switch S12 terminal #9

88

gray-black

switch S12 terminal #12

switch S12 terminal #8

89

gray-black

connector X5 port #4

switch S12 terminal #8

90

violet

switch S12 terminal #10

switch S12 terminal #6

91

violet

connector X5 port #5

switch S12 terminal #6

92

blue

connector X6 port #1

water level gauge P2 terminal G

93

blue

connector X5 port #8

connector X6 port #2

94

blue

connector X6 port #3

water level gauge P2 - E16

95

blue

connector X4 port #3

connector X6 port #5

95a

blue

pot. R2 terminal #1

pot. R2 terminal #2

95b

blue

pot. R2 terminal #2

delay relay D1 terminal #25

96

blue

pot. R2 terminal #3

delay relay D1 terminal #26

96a

blue

switch S9 terminal

delay relay D1 terminal #A1

97

blue

fuse F7 terminal #2

relay K5 terminal #30

98

brown

connector X4 port #4

connector X6 port #6

99

blue

connector X4 port #2

relay K5 terminal #87

100

brown

connector X5 port #1

connector X5 port #8

101

brown

connector X5 port #1

left panel ground terminal

102

blue

fuse F6 terminal #2

delay relay D1 terminal #18

102a

blue

delay relay D1 terminal #18

water level gauge P2 terminal +

103

blue

water gauge P2 terminal +

switch S9 terminal #2

104

gray-red

switch S12 terminal #5

switch S12 terminal #11

105

black-yellow

switch S18 - H15 terminal X2

relay K13 terminal #87

106

black-yellow

connector X5 port #6

relay K13 terminal #87

107

blue-yellow

switch S20 - H16 terminal X2

relay K14 terminal #87

108

blue-yellow

connector X5 port #7

relay K14 terminal #87

109

black

connector X4 port #1

fuse F8 terminal #1

111

violet

switch S11 terminal A

relay K12 terminal #87

112

violet

fuse F5 terminal #2

relay K12 terminal #30

113

violet

relay K12 terminal #30

Relay K13 terminal #30

3 - 46

5/21/2000

SM71001 - SECTION THREE

ELECTRICAL

WIRE

COLOR

FROM

TO

114

violet

relay K13 terminal #30

relay K14 terminal #30

115

violet

relay K14 terminal #30

switch S12 terminal #1

116

violet

relay K8 terminal #30

switch S19 - H14 terminal #13

117

violet

switch S19 - H14 terminal #13

switch S12 terminal #2

118

violet

relay K7 terminal #30

relay K8 terminal #87a

120

violet

relay K8 terminal #87

relay K10 terminal #87a

121

violet

relay K10 terminal# 87a

switch S19 - H14 terminal #14

122

violet

relay K10 terminal #30

relay K11 terminal #87a

123

violet

relay K7 terminal #87a

switch S20 - H16 terminal #13

124

violet

relay K9 terminal #87a

switch S18 - H15 terminal #13

125

violet

relay K8 terminal #86

switch S19 - H14 terminal #X2

126

violet

relay K8 terminal #86

relay K11 terminal #30

127

violet

switch S18 - H15 terminal #14

diode V4 @ K13 terminal #86

128

violet

switch S18 - H15 terminal #14

relay K7 terminal #86

129

violet

relay K7 terminal #86

relay K7 terminal #87

130

violet

relay K7 terminal #87

relay K10 terminal #86

131

violet

switch S20 - H16 terminal #14

diode V5 @ K14 terminal #86

132

violet

switch S20 - H16 terminal #14

relay K9 terminal #86

133

violet

relay K9 terminal #86

relay K9 terminal #87

134

violet

relay K9 terminal #87

relay K11 terminal #86

135

violet

relay K12 terminal #86

V1, V2, V3,

136

violet

relay K13 terminal #86

capacitor C1 +

137

violet

relay K14 terminal #86

capacitor C2 +

140

brown

left panel ground post

wire #141

141

brown

wire #140

relay K11 terminal #85

142

brown

relay K11 terminal #85

relay K10 terminal #85

143

brown

relay K10 terminal #85

relay K12 terminal #85

144

brown

relay K12 terminal #85

relay K9 terminal #85

145

brown

relay K9 terminal #85

relay K13 terminal #85

146

brown

relay K13 terminal #85

relay K8 terminal #85

147

brown

relay K8 terminal #85

relay K14 terminal #85

148

brown

relay K14 terminal #85

relay K7 terminal #85

149

brown

relay K7 terminal #85

water level gauge P2 terminal -

150

brown

water level gauge P2 terminal -

switch S11 terminal F

151

brown

switch S11 terminal F

wire #152

152

brown

wire #151

water level gauge P2 light E16

153

brown

water level gauge P2 light E16

switch S20 - H16 terminal X1

154

brown

switch S20 - H16 terminal X1

switch S19 - H14 terminal X1

155

brown

switch S19 - H14 terminal X1

switch S18 - H15 terminal X1

5/21/2000

3 - 47

SM71001 - SECTION THREE

ELECTRICAL

WIRE

COLOR

FROM

TO

156

brown

switch S18 - H15 terminal X1

capacitor C1 terminal -

157

brown

capacitor C1 terminal -

capacitor C2 terminal -

160

blue

connector X6 port #4

switch S9 terminal #1

161

blue

switch S9 terminal #1

delay relay D1 terminal #15

162

blue

delay relay D1 terminal #15

relay K5 terminal #86

163

blue

connector X6 port #6

relay K5 terminal #85

164

blue

connector X4 port #4

delay relay D1 terminal #A2

165

brown

relay K5 terminal #85

left panel ground port

WIRE CHART, FRONT HARNESS 4010/67336 WIRE

COLOR

FROM

TO

116

black

connector X3 port #1

horn

117

black-green

connector X3 port #2

right directional light

118

white

connector X3 port #3

right headlight

119

brown

connector X3 port #4

right headlight

120

brown

connector X3 port #5

left headlight

121

white

connector X3 port #6

left headlight

122

black-white

connector X3 port #7

left directional light

123

black

connector X3 port#8

horn

3 - 48

5/21/2000

SM71001 - SECTION THREE

ELECTRICAL

WIRE CHART, REAR HARNESS 4010/68335 WIRE

COLOR

FROM

TO

2

red

connector X1 port #1

starter motor M1 terminal #30

3

red

alternator G2 terminal #30

starter motor M1 terminal #30

4

blue

connector X4 port #4

water level switch S7

5

black

connector X1 port #3

relay K0 terminal #86

6

black

connector X1 port #2

connector X4 port #1

7

black

connector X2 port #8

engine water temp. switch S2

8

black-red

connector X2 port #2

connector X6 port #1

9

black-red

connector X2 port #7

connector X6 port #2

10

gray-red

connector X5 port #2

connector X6 port #4

11

gray-red

connector X5 port #3

connector X6 port #5

12

gray-black

connector X5 port #4

vibration low frequency solenoid Y1

13

brown

connector X5 port #1

vibration low frequency solenoid Y1

14

brown

connector X2 port #1

connector X5 port #1

15

brown

connector X2 port #1

vibration high frequency solenoid Y2

16

violet

connector X5 port #5

vibration high frequency solenoid Y2

17

blue-yellow

connector X2 port #4

engine temp. sensor R1

18

green

connector X2 port #5

engine oil pressure switch S6 (+)

19

blue

connector X2 port #3

alternator G2 terminal D+

20

black-green

connector X2 port #12

right rear turn light E3 +

21

yellow

connector X2 port #9

left backup light E5 +

22

gray

connector X2 port #13

right tail light E7 +

23

yellow

connector X2 port #10

right backup light E6 +

24

gray

connector X2 port #14

left tail light E8 +

25

black-white

connector X2 port #11

left rear turn light E1 +

26

blue

connector X4 port #3

water level switch S7

27

blue

connector X4 port #2

connector X9

28

black-yellow

connector X2 port #6

brake pressure switch S8 (+)

29

brown

connector X5 port #1

brake pressure switch S8 (-)

30

brown

connector X5 port #1

engine oil pressure switch S6 (-)

31

black

connector X2 port #15

connector X7

32

brown

connector X5 port #8

connector X7

33

black-red

connector X6 port #6

backup alarm connector X10

34

black-red

connector X6 port #1

connector X6 port #3

35

black-red

connector X2 port #2

fuel system Delphi connector

36

brown

connector X5 port #8

backup alarm connector X10

37

blue-brown

connector X2 port #16

water level sensor connector X8

38

blue-brown

connector X2 port #17

water level sensor connector X8

5/21/2000

3 - 49

SM71001 - SECTION THREE

ELECTRICAL

WIRE

COLOR

FROM

TO

39

brown

connector X9

sprinkler motor M2 & valve Y5 (-)

40

red

relay K0 terminal #30

starter motor M1 terminal #30

41

black

relay K0 terminal #87

starter motor M1 terminal #50

42

white

fuel system Delphi connector (K0/87)

fuel solenoild Y0

102

black-yellow

connector X5 port #6

rear drum vibration solenoid Y4

103

blue-yellow

connector X5 port #7

front drum vibration solenoid Y3

158

brown

connector X5 port #8

rear drum vibration solenoid Y4

159

brown

connector X5 port #8

front drum vibration solenoid Y3

160

brown

fuel system Delphi connector

fuel solenoild Y0

161

brown

wire #160

relay K0 terminal #85

3 - 50

5/21/2000

SECTION FOUR

HYDRAULIC

5/21/2000

4-1

4-2

5/21/2000

5/21/2000

4-3

SM71001 - SECTION FOUR

HYDRAULICS

4-4

5/21/2000

SM71001 - SECTION FOUR

HYDRAULICS

PROPULSION SYSTEM The propulsion system can be disabled for towing the machine by screwing in the two bypass valves on the propulsion pump (see the brake section for more detail).

The propulsion system uses a Hydromatik (Rexroth) propulsion pump. The pump is servo controlled and is bi-directional in operation, with a capacity of 29.6 GPM. It supplies oil to both a front and rear, two speed, bi-directional, Rexroth hydrostatic motor in a parallel flow path. The drive motors are connected to L&S planetary gearboxes.

The speed and direction of travel are controlled by a lever on either side of the steering console. The speed ranges are controlled by speed range switches located on the steering console, allowing for the selection of three travel speeds of 0 to 2.4 mph (0 to 4 km/hr), 0 to 3.9 mph (0 to 6.3 km/hr) or 0 to 7.4 mph (0 to 12 km/hr).

Charge oil for the closed loop system is supplied by the steering circuit. Return oil from the steering valve is made available as charge pressure. Its pressure is regulated by a relief valve in the propulsion pump, set at 18 bar (256 psi). The charge system provides make-up oil for the hydrostatic loop, plus pilot pressure for the servo controls and drum gearbox brakes.

Two relief valves, located in the propulsion pump, are set to 350 bar (4977 psi) and are used to protect the propulsion system from excessive pressure. Test ports at the pump outlets can be used to measure maximum obtainable pump pressures.

5/21/2000

4-5

4-6

5/21/2000

SM71001 - SECTION FOUR

5/21/2000

HYDRAULICS

4-7

4-8

5/21/2000

SM71001 - SECTION FOUR

HYDRAULICS

VIBRATION SYSTEM Located within the vibratory pump are two 350 bar (4977 psi) relief valves. They are designed to protect the circuit from excessive pressures incurred at the starting and stopping of the vibratory system. Test ports at the pump outlets can be used to measure start up pressures as well as running pressures.

The vibratory system consists of a solenoid actuated, servo controlled, bi-directional, variable displacement axial piston pump, capable of delivering 29.6 gpm (112 l/min) or 14.0 gpm (53 l/min) flow to both the front and the rear vibratory motors. The motors are fixed displacement, bi-directional, axial piston motors, located on the right side of each drum. Make-up oil (charge flow) is supplied by the same steering pump circuit as used in the propulsion pump. This makeup oil also supplies oil to the servo control circuit.

Flushing and cooling oil is circulated through the vibration motors by means of a separate valve supplied from the vibration pump.

The vibration motors can be made to function in any of three possible combinations: front drum only, rear drum only or both drums together. This is accomplished by the solenoid control valve. Depending on the direction the pump is stroked, there are two different pump flow rates resulting in two different vibrator frequencies (1980 VPM or 2520 VPM).

5/21/2000

4-9

4 - 10

5/21/2000

5/21/2000

4 - 11

SM71001 - SECTION FOUR

HYDRAULICS

4 - 12

5/21/2000

SM71001 - SECTION FOUR

HYDRAULICS

STEERING SYSTEM The steering supply pump is a 9.0 gpm (34 l/min) gear type pump which is mounted directly to the engine at the rear of the front timing cover. It supplies the necessary flow of oil for the steering hand pump, the cylinders, and charge supply oil. A main steering relief valve, set at 140 bar (1990 psi), protects the steering pump and the steering control valve. Two circuit relief valves, set at 200 bar (2844 psi), protect the cylinders and hoses from shock loads. All three of the relief valves are located in the steering control valve.

Oil from the reservoir passes through the steering supply pump and is directed to the ‘P’ port on the steering control valve. If a steering correction is not required, oil will

5/21/2000

pass through the valve and discharge out ‘T’ port, flow through the hydraulic filter and into the charge oil circuit. 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, the control valve meters a portion of the oil from the ‘P’ port to the ‘L’ or ‘R’ port, dependent on the direction the steering wheel is rotated, and out to the cylinders.

The stroking of the cylinders results in the turning of the machine. As oil flows into one end of the cylinders, oil discharges from the opposite end and returns to the steering control valve, discharges out ‘T’ port, flows through the filter and into the charge circuit.

4 - 13

4 - 14

5/21/2000

5/21/2000

4 - 15

SM71001 - SECTION FOUR

HYDRAULICS

4 - 16

5/21/2000

SM71001 - SECTION FOUR

HYDRAULICS

BRAKE CIRCUIT The parking brake on the 752C is a spring applied, hydraulically released brake. The parking brakes are physically located in the front and rear drum drive gearboxes. Hydraulic pressure is required to overcome the spring force, releasing the brake, while removal of hydraulic pressure will allow the brake to apply. Hydraulic pressure is available from the 18 bar (256 psi) charge circuit and is controlled by a manual valve on the operators platform.

The brake can be released if the machine becomes disabled through the use of a hand pump and a cut off valve (see the brake section of this manual for more detail).

A pressure switch illuminates an indicator light on the instrument panel when the pressure is removed and the brake is applied. A warning horn will sound if the brake is applied and the direction control lever is moved to forward or reverse while the machine is running.

5/21/2000

4 - 17

HYDRAULIC AND COOLING LINES

4 - 18

5/21/2000

SM71001 - SECTION FOUR

5/21/2000

HYDRAULICS

4 - 19

HYDRAULIC DRAIN SYSTEM

4 - 20

5/21/2000

5/21/2000

4 - 21

SM71001 - SECTION FOUR

HYDRAULICS

HYDRAULIC SYSTEM COMPONENTS P1 P2 P3 P4 M1 M2 M3 M4 M5 M6 M7 M8 F1 F2 VA1 VB1 VW2 VR1 Vsp1 LE OVR K B DS1 DS2

Hydrostatic propulsion pump Hydrostatic vibration pump Hydraulic steering pump Brake hand pump Rear drum drive motor Front drum drive motor Rear drum vibration motor Front drum vibration motor Steering cylinder Steering cylinder Rear drum drive gearbox Front drum drive gearbox Hydraulic charge filter Hydraulic reservoir breather filter Brake hand pump valve Vibration system control valve Brake control valve Cooler bypass check Vibration system flush valve Steering hand pump Steering valve Hydraulic cooler Hydraulic reservoir Hydraulic filter pressure switch Brake pressure switch

PRESSURE TEST POINTS MP1 MP2 MP3 MP4 MP5 MP6 MP7

Propulsion pressure - 18 to 350 bar Propulsion pressure - 18 to 350 bar Vibration system pressure - 18 to 350 bar Vibration system pressure - 18 to 350 bar Charge pressure - 18 to 30 bar Steering pressure - 18 to 200 bar Steering pressure - 18 to 200 bar

4 - 22

5/21/2000

HYDRAULIC SCHEMATIC

4 - 24

5/21/2000

SECTION FIVE

POWER TRAIN

5/21/2000

5-1

5-2

5/21/2000

752C DRUM ASSEMBLY

5/21/2000

5-3

SM71001 - SECTION FIVE

POWER TRAIN

5-4

5/21/2000

SM71001 - SECTION FIVE

5/21/2000

POWER TRAIN

5-5

SM71001 - SECTION FIVE

POWER TRAIN

5-6

5/21/2000

SM71001 - SECTION FIVE

5/21/2000

POWER TRAIN

5-7

SM71001 - SECTION FIVE

POWER TRAIN

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.

NOTE: IF ONLY WORKING ON THE DRIVE MOTOR SIDE OF THE DRUM THE SIDE FRAME CAN BE REMOVED FOR ACCESS TO THE DRIVE MOTOR, GEARBOX, OR PLATES. 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 bolts attaching the drive motor adapter to the frame on the left side of the machine.

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

6. Lift the frame and roll the drum out of the front frame.

Drum Weight = 6725 lbs (3050 kg) Machine w/o drum & ROPS = 15545 lbs (7050 kg)

5-8

5/21/2000

SM71001 - SECTION FIVE

POWER TRAIN

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.

NOTE: To complete alignment of the left side gearbox and plate might require hooking up the machine’s brake system and using the hand pump to release the brake on the gearbox (see the brake section of this manual on releasing the brakes for towing).

3. Tighten and torque the motor bracket and buffer bracket bolts.

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

5. 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.

6. It may be necessary to bleed the brake system at the brake ports.

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5-9

SM71001 - SECTION FIVE

POWER TRAIN

RIGHT SIDE BEARING COVER

5 - 10

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SM71001 - SECTION FIVE

POWER TRAIN

DRUM DRIVE BEARING REMOVAL NOTE: The drum drive bearing for the drive motor side of the drum is actually built into the drive gearbox. The right side bearings are as shown above.

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

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

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

Drum Weight = 6725 lbs (3050 kg) Machine w/o drum & ROPS = 15545 lbs (7050 kg)

4. Remove the vibration motor and motor coupling.

5. Remove frame angle plates from buffer plate (#4).

6. Remove capscrews (#5) from the bearing flange (#8) and use two jacking screws to remove the housing from the drum. Install lifting eyes into the bolt holes in bearing flange (#3) and remove the assembly. NOTE: The complete right side bearing cover assembly will be lifted out as a unit (note diagram). Care should be taken not to damage the exciter shaft. The exciter bearing cone will come out with the flange.

7. Remove capscrews (#22) from bearing flange (#8) and separate the #3 bearing flange and bearings from the #8 bearing flange.

8. Remove snap ring (#14) from the bearing flange shaft (#3) and pull bearing (#15) off the shaft. Repeat these steps with snap ring (#16) and bearing (#17).

9. Remove the shaft seal (#18), ring (#19), and cover (#21) from the bearing flange shaft. If required the bearing shaft (#3) can now be unscrewed from buffer plate (#4).

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5 - 11

SM71001 - SECTION FIVE

POWER TRAIN

DRUM DRIVE BEARING ASSEMBLY 10. Add the proper amount of oil to the exciter housing. CLP DIN 51517/3 (Mobil Gear 627).

11. Pre-assemble the right side bearing assembly as shown in the following diagram.

12. Press the bearing (#7) into the bearing flange and install snap ring (#8).

13. Attach bearing flange (#1) to buffer plate (#2).

14. Install ring (#3) onto the flange shaft (#1).

15. Install shaft seal ring (#12) into the seal retainer and place the retainer over the flange shaft.

16. Press bearing (#4) onto the bearing flange shaft (#1) and install snap ring (#10).

17. Press bearing (#5) onto the bearing flange shaft (#1) and install snap ring (#6).

18. Install the assembled bearing flange shaft (#1) into the vibratory bearing housing using gasket (#11) and the six 10mm capscrews. Use Loctite 271 and torque to 32 ft.lbs. (44 Nm).

5 - 12

5/21/2000

SM71001 - SECTION FIVE

POWER TRAIN

19. Install the completed drive bearing housing assembly onto the drum using a new O-ring (#9). Care must be taken not to damage the exciter shaft and bearings. Install the 16mm capscrews using Loctite 271 and torque to 140 ft. lbs. (190 Nm).

20. Check the vibration shaft for the proper end play (752C = 1.8mm to 3.8mm). With the drive coupling halves installed check for the 4mm shaft to motor clearance as shown below:

21. Install a new vibration motor o-ring and mount the vibration motor using capscrew and washer.

22. Reinstall the drum into the machine.

DRUM DRIVE MOTOR REPAIRS This manual is not intended to supersede or replace Mannesmann Rexroth repair instructions for the model A10VM series drum drive motor. We strongly recommend that those wanting to rebuild the drive motor obtain a copy of the manufacturer’s repair manual from their local Rexroth distributor.

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

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5 - 13

SM71001 - SECTION FIVE

POWER TRAIN

DRUM DRIVE GEARBOX The drum drive motor is attached to a Lohmann Stolterfoht Hydrotrac planetary gearbox.

The gearbox is a 2 stage design which incorporates a hydraulically released multidisc parking brake.

General Information Perform a visual inspection weekly. Also check the gearbox for noise. Check tightness of all capscrews monthly. Check the oil level every 250 hours of operation.

Oil Level 1

Remove the control plug (a).

2

Check the oil level. The oil must reach the lower edge of the bore for the control plug.

3

If necessary add CLP 220 DIN 51517/3 oil. Remove the filler plug (c) and fill to the control plug (a).

4

Reinstall the plugs and check for leaks.

5 - 14

5/21/2000

SM71001 - SECTION FIVE

POWER TRAIN

Gearbox oil change Change the oil after the first 150 hours of operation, then change oil after every 1500 to 2000 operating hours or annually.

1

Place a collecting container having a capacity of 2 gallons (6 liter) under the drain plug (b) of the drum gearbox.

2

Remove the drain plug (b) and drain the gearbox while the oil is warm. Contamination is removed more effectively when the oil is warm.

3

Install the drain plug (b) and remove the filler plug (c) and the control plug (a). Fill the gearbox with the proper oil until the oil level is at the bottom of the control plug hole (approx. 3.7 quarts [3.5 liter]).

4

Reinstall the fill and control plugs and check for leaks.

Gearbox oil recommendation Use only lubrication oil CLP 220 DIN51517/3. Using this type oil will insure that the friction coefficients of the multi disk brakes are within the permissible limits.

Some suggested oils are: Mobilgear 630 Mobilgear SHC 220 Texaco Syngear 220

The drum drive motor is attached to a Lohmann Stolterfoht Hydrotrac planetary gearbox.

The 752C uses a GFT 17 T2/312 2 gearbox.

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5 - 15

SM71001 - SECTION FIVE

POWER TRAIN

GFT 17 T2/312 2 GEARBOX

5 - 16

5/21/2000

SECTION SIX

PARKING BRAKE SYSTEM

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6-1

6-2

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5/21/2000

6-3

6-4

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SM71001 - SECTION SIX

5/21/2000

PARKING BRAKE SYSTEM

6-5

SM71001 - SECTION SIX

PARKING BRAKE SYSTEM

BRAKE CIRCUIT The parking brake on the 752C is a spring applied, hydraulically released brake. The parking brakes are physically located in the front and rear drum drive grearboxes. Hydraulic pressure is required to overcome the spring force, releasing the brake, while removal of hydraulic pressure will allow the brake to apply. Hydraulic pressure is available from the 18 bar (256 psi) charge circuit and is controlled by a manual valve on the operators platform.

The brake can be released if the machine becomes disabled through the use of a hand pump and a cut off valve.

A pressure switch illuminates an indicator light on the instrument panel when the pressure is removed and the brake is applied. A warning horn will sound if the brake is applied and the direction control lever is moved to forward or reverse while the machine is running.

6-6

5/21/2000

SM71001 - SECTION SIX

PARKING BRAKE SYSTEM

TOWING YOUR MACHINE

1

The articulation lock should be in the drive position. Chock the drums prior to manually releasing the parking brake to avoid machine movement.

2

Prior to towing the machine it is necessary to disengage the propulsion pump. To disengage the propulsion pump turn the two bypass screws in until they are flush with the retaining nuts (see pump drawing). The hydrostatics are now disengaged.

brake valve

hand pump valve

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6-7

SM71001 - SECTION SIX

PARKING BRAKE SYSTEM

3

Remove the handle from the brake valve (see photo) and install the handle on the hand pump valve. Rotate the hand pump valve 90 degrees clockwise.

4

Disengage the parking brake by actuating the hand pump located inside the door on the left side of the machine. This will build up enough hydraulic pressure to release the brake. With the key switch ON you will be able to see the brake light in the instrument cluster turn off when the brakes have released.

5

Tow the machine.

NOTE: Do not tow the machine faster than 1.9 miles per hour (3km/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 other means of transport.

6

Return the hand pump valve to the operate position (90 degrees counterclockwise) after towing.

Remove the valve handle and reinstall the handle and lock plate into the proper position on the brake valve.

7

Return the bypass valve screws on the propulsion pump to the operate position (full out) and tighten the nuts

PRIOR TO OPERATING THE MACHINE IT IS NECESSARY TO TEST THE BRAKE FUNCTION. This is done to insure that the brake system has been returned to the original operating condition.

6-8

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SECTION SEVEN

VIBRATION SYSTEM

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7-1

LIFTING DEVICE

7-2

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SM71001 - SECTION SEVEN

VIBRATION SYSTEM

DRUM EXCITER SHAFT

The following drawing shows a typical exciter shaft with overturning weights as would be found in the Model 752C.

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7-3

752C VIBRATION SYSTEM

7-4

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SM71001 - SECTION SEVEN

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VIBRATION SYSTEM

7-5

7-6

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SM71001 - SECTION SEVEN

VIBRATION SYSTEM

VIBRATION SYSTEM The vibratory system consists of a solenoid actuated, servo controlled, bi-directional, variable displacement axial piston pump, capable of delivering 29.6 gpm (112 l/min) or 14.0 gpm (53 l/min) flow to both the front and the rear vibratory motors. The motors are fixed displacement, bi-directional, axial piston motors, located on the right side of each drum. Make up oil (charge pressure) is supplied by the same steering pump circuit as used in the propulsion pump. This make up oil also supplies oil to the servo control circuit.

The vibration motors can be made to function in any of three possible combinations: front drum only, rear drum only or both drums together. This is accomplished by the solenoid control valve. Depending on the direction the pump is stroked, there are two different pump flow rates resulting in two different vibrator frequencies (1980 VPM or 2520 VPM).

Located within the vibratory pump are two 350 bar (4977 psi) relief valves. They are designed to protect the circuit from excessive pressures incurred at the starting and stopping of the vibratory system. Test ports at the pump outlets can be used to measure start up pressures as well as running pressures.

Flushing and cooling oil is circulated through the vibration motors by means of a separate valve supplied from the vibration pump.

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7-7

VIBRATION FREQUENCY

This drawing illustrates a typical exciter shaft and the two overturning weights used to change the amplitude on a Model 752C vibratory roller.

The shaft rotation can be faster in one direction and slower in the other direction. These two speeds create the two frequencies. 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.

7-8

5/21/2000

SM71001 - 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

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AMPLITUDE

7-9

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.

SM71001 - SECTION SEVEN

VIBRATION SYSTEM

VIBRATORY SYSTEM DIAGNOSTICS The Model 752C is equipped with two overturning weights. The vibration shaft is bi-directionally rotated to obtain a vibration frequency of 1980 vibrations per minute (33 Hz) in one rotational direction and 2520 vibrations per minute (42 Hz) with the opposite rotational direction.

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.

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 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 (4977 psi) but will drop to 100 to 240 bar (1400 and 3400 PSI) once operating speed has been obtained.

7 - 10

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752C DRUM DRAWING

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7 - 11

SM71001 - SECTION SEVEN

VIBRATION SYSTEM

DRUM - LEFT SIDE

7 - 12

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SM71001 - SECTION SEVEN

5/21/2000

VIBRATION SYSTEM

7 - 13

7 - 14

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DRUM - RIGHT SIDE

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7 - 15

SM71001 - SECTION SEVEN

VIBRATION SYSTEM

7 - 16

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SM71001 - SECTION SEVEN

5/21/2000

VIBRATION SYSTEM

7 - 17

SM71001 - 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. Lift the machine and roll or lift the drum out of the front frame. drum = 6725 lbs (3050 kg) machine w/o drum & ROPS = 15545 lbs (7050 kg)

7 - 18

5/21/2000

SM71001 - SECTION SEVEN

VIBRATION SYSTEM

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.

NOTE: To complete alignment of the left side gearbox and plate might require hooking up the machine’s brake system and using the hand pump to release the brake on the gearbox (see the brake section of this manual on releasing the brakes for towing).

3. Tighten and torque the motor bracket and buffer bracket bolts.

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

5. 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.

6. It may be necessary to bleed the brake system at the brake ports.

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7 - 19

SM71001 - SECTION SEVEN

VIBRATION SYSTEM

RIGHT SIDE BEARING COVER

7 - 20

5/21/2000

SM71001 - 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, gearbox, and drive plate from the left side of the drum.

3. Stand the drum on its end with the vibration motor facing upward. drum = 6725 lbs (3050 kg) 4. Remove the vibration motor and motor coupling.

5. Remove frame angle plates from buffer plate (#4).

6. Remove capscrews (#5) from the bearing flange (#8) and use two jacking screws to remove the housing from the drum. Install lifting eyes into the bolt holes in bearing flange (#3) and remove the assembly. NOTE: The complete right side bearing cover assembly will be lifted out as a unit (note diagram). Care should be taken not to damage the exciter shaft. The exciter bearing cone will come out with the flange.

7. Remove capscrews (#22) from bearing flange (#8) and separate the #3 bearing flange and bearings from the #8 bearing flange.

8. Remove snap ring #(11) and pull the exciter bearing cone #(10) with an internal puller out of flange (#8).

9. Remove snap ring (#14) from the bearing flange shaft (#3) and pull bearing (#15) off the shaft.

Repeat these steps with snap ring (#16) and bearing (#17).

10. Remove the shaft seal (#18), ring (#19), and cover (#21) from the bearing flange shaft. If required the bearing shaft (#3) can now be unscrewed from buffer plate (#4).

11. Use the exciter shaft lifting device or a suitable lifting eye to secure and remove the exciter shaft from the drum.

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

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

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7 - 21

SM71001 - SECTION SEVEN

VIBRATION SYSTEM

7 - 22

5/21/2000

SM71001 - SECTION SEVEN

VIBRATION SYSTEM

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

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

3. Install a new bearing into the left side cover and install the retaining ring. Install the left side bearing cover, using a new o-ring seal, into the left side of the drum. Apply Loctite 271 and torque the 16mm bolts to 140 ft. lbs. (190 Nm).

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

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

6. Add the proper amount of oil to the exciter housing. CLP DIN 51517/3 (Mobil Gear 627).

7. Pre-assemble the right side bearing assembly as shown in the following diagram.

8. Press the bearing (#7) into the bearing flange and install snap ring (#8).

9. Attach bearing flange (#1) to buffer plate (#2).

10. Install ring (#3) and onto the flange shaft (#1).

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7 - 23

11. Install Shaft seal ring (#12) into the seal retainer and place the retainer over the flange shaft.

12. Press bearing (#4) onto the bearing flange shaft (#1) and install snap ring (#10).

13. Press bearing (#5) onto the bearing flange shaft (#1) and install snap ring (#6).

14. Install the assembled bearing flange shaft (#1) into the vibratory bearing housing using gasket (#11) and the six 10mm capscrews. Use Loctite 271 and torque to 32 ft.lbs.

(44 Nm).

15. Install the completed drive bearing housing assembly onto the drum using a new O-ring (#9). Care must be taken not to damage the exciter shaft and bearings. Install the 16mm capscrews using Loctite 271 and torque to 140 ft. lbs. (190 Nm).

16. Check the vibration shaft for the proper end play (752C = 1.8mm to 3.8mm). With the drive coupling halves installed check for the 4mm shaft to motor clearance as shown below:

17. Install a new vibration motor o-ring and mount the vibration motor using capscrew and washer.

18. Reinstall the drum into the machine.

7 - 24

5/21/2000

SECTION EIGHT

STEERING SYSTEM

5/21/2000

8-1

8-2

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5/21/2000

8-3

SM71001 - SECTION EIGHT

STEERING SYSTEM

8-4

5/21/2000

SM71001 - SECTION EIGHT

STEERING SYSTEM

STEERING SYSTEM The steering supply pump is a 9.0 gpm (34 l/min) gear type pump which is mounted directly to the engine at the rear of the front timing cover. It supplies the necessary flow of oil for the steering hand pump, the cylinders, and charge supply oil. A main steering relief valve, set at 140 bar (1990 psi), protects the steering pump and the steering control valve. Two circuit relief valves, set at 200 bar (2844 psi), protect the cylinders and hoses from shock loads. All three of the relief valves are located in the steering control valve.

Oil from the reservoir passes through the steering supply pump and is directed to the ‘P’ port on the steering control valve. If a steering correction is not required, oil will pass through the valve and discharge out ‘T’ port, flow through the hydraulic filter and into the charge oil circuit.

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, the control valve meters a portion of the oil from the ‘P’ port to the ‘L’ or ‘R’ port, dependent on the direction the steering wheel is rotated, and out to the cylinders. The stroking of the cylinders results in the turning of the machine. As oil flows into one end of the cylinders, oil discharges from the opposite end and returns to the steering control valve, discharges out ‘T’ port, flows through the filter and into the charge circuit.

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8-5

SM71001 - SECTION EIGHT

STEERING SYSTEM

STEERING PIVOT REMOVAL 19. Park the machine on a smooth level surface and block the front and rear drums.

20. Remove the front water tank.

21. Loosen the nuts securing the drum scrapers, move the scrapers away from the drum, and retighten the nuts to hold the scrapers away from the drum.

22. Place jacks under the left and right sides of the front roller frame. Raise the drum frame enough to release the load on the drum buffers and block the frame.

23. Disconnect, tag, and cap the hydraulic lines for the drum drive motor and gearbox on the left side of the drum.

24. Disconnect, tag, and cap the hydraulic lines for the vibration motor on the right side of the drum.

25. Remove the drum drive gearbox adapter brackets to detach the drum drive from the left roller frame.

26. Remove the front and rear buffer brackets to detach the drum from the right roller frame.

27. Attach lifting chains to the four lifting points on the front drum frame.

8-6

5/21/2000

SM71001 - SECTION EIGHT

STEERING SYSTEM

28. Using a crane or hoist raise the drum frame and push the drum clear of the machine. drum weight = 6725 lbs. (3050 Kg) machine weight w/o tank and Rops = 15545 lbs. (7050 Kg)

29. Lower and support the machine for removal of the front roller frame.

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8-7

SM71001 - SECTION EIGHT

STEERING SYSTEM

8-8

5/21/2000

SM71001 - SECTION EIGHT

STEERING SYSTEM

30. Remove the capscrews (#3) securing the cover plate (#2) to the counter flange plate (#8).

31. Remove the cover plate (#2), thrust ring (#1), and belleville spring washer (#4).

32. Remove the capscrews (#5) securing the counter flange plate (#8) to the joint support (#11) and remove the counter flange plate.

33. Remove the front roller frame from the joint support and properly support the rear of the machine.

34. Remove the machine’s belly pan.

35. Disconnect the steering cylinders from the joint support (#11).

36. Support the joint (#11) on a trolley jack and remove the capscrews (#14) holding the joint and bearing to the rear machine frame. Lower the joint and remove it from the machine.

Bolt torques for reassembly: capscrew #13 capscrew #14 capscrew #5 capscrew #3

apply Loctite 271 & torque to 79 ft. lbs. (107 Nm) apply Loctite 271 & torque to 79 ft. lbs. (107 Nm) apply Loctite 271 & torque to 140 ft. lbs. (190 Nm) apply Loctite 271 & torque to 81 ft. lbs. (110 Nm)

Proper installation of thrust ring (#1) and belleville spring washer (#4) is as follows:

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8-9

SM71001 - SECTION EIGHT

STEERING SYSTEM

STEERING CYLINDER

8 - 10

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SM71001 - SECTION EIGHT

5/21/2000

STEERING SYSTEM

8 - 11

8 - 12

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SECTION NINE

CHASSIS

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9-1

SM71001 - SECTION NINE

CHASSIS

REAR ENGINE/ROLLER FRAME

9-2

5/21/2000

SM71001 - SECTION NINE

CHASSIS

FRONT ROLLER FRAME

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9-3

SM71001 - SECTION NINE

CHASSIS

STEERING LINK

9-4

5/21/2000

SM71001 - SECTION NINE

CHASSIS

FRONT WATER/DIESEL TANK

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9-5

SM71001 - SECTION NINE

CHASSIS

REAR WATER/HYDRAULIC TANK

9-6

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SM71001 - SECTION NINE

CHASSIS

INSTRUMENT CONSOLE

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9-7

SM71001 - SECTION NINE

CHASSIS

SEAT RACK

9-8

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SM71001 - SECTION NINE

CHASSIS

ROLLOVER PROTECTION STRUCTURE (ROPS)

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9-9

9 - 10

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SECTION TEN

ATTACHMENTS

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10 - 1

SM71001 - SECTION TEN

ATTACHMENTS

10 - 2

5/21/2000

A alternator voltage checks ................................................................... 3 - 21 alternators explained.......................................................................... 3 - 19

B batteries explained ............................................................................. 3 - 17 battery diagnostics ............................................................................. 3 - 18 bolt torque chart ................................................................................. 1 - 10

C charge system diagnostics................................................................. 3 - 20 combination indicator ........................................................................... 3 - 6

D diesel fuel specification ...................................................................... 1 - 13 drive motor ........................................................................................... 1 - 3 drive motor repairs ............................................................................. 5 - 13 drum drive gearbox ............................................................................ 5 - 14

E engine oil specification ....................................................................... 1 - 14 engine specifications............................................................................ 2 - 2 engine warranty.................................................................................... 2 - 3

F fluid capacities.................................................................................... 1 - 12 fluid specifications .............................................................................. 1 - 12

H hydrostatic pump.................................................................................. 1 - 3

I identifying machine parts ..................................................................... 1 - 6 instrument panel................................................................................. 3 - 27

L lighting circuit ..................................................................................... 3 - 29

R relays, understanding......................................................................... 3 - 14 relays, Vibromax types....................................................................... 3 - 15 ROPS ................................................................................................. 1 - 15

S safety, during maintenance ................................................................ 1 - 22 safety, electrical rules ......................................................................... 1 - 21 safety, general.................................................................................... 1 - 16 safety, machine operation .................................................................. 1 - 19 safety, personal.................................................................................. 1 - 17 spark arrester ..................................................................................... 1 - 16 starter diagnostics .............................................................................. 3 - 23 starter motor test ................................................................................ 3 - 25 starters explained............................................................................... 3 - 22 steering pump ...................................................................................... 1 - 4

T torque data ......................................................................................... 1 - 10 towing your machine ............................................................................ 6 - 7

U understanding electrical schematics .................................................. 3 - 11

V vibration amplitude explained............................................................... 7 - 9 vibration frequency............................................................................... 7 - 8 vibration pump...................................................................................... 1 - 3 vibration shaft....................................................................................... 7 - 3 vibration shaft bearings ....................................................................... 7 - 21

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