JCB Vibromax Tandem Rollers 255, 265 Service Repair Manual – PDF Download

255 / 265 TANDEM ROLLER SERVICE MANUAL SM61005 December 2000

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

table of contents

SECTION ONE GENERAL INFORMATION MACHINE DESCRIPTION ............................................................................... 1 - 3 SAFETY, GENERAL ........................................................................................ 1 - 7 SAFETY, PERSONAL...................................................................................... 1 - 7 SAFETY, MACHINE OPERATION .................................................................. 1 - 8 SAFETY, MAINTENANCE ............................................................................. 1 - 10 GENERAL INFORMATION............................................................................ 1 - 12 STANDARD TORQUE DATA ........................................................................ 1 - 13 METRIC/USA CONVERSIONS ..................................................................... 1 - 14 MACHINE SPECIFICATIONS........................................................................ 1 - 15 FLUID SPECIFICATIONS.............................................................................. 1 - 17 DIESEL FUEL SPECIFICATION.................................................................... 1 - 18 ENGINE OIL SPECIFICATION ...................................................................... 1 - 19

SECTION TWO ENGINE R&I ENGINE REMOVAL & INSTALLATION........................................................... 2 - 3

SECTION THREE ELECTRICAL CIRCUITS INSTRUMENT PANEL..................................................................................... 3 - 2 Instrument panel, left side.......................................................................... 3 - 3 Combination indicator ................................................................................. 3 - 4 Instrument panel, right side ........................................................................ 3 - 5 OPERATOR’S CONSOLE ............................................................................... 3 - 6 ELECTRICAL INFORMATION......................................................................... 3 - 8 RELAY LOCATION CHART............................................................................. 3 - 9 FUSE LOCATION CHART ............................................................................... 3 - 9 UNDERSTANDING ELECTRICAL SCHEMATICS ....................................... 3 - 11 UNDERSTANDING RELAYS......................................................................... 3 - 14 EMERGENCY STOP CIRCUIT...................................................................... 3 - 17 STARTER/ CHARGING CIRCUIT ................................................................. 3 - 19 UNDERSTANDING BATTERIES................................................................... 3 - 19 UNDERSTANDING ALTERNATORS.......................................................3 - 21 STARTER SYSTEM DIAGNOSTICS............................................................. 3 - 25

i

table of contents NEUTRAL SWITCH CIRCUIT........................................................................ 3 - 29 INSTRUMENTATION PANEL........................................................................ 3 - 31 COMBINATION INDICATOR....................................................................3 - 32 OPERATOR’S CONSOLE ............................................................................. 3 - 33 PARKING BRAKE CIRCUIT .......................................................................... 3 - 35 VIBRATION CONTROL CIRCUIT.................................................................. 3 - 35 SPRINKLER CIRCUIT ................................................................................... 3 - 37 ACCESSORY SOCKETS .............................................................................. 3 - 37 SPRINKLER CIRCUIT ("K" option) ................................................................ 3 - 39 LIGHTING CIRCUIT....................................................................................... 3 - 41 HAZARD/ DIRECTIONAL CIRCUIT............................................................... 3 - 41 BACK-UP ALARM.......................................................................................... 3 - 42 WIRE HARNESS LAYOUT ............................................................................ 3 - 43 WIRE HARNESS 7131/80115 ....................................................................... 3 - 46 WIRE CHART 7131/80115 ............................................................................ 3 - 49 WIRE HARNESS 7131/80255 ....................................................................... 3 - 51 WIRE CHART 7131/80255 ............................................................................ 3 - 55 ELECTRICAL SCHEMATICS ........................................................................ 3 - 59

SECTION FOUR HYDRAULIC SYSTEMS PROPULSION DRAWINGS............................................................................. 4 - 2 PROPULSION SYSTEM.................................................................................. 4 - 5 PROPULSION SYSTEM DIAGNOSTICS................................................... 4 - 5 VIBRATION DRAWINGS ................................................................................. 4 - 7 VIBRATION SYSTEM .................................................................................... 4 - 10 VIBRATION SYSTEM DIAGNOSTICS.....................................................4 - 11 STEERING DRAWINGS ................................................................................ 4 - 12 STEERING SYSTEM ..................................................................................... 4 - 15 STEERING SYSTEM DIAGNOSTICS......................................................4 - 15 HYDRAULIC RESERVOIR ............................................................................ 4 - 16 HYDRAULIC OIL FILTER .............................................................................. 4 - 17 HYDRAULIC OIL RESERVOIR ..................................................................... 4 - 17 BRAKE SYSTEM DRAWINGS ...................................................................... 4 - 18 PARKING BRAKES ....................................................................................... 4 - 21 PARKING BRAKE DIAGNOSTICS...........................................................4 - 21 HYDRAULIC TEST PORTS........................................................................... 4 - 22 HYDRAULIC COMPONENT LOCATIONS .................................................... 4 - 30

ii

table of contents HYDRAULIC SCHEMATIC ............................................................................ 4 - 31 HYDRAULIC SCHEMATIC (“K” model) ......................................................... 4 - 32 “K” MODEL SYSTEMS .................................................................................. 4 - 33

HYDRAULIC COMPONENTS POCLAIN MC05 PROPULSION MOTOR...................................................... 4 - 38 SAUER/SUNDSTRAND SERIES 42 PROPULSION PUMP.......................... 4 - 41

SECTION FIVE POWER TRAIN DRUM REMOVAL.......................................................................................... 5 - 11 DRIVE MOTOR REMOVAL ........................................................................... 5 - 11 DRIVE MOTOR REPAIR ............................................................................... 5 - 13 DRIVE MOTOR INSTALLATION ................................................................... 5 - 13 DRUM DRIVE BEARING REMOVAL............................................................. 5 - 13 DRUM BEARING INSTALLATION................................................................. 5 - 15 DRUM INSTALLATION.................................................................................. 5 - 15 PNEUMATIC TIRE DRIVE............................................................................. 5 - 16

SECTION SIX PARKING BRAKE SYSTEM PARK BRAKE TESTING.................................................................................. 6 - 5 BRAKE RELEASE FOR TOWING ................................................................... 6 - 5 TOWING PROCEDURE ............................................................................. 6 - 6 BRAKE REPAIRS ............................................................................................ 6 - 8

SECTION SEVEN VIBRATORY SYSTEM VIBRATORY SHAFT REMOVAL ..................................................................... 7 - 9 INSTALLING VIBRATORY SHAFT................................................................ 7 - 11

SECTION EIGHT STEERING SYSTEM

iii

table of contents

SECTION NINE CHASSIS FRAME............................................................................................................. 9 - 3 HOOD & DOOR PANELS ................................................................................ 9 - 4 OPERATOR PLATFORM ................................................................................ 9 - 5 WATER TANK.................................................................................................. 9 - 6 WATER TANK COATING ................................................................................ 9 - 7 ROLL OVER PROTECTIVE STRUCTURE (ROPS) ........................................ 9 - 8 SUN ROOF .................................................................................................... 9 - 10

SECTION TEN ATTACHMENTS WATER SPRINKLER SYSTEM ..................................................................... 10 - 2 DRUM SCRAPERS........................................................................................ 10 - 6 ROAD LIGHT KIT 87130/20120..................................................................... 10 - 8 WORK LIGHT KIT 87130/20100.................................................................. 10 - 10

iv

SECTION ONE

GENERAL INFORMATION

1-1

SM61005 - SECTION ONE

GENERAL INFORMATION

Built with serviceability in mind .

1-2

SM61005 - SECTION ONE

GENERAL INFORMATION

MACHINE DESCRIPTION The 255/265 Series vibratory roller is a redesign of the 253/263.

The machine remains a

2.5 metric ton, tandem drum machine with articulated steering, hydrostatic drive and a hydraulically driven vibration system. The 255 has a 1000 mm (39 inch) drum width while the 265 is a 1200 mm (47 inch) drum width version. These machines are also offered with a “K” version which is a combination roller built with pneumatic tires in place of the rear drum.

A Kubota D1403B, water cooled, three cylinder in-line diesel engine, mounted in the rear chassis, provides the power for the machine. The standard engine has a 29.0 Net Horse Power rating at 2600 RPM. An optional high horsepower Kubota D1403B (37 horsepower) is also available. Both engines meet the latest exhaust emissions standards.

A Sauer Sunstrand hydrostatic propulsion pump provides oil for the front and rear Poclain, fixed displacement, drum drive motors in a parallel path. On the “K” model combination roller there are three propulsion motors in parallel. Propulsion system controls are enhanced with the addition of a high and low operating range. The motors are located on the right hand side of the drums and are connected directly to the drum.

The vibration system consists of a fixed displacement gear pump mounted to the back of the propulsion pump. This gear pump drives the two gear motors (one on each drum, left hand side) in a series flow path, with options of vibration to the front drum only, rear drum only, both drums or neither drum. Oil from the vibration circuit passes through an air to oil cooler at the engine radiator. The exciter shafts and the drum bearings are oil lubricated, eliminating the need for grease zerks.

Pressure testing of the hydraulic system has been simplified by the location of a test station inside the left side access door. Pressure testing of the drive, charge, vibratory and steering systems can be performed from this one location.

1-3

SM61005 - SECTION ONE

GENERAL INFORMATION

The electrical system consists of the stan-

Front and rear parking brakes are provided

dard starter, battery and charging circuit

on the 255/265. The drum brakes are inte-

along with optional lighting, hazard and

gral to the drive motors. The brakes are

directional lights.

spring applied / hydraulically released and

includes switches for vibration, sprinklers,

are controlled by a switch on the dash and

lights and brakes along with the standard

by an emergency stop switch on the right operators console.

The instrument panel

instrument cluster of warning lights and an

A brake release valve

hour meter. An emergency stop button is

and a brake hand pump are located under

located right of the operator’s seat. All elec-

the hood on the left side of the machine.

trical fuses and relays are located behind a

These items provide for brake release

door panel on the right side of the opera-

when towing a disabled machine.

tors platform.

A steering pump, mounted to the back of A 53 gallon water tank is located on the

the vibration pump, provides oil for the

front chassis, providing water for the

steering control valve and a single steering

asphalt sprinkler system. The tank’s modu-

cylinder at the articulation joint. The joint is

lar design allows for easy removal if neces-

maintenance free, providing 40 degrees of

sary. On the “K” model combination roller

articulation and 15 degrees of oscillation.

the water tank has two separate compart-

An articulation joint safety lock completes

ments and the system has two water

the steering system.

pumps to allow for the use of a special spray on the pneumatic tires. Pressurized

The return oil flow from the vibratory circuit

sprinkler bars with spray nozzles on each

and the steering circuit passes through a

drum, or tires on the “K” model, complete

10 micron oil filter mounted in the top of the

the water system. Spring loaded scrapers

hydraulic reservoir. A filter bypass and a

are provided on the front and rear of each

pressure differential switch completes the filter circuit.

drum. This arrangement keeps a constant

The hydraulic reservoir is

scraper

located below the operators platform on the left side of the rear chassis.

1-4

pressure

against

the

drum.

SM61005 - SECTION ONE

GENERAL INFORMATION

SERIAL NUMBERS 1 2 3 4 5 6 7 8

Model / Serial Number Front Drum Drive Motor S/N Rear Drum Drive Motor S/N Steering Unit S/N Front Vibratory Motor S/N Rear Vibratory Motor S/N Hydraulic Pumps S/N Engine S/N

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SM61005 - SECTION ONE

GENERAL INFORMATION

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

Articulation joint Smooth drum Lifting eye Operator’s stand Battery Hydraulic tank Engine Drum drive motor Rubber buffer Scraper

11 12 13 14 15 16 17 18 19 20

1-6

Spring loaded brake Water tank Fuel tank Air filter canister Water - oil cooler Roll over protection Vibration motor Steering cylinder Hydraulic pumps Sun roof

SM61005 - SECTION ONE

GENERAL INFORMATION

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

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.

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

•

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

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

Know the location and function of all machine controls.

•

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

•

Always use the seat belt when operating the machine.

Make sure the buckle for the seat is fastened correctly.

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

Make sure cab windows are clean and unobstructed.

times.

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

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

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

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

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

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SM61005 - SECTION ONE

GENERAL INFORMATION

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

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

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

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

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

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

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

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

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

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

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

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

Do not permit other persons to ride on the machine.

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SM61005 - SECTION ONE

GENERAL INFORMATION

The vibrations from this machine can cause the walls of a trench or high bank to collapse. If you must operate this machine close to a trench or high bank, make sure the walls of the trench or bank are braced. If you do not follow these instructions, you can cause personal injury or death to persons working in these areas.

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

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

Electrical Safety Rules

Cable Voltage

Minimum Clearance From Cable When Machine is Working

Minimum Clearance From Cable When Transporting Machine

50,000 volts or less

10 feet (3 meters)

4 feet (1.2 meters)

50,000 volts to 345,000 volts

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

10 feet (3 meters)

345,000 volts to 750,000 volts

23 feet (7m) plus 1/2 inch (13mm) for every 1000 volts over 345,000 volts

16 feet (5 meters)

1-9

SM61005 - SECTION ONE

GENERAL INFORMATION

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

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.

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

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

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.).

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.

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.

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

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

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

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

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

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

1 - 10

SM61005 - SECTION ONE

GENERAL INFORMATION

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

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

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

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

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

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

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

1 - 11

SM61005 - SECTION ONE

GENERAL INFORMATION

GENERAL INFORMATION

Before pressing bearing, lubricate the inner and outer diameters as needed.

CLEANING Clean all metal parts, except bearings, in

GEARS Check and replace all gears that have wear

mineral spirits or by steam cleaning. Do not

or damage.

use caustic soda when steam cleaning.

After cleaning, dry and put oil on all parts.

Clean oil passages with compressed air.

Clean bearings in kerosene, dry the bear-

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

ings completely and put oil on the bearings.

INSPECTION Check all parts as they are disassembled.

Replace all parts that have wear or dam-

SHAFTS Check all shafts for wear damage. Check the surfaces where bearings and oil seals operate for signs of wear.

age. Small scoring or grooves can be

plete visual inspection for indications of

SERVICE PARTS Always install genuine Vibromax service

wear and pitting. Replacement of bad parts

parts. When ordering refer to the parts

will prevent early failure.

manual for the correct part numbers. Fail-

removed with a hone or crocus cloth. Com-

ure to use genuine Vibromax replacement BEARINGS Check bearings for easy movement. If

parts can void your warranty.

bearings have a loose fit or rough action, replace the bearing. Wash bearings in ker-

LUBRICATION Use the oils and lubricants specified in the

osene and allow to air dry. DO NOT USE

Operator’s or Service Manual. Failures due

COMPRESSED AIR TO DRY BEARINGS.

to the use of non specified lubricants are not covered by warranty.

NEEDLE BEARINGS Before pressing needle bearings into a bore, always remove any metal protrusions in the bore or at the edge of the bore.

1 - 12

SM61005 - 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. Loctite products also act as a lubricant.

STANDARD TORQUE SPECIFICATIONS +/- 10% GRADE 8.8

GRADE 10.9

GRADE 12.9

SIZE

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

5mm

4

5.5

5.5

7.5

6.6

9

6mm

6.6

9

9.2

12.5

11

15

8mm

16.5

22.5

23

31.5

26.5

36

10mm

32

44

45

62

55

75

12mm

57

77.5

81

110

95

130

14mm

88

120

125

170

155

210

16mm

140

190

195

265

236

320

18mm

192

260

269

365

320

435

20mm

273

370

383

520

457

620

22mm

369

500

516

700

619

840

24mm

471

640

665

900

796

1080

27mm

702

950

996

1350

1195

1620

30mm

955

1300

1328

1800

1593

2160

NUTS FOR TUBES AND HOSES DIAMETER & PITCH 16MM X 1.5 18MM X 1.5 20MM X 1.5 24MM X 1.5

NEWTONS/METER 20 35 45 60

1 - 13

POUNDS/FOOT 14.5 26 33.2 44

SM61005 - SECTION ONE

GENERAL INFORMATION

FITTINGS, CONNECTIONS AND PLUGS DIAMETER & PITCH 10MM X 1 12MM X 1.5 14MM X 1.5 16MM X 1.5 18MM X 1.5 22MM X 1.5 27MM X 2 33MM X 2 42MM X 2

NEWTONS/METER 20 35 45 60 70 100 200 280 380

POUNDS/FOOT 14.5 26 33.2 44 51 73 147 207 281

FLANGES DIAMETER & PITCH 8MM X 1.5 10MM X 1.5 12MM X 1.75 14MM X 2 16MM X 2

NEWTONS/METER 28 55 90 145 230

POUNDS/FOOT 21 41 67 107 170

METRIC/USA CONVERSIONS

METRIC UNITS millimeters (mm) bars kilograms (kg) kilowatts (kW)

CHANGE TO inches (in) pound per sq. in. (psi) pounds (lb) horsepower (hp)

celsius (oC) newton meters (Nm) newton meters (Nm) liters (L) liters (L)

farenheit (oF) pounds feet (lb ft) pounds inch (lb in) U.S. gallon U.S. quarts

C x 1.8 + 32 = oF Nm x .737 = lb ft Nm x 8.85 = lb in liters x .264 = gallons liters x 1.056 = quarts

cubic centimeters (cm3)

cubic inches (in3)

cm3 x .061 = in3

1 - 14

ARITHMETIC mm x .03937 = inches bar x 14.22 = psi kg x 2.204 = pounds kW x 1.341 = horsepower o

SM61005 - SECTION ONE

GENERAL INFORMATION

MACHINE SPECIFICATIONS

SIDE VIEW

255 / 265

a d h1 h2 k1 l s

in.

66.9 27.6 67.7 98.4 11.4 94.5 0.5

mm 1700 700 1720 2500 290 2400 12

in.

43.1 51.0 22.4 22.4 1.9 1.9 39.4 47.2

mm 1096 1296 570 570 48 48 1000 1200

FRONT VIEW 255 / 265

b k2 o w

1 - 15

model 255 265 255 265 255 265 255 265

SM61005 - SECTION ONE

GENERAL INFORMATION

ENGINE DATA Make / Model / Type Kubota, 1403B, 3 cylinder, diesel Cooling Water Displacement - cu.in. (cc) 85.7 (1400) HP, SAE net (kW) @ 2600 rpm 29 (21.5) Air Cleaner Dual replacement elements Fuel filter Cartridge Fuel Consumption - gal/hr (liter/hr) 1.32 (5) Fuel capacity - gal (liter) 16.6 (63) Electrical system 12 volt Battery, amp hours 88 Injector pump timing 17 to 19 degrees Injector pop off pressure 1991 to 2133 psi. valve clearance (intake/exhaust) .018/.022 mm (cold) DRIVE SYSTEM DATA Propulsion - front and rear Infinitely variable hydrostatic Travel speed - mph (km/hr) 1st gear 0 - 3.7 (0-6) 2nd gear 0 - 6.8 (0-11) Theoretical gradeability, forward -% 40 Brakes, operating Hydrostatic braking thru ground drive Brakes, parking Spring applied, hydraulic release Steering Articulated, hydraulic powered Articulation/oscillation - degrees 40 / 15

OPERATING DATA Operating Weight - lbs (kg) Static linear drum load - lb/in (kg/cm) ea.drum Centrifugal force per drum - lbf (kN) Centrifugal force/rolling width - lbf/in (N/cm) Total applied force/rolling width - lbf/in (N/cm) Frequency - vpm (Hz) Nominal Amplitude - in. (mm) Drum shell thickness - in. (mm) Water tank capacity - gal (liter)

1 - 16

255 5843 (2650) 74.1 (13.2) 6744 (30) 171 (300) 245.1 (428.9) 3480 (58) .020 (0.5) 0.50 (12) 52.8 (200)

265 6064 (2750) 64.2 (11.4) 8100 (36) 171 (300) 235.2 (411.6) 3480 (58) .020 (0.5) 0.50 (12) 52.8 (200)

SM61005 - SECTION ONE

GENERAL INFORMATION

FLUID SPECIFICATIONS MACHINE PART Fuel tank Engine crankcase

CAPACITY USA (metric) 16.6 gal (63 l) 6 qts(5.6 l)

Hydraulic system

15.9 gal (60 l)

Reservoir only

13.2 gal (47 l)

Vibration system 255 265 Battery Grease

(each drum) 1.3 qts. (1.2 l) 1.9 qts. (1.8 l) as required as required

Engine coolant Sprinkling Device

8.5 qts (8 l) 52.8 gal (200 l)

SPECIFICATIONS see diesel fuel engine oil API classification API-CD MIL-L-2104C multigrade engine oil (see oil chart) single grade engine oil (see oil chart) cold weather HLP 46 DIN 51524 hot weather HLP 68 DIN 51524 Mobil DTE 25,26 Shell Tellus OL 46,68 Amoco Rykon HD 46,68 Texaco Rando HD 46,68 Mobil Gear 627

Distilled water KP3K DIN 51502 Mobil Oil - Mobilux 3 Shell Oil - Alvania 3 Texaco Oil - Starplex 3 50% ethylene glycol and 50% water Tap water

1 - 17

SM61005 - 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 #2 diesel fuel you use meets the following minimum requirements.

MINIMUM REQUIREMENTS FOR #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 ...................................... 40 (45 to 55 in winter or at high altitude) Max. sulphur content, by weight ................................................................................. 0.50% Max. water content & sediment by volume................................................................. 0.05% Max. ash content, by weight....................................................................................... 0.01% Max. carbon residue (10% point) ............................................................................... 0.20% Distillation temperature @ 90% point ...........................................540 to 625OF (282-329OC) Distillation temperature @ end point .............................................................. 675OF (357OC) Minimum flash point ................................................................................. 125OF (52OC) Viscosity at 100OF (38OC) Centistokes .......................................................................................2.0 to 4.3 Saybolt Universal Seconds (SUS) ............................................................................32 to 40 Copper strip test, 3 hours @ 212OF (100OC)....................................................... No 3 ASTM Minimum API gravity ..................................................................................................30

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SM61005 - 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

1 - 19

1 - 20

SECTION TWO ENGINE R&I

2-1

SM61005 - SECTION TWO

ENGINE

2-2

SM61005 - SECTION TWO

ENGINE

ENGINE REMOVAL & INSTALLATION

2-3

SM61005 - SECTION TWO

ENGINE 13. Disconnect the hydraulic pump control cable and the two speed control linkage.

ENGINE REMOVAL

1.

Open the left and right doors below the operator’s seat.

2.

Remove the wing nuts holding the seat platform to the frame and tilt the seat platform forward.

3.

Disconnect and remove the battery.

4.

Remove the engine compartment hood by removing the hood hinge bolts and the support cylinder.

5.

Drain the engine oil and radiator cooling system.

6.

Disconnect the upper and lower radiator hoses and the coolant bottle hose.

7.

Disconnect, cap, and mark the two lines to the hydraulic oil cooler.

8.

9.

14. Disconnect, cap, and tag the hydraulic lines at the propulsion, vibration, and steering pumps.

15. Remove the bolts holding the vibration valve mounting plate and slide the vibration valve assembly to the side.

16. Loosen the engine mounts at the mount buffers.

17. Remove the engine and hydraulic pump assembly using the two lifting eyes provided on the engine. The pump assembly can then be removed outside of the machine.

ENGINE OVERHAUL

Remove the radiator and shroud assembly from the machine by removing the four buffer nuts.

The Kubota Model 1403B engine in your machine is warranted by Kubota. If you experience problems with your engine during the warranty period, contact your local Kubota repair center. This manual is not intended to supersede engine overhaul material provided by Kubota. Beyond the warranty period, it is highly recommended that you obtain the Kubota Engine Overhaul Manual 97897-01096 from your local dealer for proper overhaul instructions. The Kubota manual is also available through your Vibromax dealer by ordering part# V40102.

Disconnect the flexible exhaust pipe at the exhaust manifold. The muffler assembly can remain in the machine’s rear frame.

10. Disconnect, cap, and tag the engine fuel supply and return lines.

11. Engine removal can be made easier by taking the time to remove the coolant bottle on the right side and the air cleaner assembly on the left side of the machine.

12. Disconnect and tag the following electrical connections: engine oil pressure switch, air cleaner indicator switch, engine temperature switch, engine shutdown solenoid, three starter wires, two alternator connectors, engine ground strap, hydraulic pump solenoid and neutral switch.

2-4

SM61005 - SECTION TWO

ENGINE 18. Block the engine fuel lever to allow the engine to crank but not start. Continue cranking the engine until a charge pressure reading can be obtained in the propulsion system at test port MP3.

INSTALLATION

1.

Install the engine and hydraulic pump assembly using the two lifting eyes provided on the engine.

2.

Secure the engine in place with the engine mounts.

3.

4.

19. Prime and bleed the engine fuel system.

Connect the vibration control valve by installing the two capscrews.

20. Start the engine and inspect the machine for hydraulic, fuel, and water leaks.

Connect all hydraulic lines to the propulsion, vibration, and steering pumps. Make sure the case drain on the propulsion pump is filled with oil.

5.

Connect the propulsion pump control cable and the 2 speed linkage.

6.

Connect all pump and engine electrical lines.

7.

Connect the engine fuel lines.

8.

Connect the flexible tube to the exhaust manifold.

9.

Install the radiator and shroud assembly securing it at the buffers.

21. Recheck all fluid levels.

22. Install the hood.

10. Reinstall the coolant bottle.

11. Reinstall the air cleaner assembly.

12. Connect the engine air inlet hose.

13. Connect the upper and lower hydraulic cooler lines.

14. Connect the upper and lower radiator hoses and clamp in place.

15. Refill the radiator with the proper antifreeze and water mixture.

16. Check the engine oil level.

17. Install the machine’s battery.

2-5

NOTES

2-6

SECTION THREE

ELECTRICAL CIRCUITS

3-1

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

INSTRUMENT PANEL

The instrument panel cover prevents unauthorized operation of the machine. Remove the cover from the storage position. Attach over the instrument panel and secure with the padlock.

3-2

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

Instrument panel, left side

NOTE: Switch vibration on only when the machine is in motion.

1. Vibration switch, front: Controls the vibration for the front drum.

2. Automatic vibration switch: Stops the vibration of the front and/ or rear drum when the forward/ reverse lever is placed in neutral.

3. Vibration switch, rear: Controls the vibration for the rear drum.

The vibration control on the forward/reverse lever activates the vibration after front and/ or rear vibration selection has been made.

4. Power socket: Used for lighting accessories.

5. Pressure sprinkler switch: AUTOMATIC/OFF/MANUAL pressure sprinkler control. Rotate switch clockwise for manual sprinkling or counterclockwise for automatic timed sprinkling.

6. Interval sprinkler control: This potentiometer adjusts the off time interval when the pressure sprinkler switch is in the automatic position.

7. Optional "K" model rear pressure sprinkler switch: AUTOMATIC/OFF/MANUAL pressure sprinkler control. Rotate switch clockwise for manual sprinkling or counterclockwise for automatic timed sprinkling.

8. Optional "K" model rear interval sprinkler control: This potentiometer adjusts the off time interval when the pressure sprinkler switch is in the automatic position.

3-3

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

Combination indicator

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

Water level indicator light (not used) 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 Fuel level indicator light Neutral position indicator light Directional light indicator (optional equipment)

3-4

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

Instrument panel, right side

1. Key switch: The switch has four positions; OFF, ON, PREHEAT and START. Place the switch in the ON position to turn on the electrical system. Place the switch in preheat position and hold until the preheat indicator light (item 4) goes out. Place the switch in the start position. When engine starts, release the switch and it will return to the ON position. To stop the engine, place the switch in the OFF position. Remove the key 2. Parking brake switch: Push the switch in to engage the brakes. With the key switch on, the brake indicator light in the combination indicator will illuminate. Push in a second time to release the switch, disengaging the brakes.

3. Horn switch: Depress the switch to sound the horn.

4. Preheat indicator lamp: The lamp illuminates for a predetermined length of time when the key switch is placed in the preheat position.

5. Hazard warning switch (optional): This switch will turn on the hazard warning lights.

6. Directional switch (optional): The switch positions are LEFT DIRECTIONAL, OFF, and RIGHT DIRECTIONAL. 7. Light switch (optional): This switch has an ON and an OFF position and controls the road lights.

3-5

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

OPERATOR’S CONSOLE 1. Drive lever: The drive lever has three positions, FORWARD, NEUTRAL and REVERSE. Use this lever for changing direction and for adjusting travel speed. Move the lever forward to drive forward. Move the lever backward to reverse the machine. A backup alarm should sound if installed. The further the lever is moved forward or backward from the neutral position, the greater the machine speed.

To stop the machine movement, place the drive lever in the neutral position.

There is a machine starting lock in the neutral position of the drive lever. To release the lock, pull the lever to the left, then select the desired driving direction. When starting and stopping the machine, be certain the drive lever is in the neutral position.

2. Emergency OFF switch: Check the function of the emergency OFF switch at the start of each work shift and prior to driving on steep grades. Depressing the emergency OFF switch will place the machine in neutral, apply the brakes, stop vibration and shut off the engine.

3. Vibration switch: The vibration can be switched on and off after the pre-selection of desired drums has been made on the control panel.

3-6

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

3-7

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

ELECTRICAL INFORMATION Inside the door a row of relays is located immediately below the fuses. The relay positions are numbered for identification and function (see location chart and schematic for relay functions).

The electrical system on the 255/265 is a 12 volt, negative ground system. The engine uses a standard gear type starter motor and a belt driven alternator. The battery is accessible by opening the door of the electrical compartment on the right side of the machine. The electrical compartment is the central location for all major electrical components. All fuses, relays and timers are located inside this compartment along with the horn, backup alarm, sprinkler pump, and other equipment.

Relay K9 is the hazard/directional light relay. Relay K10 is for vibration control. All other relays have the same part number and can be interchanged for trouble shooting of the electrical system.

Located below and forward of the “K� relays are several delay relays. The purpose of these relays is for engine preheating time, engine shut down solenoid delay time, seat switch safety relay and a sprinkler delay relay.

The fuses, accessible through the side door are arranged in two rows. The top row provides terminals for fuses 1 through 8 while the bottom row provides terminals for fuses 9 through 16 (see schematic for fuse functions).

The horn is mounted at the lower rear area of the electrical compartment with the sprinkler pump mounted immediately forward of the horn.

3-8

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

RELAY LOCATION CHART D1 Delay Relay, Seat Monitor Option D2 Delay Relay, Sprinkler Cycle D3 Delay Relay, Engine Preheat D4 Delay Relay, Engine Stop D5 Delay Relay, Sprinker Optional K1 Relay, Neutral K2 Relay, Engine Monitor K3 Relay, Emergency Off K4 Relay, Auto Vibration K5 Relay, Brake Release K6 Relay, Brake Release K8 Relay, Sprinkler Pump K9 Relay, Flashers K10 Relay, Vibration K11 Relay, Sprinkler Pump Option

FUSE LOCATION CHART

F1 Warning and Signal Device & Emergency Off Switch F2 not used F3 Pressure Sprinkler F4 Socket and Working Lights F5 Flasher Device F6 Back up Alarm F7 Alternator F8 Not Used

F9 Parking Brake and Release F10 Vibratory System F11 Pressure Sprinkler Control F12 Lighting System F13 Flasher Device F14 Lighting System, Left Side F15 Lighting System, Right Side F16 Pressure Sprinkler Optional rear

3-9

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

UNDERSTANDING ELECTRICAL SCHEMATICS

3 - 10

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW 2 indicates it is the X1 connector, wire #2.

X2/4 on line 13 means it is the X2 connector, wire #4.

UNDERSTANDING ELECTRICAL SCHEMATICS European electrical schematics differ somewhat from USA machinery 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. In the USA they are often used in industrial applications.

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.

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, terminal number, and a line number (see drawing, line 10). At the line number indicated, in this case line 28, the component number is shown, followed by the line number 10 and the completion of the circuit.

Ladder diagrams seldom allow crossing lines. This keeps the diagram clean and easy to follow. To maintain the rules of noncrossing lines, it is sometimes necessary to split the functions of a component and show these functions separately (see drawing) for example, the K2 relay control circuit on line 5 shows terminal 86 as power to the control coil while 85 is control 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 working circuit of the K2 relay and 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.

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/

3 - 11

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

UNDERSTANDING ELECTRICAL SCHEMATICS

3 - 12

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

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

Delay relay

E

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

F

Fuse

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

Other items which may help you understand the diagram:

G

Battery, alternator

All drawings are shown without power

H

Indicator (panel indicator light, horn, alarm)

All components are shown in the OFF position

K

Relay

All relay contact #87 are normally open contacts

M

Motor

P

Gauges (hour meter, temperature gauge, etc.)

R

Resistor

S

Switch

V

Diode

X

Connector

Y

Solenoid control valve

All relay contact #87a are normally closed contacts Relay terminal #30 is power to the contacts (when possible) Relay terminal #87 or #87a is power from the contacts (when possible) Power to the control coil of the relay is always terminal #86 Ground for the relay control coil 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.

3 - 13

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW sprinkler pump, emergency flashers, etc.

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

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.

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

3 - 14

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

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.

Relay terminal #85 is always ground.

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.

3 - 15

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

EMERGENCY STOP CIRCUIT

3 - 16

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

EMERGENCY STOP CIRCUIT The emergency stop circuit receives power from the ignition switch S1 terminal 15, when the switch is in the ON position. Current from the ignition switch passes through Fuse F1 [line 15], through the normally closed emergency stop switch S3, through the coil of the emergency stop Relay K3 and to ground [line 22]. Power through the K3 relay coil causes the contacts of Relay K3 [line 23] to close, providing power to the brake circuit [line 25], the vibration circuit [lines 31 to 33a], and to the sprinkler circuits [lines 37 to 41]. If the emergency stop switch is depressed, the power is removed from the brake release circuit, the vibration and sprinkler circuit and the engine shut down solenoid timer.

NOTE: Further details on the vibration, brake and sprinkler circuits will be discussed later.

3 - 17

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

STARTER & CHARGE CIRCUITS

3 - 18

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

STARTER/ CHARGING CIRCUIT

UNDERSTANDING BATTERIES

The major components of the starter and charging circuit are the starter motor, alternator, battery, the ignition switch, neutral start switch and the pre-heater circuit [lines 0 to 6].

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.

When the ignition switch S1 is turned to the ON position, power from the emergency stop circuit is available through the neutral start switch S2 (located on the propulsion pump) if the machine is in neutral [line 6], through the coil of relay K1 and to ground.

The contacts of relay K1 close [line 2], providing a current path between the start terminal 50a on the ignition switch and the starter motor. Turning the ignition switch to the start position will allow the starter to crank the engine.

An ignition switch position between ON and START provides power to the engine preheater circuit [lines 0 and 1]. Placing the switch in this position provides current to the pre-heaters [line 0], to the indicator light H0 on the dash and to the heater timer [line 1]. Preheat time is approximately 5 seconds.

When the machine has been started and the alternator [line 4] is producing output current, the alternator indicator light on the dash will extinguish because the alternator regulator, previously at ground, now provides 12 volts which is equal to the current to the indicator light. With 12 volts on both sides of the indicator light, there is no current flow and the light will not glow. The hour meter [line 5] only has power if the alternator is producing power, eliminating hour meter errors if the ignition switch is inadvertently left on.

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.

A mechanical anti-restart feature is incorporated into the ignition switch design.

3 - 19

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW BATTERY DIAGNOSTICS

Batteries produce explosive gases.

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

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

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

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

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

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

4) Keep the electrolyte level topped off.

5) Keep the alternator belt tight.

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

3 - 20

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW cold crank amperage rating for 15 seconds.

Measure the voltage just before removing the load.

STATE OF CHARGE VOLTAGE READING

SPECIFIC GRAVITY

% CHARGE

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

12.66

1.260

100

12.60

1.250

91

Temp C

21

16

10

4

-1

12.54

1.240

83

Temp F

70

60

50

40

30

12.48

1.230

75

Min-voltage

9.6

9.5

9.4

9.3

9.1

12.42

1.220

62*

12.36

1.210

58

12.30

1.200

0**

UNDERSTANDING ALTERNATORS

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

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

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.

Apply a load of approximately 1/2 of the

3 - 21

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

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

terminal to the positive terminal of the starter solenoid.

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

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.

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

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

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

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

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

CHARGING SYSTEM DIAGNOSTICS Normal warning lamp operation.

KEY

ENGINE

LAMP

OFF

OFF

OFF

ON

OFF

ON

ON

ON

OFF

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

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

3 - 22

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

VOLTAGE CHECKS AT ALTERNATOR

going to ground. This will eventually discharge the battery.

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

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

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

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

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

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

3 - 23

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

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

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

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

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

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

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

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

3 - 24

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

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

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

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

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

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

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

Turn the key switch to the start position.

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

3 - 25

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

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

STARTER CIRCUIT WIRING TEST

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

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

3 - 26

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

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.

3 - 27

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

NEUTRAL CONTROL CIRCUIT

3 - 28

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

NEUTRAL SWITCH CIRCUIT

ing the removal of brake release pressure.

Besides providing the assurance that the

If the machine is started outside of neutral

machine will not start unless in neutral, the

this prevents machine operation until the

circuit has other functions. One feature is

machine control lever is returned to neutral.

an automatic vibration control. Relay K4

(These circuits will be discussed later). The

[line 8] is controlled by the neutral switch,

neutral indicator light H2 [line 10] is also

receiving power and controlling the vibra-

controlled by the neutral switch.

tion circuit [line 31]. Relay K5 [line 9] will open its contacts [line 20] in neutral, caus-

3 - 29

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

INSTRUMENTATION PANEL

3 - 30

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

INSTRUMENTATION PANEL

gine water temperature becomes exces-

The instrumentation panel receives power

sive.

through fuse F1, by way of line 15, when the

from the ignition switch, through fuse F1. If

ignition switch is in the "ON" position. Pow-

switch S4 or switch S5 close during engine

er is provided through indicators H3, H4,

operation, ground for K2 relay is activated,

H5, H6 and H7 to switches S4, S5, S6, S7

opening its normally closed contacts [line

and S8. When a switch is closed, circuit

26]. This removes power from the D4 timer

current to ground is completed and the indi-

relay [line 26] and applies power to solenoid

cator will illuminate.

Y1, (line 26) shutting down the engine. A

Relay K2 [line 14] receives power

second function of D4 relay is to shut down As a safety feature in the instrumentation

the engine when the temperature and oil

circuit, engine shut down will occur if there

pressure limits are exceeded.

is a loss of engine oil pressure or if the en-

3 - 31

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

COMBINATION INDICATOR

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

Water level indicator light (not used) 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 Fuel level indicator light Neutral position indicator light Directional light indicator (optional equipment)

3 - 32

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

OPERATOR’S CONSOLE 1. Drive lever: The drive lever has three positions, FORWARD, NEUTRAL and REVERSE. Use this lever for changing direction and for adjusting travel speed. Move the lever forward to drive forward. Move the lever backward to reverse the machine. A backup alarm should sound if installed. The further the lever is moved forward or backward from the neutral position, the greater the machine speed.

To stop the machine movement, place the drive lever in the neutral position.

There is a machine starting lock in the neutral position of the drive lever. To release the lock, pull the lever to the left, then select the desired driving direction. When starting and stopping the machine, be certain the drive lever is in the neutral position.

2. Emergency OFF switch: Check the function of the emergency OFF switch at the start of each work shift and prior to driving on steep grades. Depressing the emergency OFF switch will place the machine in neutral, apply the brakes, stop vibration and shut off the engine.

3. Vibration switch: The vibration can be switched on and off after the pre-selection of desired drums has been made on the control panel.

3 - 33

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

VIBRATION CIRCUIT

BRAKE CIRCUIT

3 - 34

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

PARKING BRAKE CIRCUIT

power to K10 but the relay remains latched

The parking brake circuit is located on line

until energized again through S12. This pro-

25 of the schematic. Power to the brake re-

vides power through S11 and K10 to the vi-

lease solenoid, provided the key is on and

bration selector switches S13 (front) and

the emergency stop switch is not de-

S14 (rear) on the dash. Closing either or

pressed, is supplied through fuse F9. Cur-

both switches energizes the H11 and/or

rent flows through the normally closed

H12 indicators as well as providing current

brake switch S10, through the contacts of

to energize solenoids Y3 (rear) and/ or Y4

the optional delay relay D1 (the normally

(front). Diodes V4 and V5 are provided at

open contact will close if the operator is sit-

the vibration circuit solenoids to reduce coil

ting on the seat to close optional switch S22

collapse spikes and improve the life cycle of

[line 29] ), through the normally closed con-

K10 relay.

tacts of relay K6 and to the brake release An interruption of current

In the automatic mode, vibration will stop

through these components will de-energize

whenever the machine is placed in neutral

the Y2 solenoid, which will remove the pres-

and will restart when the machine is set in

sure from the brakes and allow spring force

motion. When depressing switch S11 for

to apply the brake.

automatic operation, the manual contacts

solenoid Y2.

[S] open and the automatic contacts [S2]

VIBRATION CONTROL CIRCUIT

close. This provides power to indicator H10

Power for the vibration control circuit is

as well as to the contacts of relay K4. Cur-

available through fuse F10 [line 31] if the

rent passing through these relay contacts

key is on and the emergency stop switch is

provides power to switches S13 and S14

not depressed. Power from the fuse pass-

along with their associated indicators and

es

selector

solenoids. Relay K4 [line 8] receives power

switch S11 (depress switch for automatic,

from the neutral start switch when in neu-

release for manual). In the manual mode,

tral, causing the contacts to open and inter-

current from F10 passes through switch

rupt power. In the automatic vibration mode

S12 on the forward/reverse lever, momen-

the S12 switch on the forward/reverse lever

tarily actuating and latching K10 relay.

does not override the automatic vibration

Releasing the S12 switch drops control

function.

through

manual/automatic

3 - 35

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

SPRINKLER CIRCUIT

3 - 36

POWER SOCKET (spotlight option)

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

SPRINKLER CIRCUIT The sprinkler pump receives its supply power from fuse F3 [line 41], but is controlled by the delay relay D2 circuitry [lines 37 through 40]. Power for fuse F3 is supplied by the ignition switch and is available if the switch is in the on position. Current from fuse F3 passes through the contacts of relay K8 and on to the sprinkler motor, water shutoff solenoid Y5, and to indicator H13. The opening and closing of relay K8 is controlled by the D2 circuitry. fuse F11 supplies power to the sprinkler "ON/OFF" switch S16. In the continuous position, current flows out the C terminal, through the coil of the K8 relay to ground, closing K8 contact [line 41]. In the intermittent position, current passes through switch terminal B to the delay relay D2. D2 produces an on/off interval, dependent on the positioning of potentiometer R1.

When in the "ON" phase, current from D2 passes through relay K8 to ground, closing K8 contacts [line 41]. When in the "OFF" phase, there is no current output to the K8 relay.

tentiometer 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".

ACCESSORY SOCKETS An accessory socket X7, located on the left side of the steering console, provides electrical power for an optional spotlight. A sec-

The delay relay located behind the right side panel and the sprinkler potentiometer on the 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 po-

ond optional socket is located in the upper right corner of the ROPS. Power for these circuits is supplied through fuse F4 [line 42] requiring the key to be in the "ON" position (element E1 is a spot light with attached switch S17). Grounding for these spotlights is carried through the chassis.

3 - 37

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

SECOND SPRINKLER CIRCUIT ("K" option)

3 - 38

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

SPRINKLER CIRCUIT ("K" option) The second sprinkler system used on the "K" model combination roller is identical to the system shown on the previous pages.

The sprinkler pump receives its supply power from fuse F16 [line 60], but is controlled by the delay relay D5 circuitry [lines 55 through 58]. Power for fuse F16 is supplied by the ignition switch and is available if the switch is in the on position. Current from fuse F16 passes through the contacts of relay K11 and on to the sprinkler motor, water shutoff solenoid Y6, and to indicator H19.

The opening and closing of relay K11 is controlled by the D5 circuitry. fuse F11 supplies power to the sprinkler "ON/OFF" switch S25. In the continuous position, current flows out the C terminal, through the coil of the K11 relay to ground, closing K11 contact [line 60]. In the intermittent position, current passes through switch terminal B to the delay relay D5. D5 produces an on/ off interval, dependent on the positioning of potentiometer R2. When in the "ON" phase, current from D5 passes through relay K11 to ground, closing K11 contacts [line 60].

When in the "OFF" phase, there is no current output to the K11 relay.

The delay relay located behind the right side panel and the sprinkler potentiometer on the 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 - 39

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

3 - 40

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW out the L and R terminals, through the lights

LIGHTING CIRCUIT The lighting system receives its power from

to ground.

line 15, through fuse F12 [line 45] provided the ignition switch is on. Current from the fuse enters the light switch S18. When the switch is in the engaged position, current passes through indicator H15 to ground [line 48]. Current passes through terminal S1, through fuse F14 and on to the front and rear lights on the machine’s right side [lines 44-45]. Current also passes through terminal S2, through Fuse F15 and on to the front and rear lights on the machine’s left

In the directional light mode, switch S19 remains open, current from the "ON" position of the ignition switch passes through fuse F5, into terminal 15 of switch S19, out terminal 49, through relay K9, out terminal 49a and to the A terminal of the directional switch S20. Turning the switch to the left enables a current flow through the left side lights to ground. Turning the switch to the right enables a current flow through the right side lights to ground.

side [lines 46-47].

Indicator light H18 [line 53], located inside the instrument cluster, receives its power from relay K9, and thus flashes whenever

HAZARD/ DIRECTIONAL CIRCUIT

the flasher circuit or the directional circuit is The hazard lights and directional lights

active.

[lines 49-53] are two circuits in one. Power for the hazard circuit is provided directly from the battery through fuse F13 and to switch S19, terminal 30. Depressing the hazard switch latches terminal 30 to terminal 49 and also closes the switch contacts to terminals L, 49a and R. Current flows from terminal 49 on switch S19 to terminal 49 on the K9 flasher relay, out terminal 49a of the relay, to 49a of switch S19. Current can now pass through the closed contacts,

3 - 41

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

BACK-UP ALARM Back-up alarm H9 [line 54] is powered through the ignition switch and fuse F6. Power from the fuse passes through the alarm to back-up switch S21. Switch S21, located on the propulsion pump along with the neutral start switch, closes whenever the machine is placed in reverse, creating a current path to ground and activating the alarm.

3 - 42

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

WIRE HARNESS LAYOUT

3 - 43

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

3 - 44

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

3 - 45

WIRE HARNESS 7131/80115

3 - 46

3 - 47

3 - 48

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

WIRE CHART 7131/80115 No.

Color

From

To

3

red

key switch S1 terminal 30

plug connector X2 port 1

4

red

key switch S1 terminal 15

plug connector X2 port 2

5

black

key switch S1 terminal 50a

plug connector X2 port 3

8

blue

alt. indicator H1 connector X17 port 7

plug connector X1 port 1

12

black-red

hourmeter P1 connector X17 port 13

plug connector X1 port 2

19

black

neutral indicator H2 connector X17 port 9

plug connector X1 port 3

21

green

diode V2 @ H3-

plug connector X1 port 4

22

red-white

diode V3 @ H4-

plug connector X1 port 5

23

brown-red

air filter indicator H5 connector X17 port 1

plug connector X1 port 6

24

green-red

hyd. filter indicator H6 connector X17 port 12

plug connector X1 port 7

26

black-yellow

brake indicator H7 connector X17 port 6

plug connector X1 port 8

28

brown-yellow

horn switch S9 connector port 5

plug connector X1 port 9

33

black-yellow

brake switch S10 connector port 1

plug connector X1 port 10

34

black-yellow

brake switch S10 connector port 4

plug connector X1 port 11

42

gray-green

auto vib. switch S11 connector port 1

plug connector X1 port 12

43

gray

auto vib. switch S11 connector port 4

plug connector X1 port 13

44

gray

front vib. switch S13 connector port 3

plug connector X1 port 16

45

gray

front vib. switch S13 connector port 3

rear vib. switch S14 connector port 3

47

gray

auto vib. switch S11 connector port 4

plug connector X1 port 14

48

gray-violet

front vib. switch S13 connector port 2

plug connector X1 port 17

49

gray-yellow

rear vib. switch S14 connector port 2

plug connector X1 port 18

50

blue

auto sprinkle switch S16 connector port "A"

plug connector X1 port 19

51

blue

auto sprinkle switch S16 connector port "A"

plug connector X20 port 1

52

blue

auto sprinkle switch S16 connector port "C"

plug connector X1 port 24

54

blue

auto sprinkle switch S16 connector port "B"

plug connector X1 port 23

56

blue

sprinkler pot. R1 connector port 1

plug connector X1 port 22

57

blue

sprinkler pot. R1 connector port 3

plug connector X1 port 21

58

blue

sprinkler pot. R1 connector port 3

sprinkler pot. R1 connector port 2

61

blue

sprinkle indicator H13 connector X17 port 4

plug connector X1 port 20

62

black

auxiliary power socket X7+

plug connector X2 port 6

64

red

light switch S18 connector port 1

plug connector X1 port 26

65

yellow-white

light switch S18 connector port 2

plug connector X1 port 27

66

yellow-white

front light connector X5 port 1

plug connector X1 port 29

68

yellow

light switch S18 connector port 3

plug connector X1 port 28

69

yellow

front light connector X5 port 3

plug connector X1 port 30

71

red

hazard light switch S19 connector port 3

plug connector X1 port 32

72

black-red

hazard light switch S19 connector port 1

plug connector X1 port 31

73

black-white

hazard light switch S19 connector port 6

front light connector X5 port 2

3 - 49

SM61005 - SECTION THREE No.

Color

ELECTRICAL OVERVIEW

From

To

74

black-white

hazard light switch S19 connector port 6

plug connector X1 port 35

75

black-white

hazard light switch S19 connector port 6

direction switch S20 connector port "B"

74

black-white

direction switch S20 connector port "B"

direction switch S20 connector port "E"

77

black-green

hazard light switch S19 connector port 7

front light connector X5 port 4

78

black-green

hazard light switch S19 connector port 7

plug connector X1 port 36

79

black-green

hazard light switch S19 connector port 7

direction switch S20 connector port "C"

80

black-green

direction switch S20 connector port "C"

direction switch S20 connector port "F"

81

black-yellow

hazard light switch S19 connector port 5

direction switch S20 connector port "A"

82

black-yellow

hazard light switch S19 connector port 5

plug connector X1 port 34

83

black

hazard light switch S19 connector port 4

plug connector X1 port 33

84

black

hazard light switch S19 connector port 4

hazard light switch S19 connector port 2

85

blue-yellow

direction indicator H18 connector X17 port 5

plug connector X1 port 15

90

black-blue

key switch S1 terminal 8

plug connector X2 port 4

91

black-blue

key switch S1 terminal 3

key switch S1 terminal 9

92

black-blue

key switch S1 terminal 3

plug connector X2 port 7

93

black-blue

preheat indicator H0-

plug connector X2 port 8

95

black-blue

key switch S1 terminal 3

preheat indicator H0+

97

white

fuel indicator H14 connector X17 port 2

plug connector X2 port 9

111

green-red

diode V3

plug connector X1 port 25

112

green

combination indicator cluster

diode V2

113

red-white

combination indicator cluster

diode V3

114

green-red

diode V2

diode V3

120

brown

instrument panel ground post

plug connector X2 port 5

121

brown

instrument panel ground post

horn switch S9 connector port 7

122

brown

horn switch S9 connector port 7

light switch S18 connector port 6

123

brown

light switch S18 connector port 6

hourmeter P1-

126

brown

instrument panel ground post

front vib. switch S13 port 7

127

brown

front vib. switch S13 port 7

auto vib. switch S11 port 6

128

brown

auto vib. switch S11 port 6

rear vib. switch S14 port 7

129

brown

rear vib. switch S14 port 7

plug connector X20 port 2

3 - 50

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

WIRE HARNESS 7131/80255

3 - 51

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

3 - 52

3 - 53

3 - 54

SM61005 - SECTION THREE

ELECTRICAL OVERVIEW

WIRE CHART 7131/80255 No.

COLOR

FROM

TO

1

red

battery terminal +

fuse F12 terminal 1

2

red

starter terminal 30

alternator terminal 30

3

red

fuse F12 terminal 1

plug connector X2 port 1

4

black-red

fuse F1 terminal 1

plug connector X2 port 2

5

black

relay K1 terminal 30

plug connector X2 port 3

6

black

relay K1 terminal 87

starter terminal 50a

7

blue

alternator terminal "L"

fuse F7 terminal 1

8

blue

fuse F7 terminal 2

plug connector X1 port 1

10

black

fuse F4 terminal 2

auxiliary power socket X7+

12

black-red

fuse F1 terminal 2

plug connector X1 port 2

13

black-red

fuse F9 terminal 2

plug connector X15.1 port "A"

14

black-red

fuse F1 terminal 2

relay K6 terminal 86

15

black-red

fuse F1 terminal 2

horn H8 terminal +

16

violet

relay K4 terminal 86

plug connector X15.1 port "B"

17

violet

relay K4 terminal 86

relay K1 terminal 86

18

violet

relay K4 terminal 86

relay K5 terminal 86

19

violet

relay K5 terminal 86

plug connector X1 port 3

21

green

plug connector X1 port 4

engine oil psi sensor S4

22

red-white

plug connector X1 port 5

engine temp. sensor S5

23

brown-red

plug connector X1 port 6

air filter sensor S6+

24

green-red

plug connector X1 port 7

hyd. filter sensor S7

25

black-yellow

relay K5 terminal 30

brake pressure switch S8

26

black-yellow

relay K5 terminal 30

plug connector X1 port 8

27

black-yellow

relay K5 terminal 87a

relay K6 terminal 85

28

brown-yellow

plug connector X1 port 9

horn H8 terminal -

29

black-red

fuse F1 terminal 2

emergency switch S3 terminal 1

30

black-yellow

relay K3 terminal 86

emergency switch S3 terminal 2

31

red

fuse F1 terminal 1

relay K3 terminal 30

32

red

fuse F9 terminal 1

relay K3 terminal 87

33

black-yellow

fuse F9 terminal 2

plug connector X1 port 10

34

black-yellow

delay relay D1 terminal 15, X12 port 3

plug connector X1 port 11

35

black

fuse F9 terminal 2

relay K2 terminal 30

36

black

relay K2 terminal 30

delay relay D1 terminal A1, X12 port 1

37

black-yellow

relay K6 terminal 87a

delay relay D1 terminal 18, X12 port 4

38

black-yellow

relay K6 terminal 30

plug connector X15.2 port "A"

39

black

relay K2 terminal 87a

plug connector X11 port 3

40

black

plug connector X11 port 1

engine shut off solenoid Y1

41

red

fuse F13 terminal 1

plug connector X11 port 4

3 - 55

SM61005 - SECTION THREE No.

COLOR

ELECTRICAL OVERVIEW

FROM

TO

fuse F10 terminal 2

plug connector X1 port 12

42

gray-green

43

gray

relay K10 terminal 85

plug connector X1 port 13

44

gray

rekay K10 terminal 87

plug connector X1 port 16

46

gray

relay K10 terminal 87

relay K4 terminal 30

47

gray

relay K4 terminal 87a

plug connector X1 port 14

48

gray-violet

front vib. solenoid Y4 terminal 2

plug connector X1 port 17

49

gray-yellow

rear vib. solenoid Y3 terminal 2

plug connector X1 port 18

50

blue

fuse F11 terminal 2

plug connector X1 port 19

52

blue

delay relay D2 terminal 18, X4 port 4

plug connector X1 port 24

53

blue

relay K8 terminal 86

delay relay D2 terminal 18, X4 port 4

54

blue

delay relay D2 terminal A1, X4 port 3

plug connector X1 port 23

56

blue

delay relay D2 terminal 25, X4 port 1

plug connector X1 port 22

57

blue

delay relay D2 terminal 26, X4 port 2

plug connector X1 port 21

58

blue

plug connector X3 port 1

water solenoid Y5 terminal 1

59

blue

fuse F3 terminal 2

relay K8 terminal 30

60

blue

relay K8 terminal 87

plug connector X3 port 1

61

blue

relay K8 terminal 87

plug connector X1 port 20

62

black

fuse F4 terminal 2

plug connector X2 port 6

64

red

fuse F12 terminal 2

plug connector X1 port 26

65

yellow-white

fuse F14 terminal 1

plug connector X1 port 27

66

yellow-white

fuse F14 terminal 2

plug connector X1 port 29

67

yellow-white

fuse F14 terminal 2

light plug connector X9 port 1

68

yellow

fuse F15 terminal 1

plug connector X1 port 28

69

yellow

fuse F15 terminal 2

plug connector X1 port 30

70

yellow

fuse F15 terminal 2

light plug connector X9 port 3

71

red

fuse F13 terminal 2

plug connector X1 port 32

72

black-red

fuse F5 terminal 2

plug connector X1 port 31

74

black-white

plug connector X1 port 35

light plug connector X9 port 2

78

black-green

plug connector X1 port 36

light plug connector X9 port 4

82

black-yellow

relay K9 terminal 49a

plug connector X1 port 34

83

black

relay K9 terminal 49

plug connector X1 port 33

85

blue-yellow

relay K9 terminal "C"

plug connector X1 port 15

86

green-white

fuse F6 terminal 2

backup alarm connector X6 port 1

87

brown-green

plug connector X15.1 port "C"

backup alarm connector X6 port 2

90

black-blue

RH engine preheater

plug connector X2 port 4

92

black-blue

plug connector X10 port 4

plug connector X2 port 7

93

black-blue

plug connector X10 port 6

plug connector X2 port 8

94

black-blue

relay K2 terminal 30

plug connector X10 port 5

97

white

fuel switch S23

plug connector X2 port 9

3 - 56

SM61005 - SECTION THREE No.

COLOR

ELECTRICAL OVERVIEW

FROM

TO

101

black-yellow

plug connector X13 port 1

D1 plug connector X12 port 5

102

black-yellow

plug connector X13 port 3

D1 plug connector X12 port 6

110

black-red

relay K2 terminal 86

relay K6 terminal 86

111

green-red

relay K2 terminal 85

plug connector X1 port 25

115

black-red

fuse F1 terminal 2

alternator terminal 1g

120

brown

ground post

plug connector X2 port 5

132

brown

relay K9 terminal 31

relay K10 terminal 86

133

brown

relay K3 terminal 85

relay K4 terminal 85

134

brown

relay K4 terminal 85

relay K5 terminal 85

135

brown

relay K10 terminal 86

ground post

136

brown

relay K5 terminal 85

relay K8 terminal 85

137

brown

relay K8 terminal 85

relay K9 terminal 31

138

brown

D1 connector X12 port 2

ground post

139

brown

D2 connector X4 port 5

ground post

140

brown

plug connector X10 port 3

ground post

141

brown

plug connector X11 port 2

ground post

142

brown

air cleaner sensor S6-

ground post

143

brown

hyd. filter sensor S7-

ground post

144

brown

brake switch S8-

ground post

145

brown

relay K1 terminal 85

relay K3 terminal 85

146

brown

brake solenoid Y2

ground post

147

brown

front vib. solenoid Y4

ground post

148

brown

rear vib. solenoid Y3

ground post

149

brown

plug connector X3 port 2

ground post

153

brown

plug connector X15.1 port "D"

ground post

154

brown

water solenoid Y5

ground post

160

gray

fuse F10 terminal 2

plug connector X8 port 1

161

gray

relay K10 terminal 30

plug connector X8 port 2

164

brown

plug connector X15.2 port "B"

ground post

3 - 57

3 - 58

ITEM LINE D1 25-28 D2 39 D3 1 D4 26 E1-E6 42-43 E2-E4 44-46 E3-E5 45-47 F1 15 F2 F3 41 F4 42 F5 49 F6 54 F7 4 F9 25 F10 31 F11 39 F12 45a F13 48a F14 45 F15 46 G1 3 G2 4 H0 1 H1 4 H2 10 H3 15 H4 16 H5 17 H6 18 H7 19 H8 21 H9 54 H10 32 H11 31a H12 33a

DESCRIPTION DELAY RELAY, SEAT MONITOR DELAY RELAY, SPRINKLER CYCLE DELAY RELAY, ENGINE PREHEAT DELAY RELAY, ENGINE SHUTDOWN SOLENOID SPOTLIGHT OPTION LIGHTS, FRONT LIGHTS, REAR FUSE, INSTRUMENTATION NOT USED FUSE, SPRINKLER PUMP FUSE, SPOT LIGHT SOCKET FUSE, HAZARD FLASHER FUSE, BACK UP ALARM FUSE, ALTERNATOR FUSE, BRAKE RELEASE FUSE, VIBRATION FUSE, SPRINKLER CONTROL FUSE, LIGHTING SYSTEM FUSE, DIRECTIONAL LIGHTS FUSE, LIGHTS, LEFT FUSE, LIGHTS, RIGHT BATTERY ALTERNATOR INDICATOR LIGHT, PRE-HEAT INDICATOR LIGHT, ALTERNATOR CHARGE INDICATOR, NEUTRAL POSITION INDICATOR, ENGINE OIL PRESSURE INDICATOR, ENGINE TEMPERATURE INDICATOR, AIR FILTER INDICATOR, HYDRAULIC FILTER INDICATOR, BRAKE PRESSURE HORN ALARM, BACK UP INDICATOR LIGHT, AUTO VIBRATION INDICATOR LIGHT, FRONT VIBRATOR INDICATOR LIGHT, REAR VIBRATOR

ITEM H13 H14 H15 H16 H17 H18 H21 H22 H23 H24 K1 K2 K3 K4 K5 K6 K8 K9 K10 K11 M1 M2 P1 RH R1 R2 S1 S2 S3 S4 S5 S6 S7 S8 S9 S10

LINE 39 12 46 51 50a 53 49 50 51 52 6 14 22 8 9 20 39 50 30 57 2 41 5 0 38 56 4 6 22 15 16 17 18 19 21 25

DESCRIPTION INDICATOR LIGHT, SPRINKLER PUMP INDICATOR LIGHT, LOW FUEL LEVEL INDICATOR LIGHT, LIGHTING SYSTEM INDICATOR LIGHT, HAZARD FLASHER INDICATOR LIGHT, DIRECTIONAL FLASH SW. INDICATOR LIGHT, DIRECTIONAL FLASH IND INDICATOR LIGHT, DIRECTIONAL, FT. LEFT INDICATOR LIGHT, DIRECTIONAL REAR LEFT INDICATOR LIGHT, DIRECTIONAL, FT. RIGHT INDICATOR LIGHT, DIRECTIONAL, REAR RIGHT RELAY, STARTING RELAY, BRAKE MONITOR, ALT. RELAY, BRAKE MONITOR, NEUTRAL. RELAY,NEUTRAL POSITION RELAY, BRAKE RELEASE RELAY, BRAKE CONTROL RELAY, SPRINKLER PUMP RELAY, HAZARD FLASHERS RELAY, MANUAL VIBRATION RELAY, OPTIONAL SPRINKLER PUMP MOTOR, STARTER MOTOR, SPRINKLER PUMP HOURMETER ENGINE PREHEATER POTENTIOMETER, SPRINKLER OFF TIME POTENTIOMETER, SPRINKLER OFF TIME SWITCH, IGNITION AND PREHEATER SWITCH, NEUTRAL POSITION SWITCH, EMERGENCY STOP SWITCH, ENGINE OIL PRESSURE SWITCH, ENGINE EXCESSIVE TEMPERATURE SWITCH, AIR FILTER RESTRICTION SWITCH, HYDRAULIC FILTER RESTRICTION SWITCH, BRAKE PRESSURE SWITCH, HORN SWITCH, BRAKE ON/ OFF

ITEM LINE DESCRIPTION S11 31 SWITCH, AUTOMATIC VIBRATION S12 31 SWITCH, VIBRATION ON S13 31 SWITCH, VIBRATION, FRONT S14 33 SWITCH, VIBRATION, REAR S15 NOT USED S16 39 SWITCH, SPRINKLER, AUTO INTERVAL S17 42 SWITCH, SPOTLIGHT S18 45 SWITCH, LIGHTING S19 45 SWITCH, HAZARD FLASHER S20 50 SWITCH, DIRECTIONAL S21 54 SWITCH, BACK UP ALARM S22 29 SWITCH, SEAT MONITOR S23 12 SWITCH, LOW FUEL LEVEL S24 43 SWITCH, SPOTLIGHT S25 57 SWITCH, SPRINKLER, AUTO INTERVALS V2-V3 14 DIODE, ISOLATION X1-X2 CONNECTORS, INSTRUMENT PANEL X3 41 CONNECTOR, PLUG IN, SPRINKLER PUMP X4 37-38-39CONNECTOR, PLUG IN, SPRINKLER TIMING X5 44-46-49-51 CONNECTOR, PLUG IN, LIGHTING, FRONT X6 54 CONNECTOR, PLUG IN, BACK UP ALARM X7 42-43 CONNECTOR, PLUG IN, SOCKET X8 30 CONNECTOR, PLUG IN, VIBRATION SWITCH X9 45-47-50-52 CONNECTOR, PLUG IN, LIGHTING, REAR X10 1 CONNECTOR, PLUG IN, HEAT TIMER X11 26-27 CONNECTOR, PLUG IN, DELAY RELAY, X12 28-29 CONNECTOR, PLUG IN, SEAT MONITOR X13 29 CONNECTOR, PLUG IN, SEAT SWITCH X14 12 CONNECTOR, PLUG IN, LOW FUEL SWITCH X15 6-25-54CONNECTOR, PLUG IN, NEUTRAL IND. SWITCH X17 10-19 CONNECTOR, PLUG IN, INSTRUMENTS Y1 26 SOLENOID, ENGINE SHUT OFF Y2 25 SOLENOID, HYDRAULIC BRAKE Y3 33 SOLENOID, REAR VIBRATION Y4 31 SOLENOID, FRONT VIBRATION Y5 40A SOLENOID, WATER SYSTEM

ELECTRICAL SCHEMATICS

3 - 59

3 - 60

ITEM LINE D1 25-28 D2 39 D3 1 D4 26 E1-E6 42-43 E2-E4 44-46 E3-E5 45-47 F1 15 F2 F3 41 F4 42 F5 49 F6 54 F7 4 F9 25 F10 31 F11 39 F12 45a F13 48a F14 45 F15 46 G1 3 G2 4 H0 1 H1 4 H2 10 H3 15 H4 16 H5 17 H6 18 H7 19 H8 21 H9 54 H10 32 H11 31a H12 33a

DESCRIPTION DELAY RELAY, SEAT MONITOR DELAY RELAY, SPRINKLER CYCLE DELAY RELAY, ENGINE PREHEAT DELAY RELAY, ENGINE SHUTDOWN SOLENOID SPOTLIGHT OPTION LIGHTS, FRONT LIGHTS, REAR FUSE, INSTRUMENTATION NOT USED FUSE, SPRINKLER PUMP FUSE, SPOT LIGHT SOCKET FUSE, HAZARD FLASHER FUSE, BACK UP ALARM FUSE, ALTERNATOR FUSE, BRAKE RELEASE FUSE, VIBRATION FUSE, SPRINKLER CONTROL FUSE, LIGHTING SYSTEM FUSE, DIRECTIONAL LIGHTS FUSE, LIGHTS, LEFT FUSE, LIGHTS, RIGHT BATTERY ALTERNATOR INDICATOR LIGHT, PRE-HEAT INDICATOR LIGHT, ALTERNATOR CHARGE INDICATOR, NEUTRAL POSITION INDICATOR, ENGINE OIL PRESSURE INDICATOR, ENGINE TEMPERATURE INDICATOR, AIR FILTER INDICATOR, HYDRAULIC FILTER INDICATOR, BRAKE PRESSURE HORN ALARM, BACK UP INDICATOR LIGHT, AUTO VIBRATION INDICATOR LIGHT, FRONT VIBRATOR INDICATOR LIGHT, REAR VIBRATOR

ITEM H13 H14 H15 H16 H17 H18 H21 H22 H23 H24 K1 K2 K3 K4 K5 K6 K8 K9 K10 K11 M1 M2 P1 RH R1 R2 S1 S2 S3 S4 S5 S6 S7 S8 S9 S10

LINE 39 12 46 51 50a 53 49 50 51 52 6 14 22 8 9 20 39 50 30 57 2 41 5 0 38 56 4 6 22 15 16 17 18 19 21 25

DESCRIPTION INDICATOR LIGHT, SPRINKLER PUMP INDICATOR LIGHT, LOW FUEL LEVEL INDICATOR LIGHT, LIGHTING SYSTEM INDICATOR LIGHT, HAZARD FLASHER INDICATOR LIGHT, DIRECTIONAL FLASH SW. INDICATOR LIGHT, DIRECTIONAL FLASH IND INDICATOR LIGHT, DIRECTIONAL, FT. LEFT INDICATOR LIGHT, DIRECTIONAL REAR LEFT INDICATOR LIGHT, DIRECTIONAL, FT. RIGHT INDICATOR LIGHT, DIRECTIONAL, REAR RIGHT RELAY, STARTING RELAY, BRAKE MONITOR, ALT. RELAY, BRAKE MONITOR, NEUTRAL. RELAY,NEUTRAL POSITION RELAY, BRAKE RELEASE RELAY, BRAKE CONTROL RELAY, SPRINKLER PUMP RELAY, HAZARD FLASHERS RELAY, MANUAL VIBRATION RELAY, OPTIONAL SPRINKLER PUMP MOTOR, STARTER MOTOR, SPRINKLER PUMP HOURMETER ENGINE PREHEATER POTENTIOMETER, SPRINKLER OFF TIME POTENTIOMETER, SPRINKLER OFF TIME SWITCH, IGNITION AND PREHEATER SWITCH, NEUTRAL POSITION SWITCH, EMERGENCY STOP SWITCH, ENGINE OIL PRESSURE SWITCH, ENGINE EXCESSIVE TEMPERATURE SWITCH, AIR FILTER RESTRICTION SWITCH, HYDRAULIC FILTER RESTRICTION SWITCH, BRAKE PRESSURE SWITCH, HORN SWITCH, BRAKE ON/ OFF

ITEM LINE DESCRIPTION S11 31 SWITCH, AUTOMATIC VIBRATION S12 31 SWITCH, VIBRATION ON S13 31 SWITCH, VIBRATION, FRONT S14 33 SWITCH, VIBRATION, REAR S15 NOT USED S16 39 SWITCH, SPRINKLER, AUTO INTERVAL S17 42 SWITCH, SPOTLIGHT S18 45 SWITCH, LIGHTING S19 45 SWITCH, HAZARD FLASHER S20 50 SWITCH, DIRECTIONAL S21 54 SWITCH, BACK UP ALARM S22 29 SWITCH, SEAT MONITOR S23 12 SWITCH, LOW FUEL LEVEL S24 43 SWITCH, SPOTLIGHT S25 57 SWITCH, SPRINKLER, AUTO INTERVALS V2-V3 14 DIODE, ISOLATION X1-X2 CONNECTORS, INSTRUMENT PANEL X3 41 CONNECTOR, PLUG IN, SPRINKLER PUMP X4 37-38-39CONNECTOR, PLUG IN, SPRINKLER TIMING X5 44-46-49-51 CONNECTOR, PLUG IN, LIGHTING, FRONT X6 54 CONNECTOR, PLUG IN, BACK UP ALARM X7 42-43 CONNECTOR, PLUG IN, SOCKET X8 30 CONNECTOR, PLUG IN, VIBRATION SWITCH X9 45-47-50-52 CONNECTOR, PLUG IN, LIGHTING, REAR X10 1 CONNECTOR, PLUG IN, HEAT TIMER X11 26-27 CONNECTOR, PLUG IN, DELAY RELAY, X12 28-29 CONNECTOR, PLUG IN, SEAT MONITOR X13 29 CONNECTOR, PLUG IN, SEAT SWITCH X14 12 CONNECTOR, PLUG IN, LOW FUEL SWITCH X15 6-25-54CONNECTOR, PLUG IN, NEUTRAL IND. SWITCH X17 10-19 CONNECTOR, PLUG IN, INSTRUMENTS Y1 26 SOLENOID, ENGINE SHUT OFF Y2 25 SOLENOID, HYDRAULIC BRAKE Y3 33 SOLENOID, REAR VIBRATION Y4 31 SOLENOID, FRONT VIBRATION Y5 40A SOLENOID, WATER SYSTEM

3 - 61

3 - 62

ITEM LINE D1 25-28 D2 39 D3 1 D4 26 E1-E6 42-43 E2-E4 44-46 E3-E5 45-47 F1 15 F2 F3 41 F4 42 F5 49 F6 54 F7 4 F9 25 F10 31 F11 39 F12 45a F13 48a F14 45 F15 46 G1 3 G2 4 H0 1 H1 4 H2 10 H3 15 H4 16 H5 17 H6 18 H7 19 H8 21 H9 54 H10 32 H11 31a H12 33a

DESCRIPTION DELAY RELAY, SEAT MONITOR DELAY RELAY, SPRINKLER CYCLE DELAY RELAY, ENGINE PREHEAT DELAY RELAY, ENGINE SHUTDOWN SOLENOID SPOTLIGHT OPTION LIGHTS, FRONT LIGHTS, REAR FUSE, INSTRUMENTATION NOT USED FUSE, SPRINKLER PUMP FUSE, SPOT LIGHT SOCKET FUSE, HAZARD FLASHER FUSE, BACK UP ALARM FUSE, ALTERNATOR FUSE, BRAKE RELEASE FUSE, VIBRATION FUSE, SPRINKLER CONTROL FUSE, LIGHTING SYSTEM FUSE, DIRECTIONAL LIGHTS FUSE, LIGHTS, LEFT FUSE, LIGHTS, RIGHT BATTERY ALTERNATOR INDICATOR LIGHT, PRE-HEAT INDICATOR LIGHT, ALTERNATOR CHARGE INDICATOR, NEUTRAL POSITION INDICATOR, ENGINE OIL PRESSURE INDICATOR, ENGINE TEMPERATURE INDICATOR, AIR FILTER INDICATOR, HYDRAULIC FILTER INDICATOR, BRAKE PRESSURE HORN ALARM, BACK UP INDICATOR LIGHT, AUTO VIBRATION INDICATOR LIGHT, FRONT VIBRATOR INDICATOR LIGHT, REAR VIBRATOR

ITEM H13 H14 H15 H16 H17 H18 H21 H22 H23 H24 K1 K2 K3 K4 K5 K6 K8 K9 K10 K11 M1 M2 P1 RH R1 R2 S1 S2 S3 S4 S5 S6 S7 S8 S9 S10

LINE 39 12 46 51 50a 53 49 50 51 52 6 14 22 8 9 20 39 50 30 57 2 41 5 0 38 56 4 6 22 15 16 17 18 19 21 25

DESCRIPTION INDICATOR LIGHT, SPRINKLER PUMP INDICATOR LIGHT, LOW FUEL LEVEL INDICATOR LIGHT, LIGHTING SYSTEM INDICATOR LIGHT, HAZARD FLASHER INDICATOR LIGHT, DIRECTIONAL FLASH SW. INDICATOR LIGHT, DIRECTIONAL FLASH IND INDICATOR LIGHT, DIRECTIONAL, FT. LEFT INDICATOR LIGHT, DIRECTIONAL REAR LEFT INDICATOR LIGHT, DIRECTIONAL, FT. RIGHT INDICATOR LIGHT, DIRECTIONAL, REAR RIGHT RELAY, STARTING RELAY, BRAKE MONITOR, ALT. RELAY, BRAKE MONITOR, NEUTRAL. RELAY,NEUTRAL POSITION RELAY, BRAKE RELEASE RELAY, BRAKE CONTROL RELAY, SPRINKLER PUMP RELAY, HAZARD FLASHERS RELAY, MANUAL VIBRATION RELAY, OPTIONAL SPRINKLER PUMP MOTOR, STARTER MOTOR, SPRINKLER PUMP HOURMETER ENGINE PREHEATER POTENTIOMETER, SPRINKLER OFF TIME POTENTIOMETER, SPRINKLER OFF TIME SWITCH, IGNITION AND PREHEATER SWITCH, NEUTRAL POSITION SWITCH, EMERGENCY STOP SWITCH, ENGINE OIL PRESSURE SWITCH, ENGINE EXCESSIVE TEMPERATURE SWITCH, AIR FILTER RESTRICTION SWITCH, HYDRAULIC FILTER RESTRICTION SWITCH, BRAKE PRESSURE SWITCH, HORN SWITCH, BRAKE ON/ OFF

ITEM LINE DESCRIPTION S11 31 SWITCH, AUTOMATIC VIBRATION S12 31 SWITCH, VIBRATION ON S13 31 SWITCH, VIBRATION, FRONT S14 33 SWITCH, VIBRATION, REAR S15 NOT USED S16 39 SWITCH, SPRINKLER, AUTO INTERVAL S17 42 SWITCH, SPOTLIGHT S18 45 SWITCH, LIGHTING S19 45 SWITCH, HAZARD FLASHER S20 50 SWITCH, DIRECTIONAL S21 54 SWITCH, BACK UP ALARM S22 29 SWITCH, SEAT MONITOR S23 12 SWITCH, LOW FUEL LEVEL S24 43 SWITCH, SPOTLIGHT S25 57 SWITCH, SPRINKLER, AUTO INTERVALS V2-V3 14 DIODE, ISOLATION X1-X2 CONNECTORS, INSTRUMENT PANEL X3 41 CONNECTOR, PLUG IN, SPRINKLER PUMP X4 37-38-39CONNECTOR, PLUG IN, SPRINKLER TIMING X5 44-46-49-51 CONNECTOR, PLUG IN, LIGHTING, FRONT X6 54 CONNECTOR, PLUG IN, BACK UP ALARM X7 42-43 CONNECTOR, PLUG IN, SOCKET X8 30 CONNECTOR, PLUG IN, VIBRATION SWITCH X9 45-47-50-52 CONNECTOR, PLUG IN, LIGHTING, REAR X10 1 CONNECTOR, PLUG IN, HEAT TIMER X11 26-27 CONNECTOR, PLUG IN, DELAY RELAY, X12 28-29 CONNECTOR, PLUG IN, SEAT MONITOR X13 29 CONNECTOR, PLUG IN, SEAT SWITCH X14 12 CONNECTOR, PLUG IN, LOW FUEL SWITCH X15 6-25-54CONNECTOR, PLUG IN, NEUTRAL IND. SWITCH X17 10-19 CONNECTOR, PLUG IN, INSTRUMENTS Y1 26 SOLENOID, ENGINE SHUT OFF Y2 25 SOLENOID, HYDRAULIC BRAKE Y3 33 SOLENOID, REAR VIBRATION Y4 31 SOLENOID, FRONT VIBRATION Y5 40A SOLENOID, WATER SYSTEM

3 - 63

3 - 64

SECTION FOUR

HYDRAULIC SYSTEMS

4-1

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

PROPULSION DRAWINGS

4-2

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

4-3

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

4-4

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW The relief valves on the propulsion pump can be opened for towing purposes by depressing the button on the end of each relief valve. Combined with the activation of the brake tow valve, this allows the machine to be towed without damage. The buttons will remained depressed until the engine is started and system charge pressure is obtained.

PROPULSION SYSTEM The propulsion, or drive system, consists of an engine driven, Sauer-Sunstrand, Model 42, variable displacement, bi-directional, axial piston pump with a maximum delivery of approximately 18 gallons per minute.

The pump supplies oil to a front and a rear MC05 Poclain, fixed displacement drive motor in a parallel path, completing the hydrostatic loop. The pump is servo controlled and activated by a forward/reverse lever on the operator’s platform.

PROPULSION SYSTEM DIAGNOSTICS INTERNAL LEAKAGE

All hydrostatic systems require charge pressure to function properly. This is because a hydrostatic system cannot operate at a negative pressure. The charge pump provides a positive pressure to the hydrostatic pump inlet. On the model 255/ 265, normal charge pressure is about 290 PSI and can be checked at port MP3 on the test station located in the left side of the engine compartment. Hydrostatic systems are designed to leak a small amount of oil from the pumps and motors for lubrication of parts and cooling, and in some instances, leakage is strictly due to operating clearances. The greater the system pressure the higher this leakage rate.

Fresh charge oil will make up for normal system losses.

A charge pump is built into the propulsion pump and provides all the needed oil for loop charging and for pilot pressure. Oil for the charge pump is drawn from the discharge side of the system filter. A 20 bar (290 PSI) charge relief valve, located at the bottom of the propulsion pump, regulates charge pressure which is used to pressurize the pump/motor loop, to provide pilot oil to the pump servos and to provide pilot pressure for brake release.

Also built into the propulsion pump is a neutral start switch/back up alarm switch located on top of the pump near the forward/reverse lever. Immediately to the right of the switch is a solenoid valve, controlled by the emergency stop circuit and the brake switch, designed to remove pilot pressure to the servo and vent the oil from the brakes when deactivated.

The two drum drive motors, manufactured

by Poclain, include a built in multi-plate brake. The motors are of a low speed, high torque design, eliminating the need for costly gear reduction. Hose connections at the top of the motor provide drive oil through ports 1 and 4. Port 2 is the case drain and Port 3 provides pilot pressure for the brake.

4-5

When components fail, leakage under pressure increases tremendously and is noted by a drop in charge pressure (the charge pump is not capable of keeping up with the hydrostatic system leakage rate).

The condition of a hydrostatic pump/motor circuit can be determined by a simple charge pressure test at maximum engine RPM and normal operating temperature.

Under the previously mentioned conditions (RPM and temperature), compare the charge pressure readings with the hydrostatic system at no load and maximum

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

load. If these two charge pressure readings show a difference of more than 10%, between the loaded and no load conditions, the hydrostatic system has higher than desired leakage.

Remember, the failure of one component in a hydrostatic system can cause contamination throughout the entire system. Prior to installing the new or rebuilt component, the entire system must be disassembled and cleaned.

This includes all pumps, motors, valves, coolers, hoses, and reservoirs.

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

PUMP SERVO CONTROL

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

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

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

A second method is to cap the pressure lines to the front and rear motors and determine if charge pressure increases to normal. A normal charge pressure reading under these conditions would eliminate the pump as the problem. A low charge pressure reading with the motors blocked indicates a pump or charge relief problem.

With the pump isolated and at a no stroke condition, there should be normal charge pressure. If the pressure is low, the first place to look is at the charge relief valve.

If the machine does not move in forward or reverse when the operator’s control lever is moved, check for a problem (possibly electrical) in the solenoid valve. As a quick check, see if the brake release pressure, which is also controlled by this solenoid valve, is at 290 PSI. (test station port MP4).

For more information on troubleshooting electrical problems refer to the electrical section of this manual.

The next step is to reconnect one drive motor and rerun the charge pressure test.

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

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

4-6

VIBRATION DRAWINGS

4-7

4-8

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

4-9

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

VIBRATION SYSTEM The vibration system consists of a fixed displacement gear pump mounted to the back of the propulsion pump which delivers oil to the front and rear fixed displacement gear motors on the left side of each drum.

The oil flows through the rear motor and then the front motor in a series flow path.

This flow of oil from the pump is constant as long as the engine is running and varies only when engine speed varies. The resultant vibration frequency will also be a constant and will only vary when engine speed varies. The oil flow is controlled by a solenoid valve block which allows four options: 1.Y3 & Y4OFFNo vibration Oil flows through both solenoid valves, bypassing the motors, and returns to the reservoir.

2.Y3 OnRear vibration Oil cannot flow through solenoid Y3 so it flows through the rear motor. Oil discharging from the rear motor can flow through solenoid Y4 and return to the reservoir.

3.Y4OnFront vibration Oil can flow through the Y3 solenoid but cannot flow through the Y4 solenoid and must discharge through the front drive motor. Pressure is equal on both sides of

the rear motor therefore the motor does not turn. The only path of flow is through the front motor and to the reservoir.

4.Y3 & Y4 On Dual vibration Oil cannot flow through Solenoid Y3 or Y4 and must flow through the rear motor. Oil discharging from the rear motor must flow through the front motor and return to the reservoir.

Two relief valves are also incorporated in the solenoid valve block to protect the system from excessive pressures. Note that the front and rear vibratory motors can operate in series during the dual vibration mode. Because of the series operation the first relief valve requires a higher setting than the second relief valve. A 1 bar check valve is located in the return line of each drive motor. The check valves prevent shaft rotation in the OFF drum when the machine is running in a “single drum vibration� mode. Oil from the vibration circuit passes through the oil cooler before joining steering return oil, flowing through the hydraulic oil filter and returning to the reservoir. A one bar (15 PSI) cold oil bypass valve parallels the cooler.

4 - 10

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

VIBRATION SYSTEM DIAGNOSTICS VIBRATION FREQUENCY

The model 255/265 has only one vibration frequency. To test the vibration frequency, put rubber tires or matting under the machine drums. Check the engine high idle speed for proper adjustment. Start the engine and run it at high idle. Operate one drum at a time while holding a frequency meter against the drum.

Hydraulic test ports MP5 and MP6 are provided at the test station to check the front and rear vibration system pressures. The system relief valves are set at 2600 PSI (180 bar). Pressure at MP5 will normally read about 1800 psi with the front drum vibrating. Normal operating pressures at MP6 are expected to be 1800 psi while operating one drum and about 3600 psi while operating vibration on both drums.

The pressure might spike higher at first start up.

If the pressure is constantly at 2600 psi while operating any single drum, this would be an indication that there is some type of mechanical drag.

Refer to the frequency meter manufacturer’s instructions for more details. Vibration frequency for both the 255 and 265 should be 3480 vibrations per minute or 58 cycles per second.

The system pump and motor are fixed displacement units so variations in frequency are normally due to improper engine operating speed, mechanical drag (example: bad bearings), a hydraulic malfunction or an electrical problem.

If the pressure is below 2600 psi while operating one drum and the vibration frequency checks low, it is possible that the system relief valves found on the vibration control valve are sticking or need to be adjusted. The vibration control valve is located on the left side of the machine under the operator’s seat.

If you are unable to develop any hydraulic pressure, check the vibration control valve for problems (possibly electrical). For more information on troubleshooting electrical problems see the electrical section of this manual.

4 - 11

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

STEERING DRAWINGS

4 - 12

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

4 - 13

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

4 - 14

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

STEERING SYSTEM The steering system consists of a fixed displacement gear pump mounted onto the back of the vibration pump, a steering control valve (steering orbital) and a single steering cylinder. The oil supply for the steering circuit is provided by the common inlet with the vibration pump. Oil from the steering pump enters the steering control valve at port P. If steering is not required, oil will pass through the valve and discharge out port T and return to the filter/ reservoir. Oil in the L and R passages and in the cylinder is trapped and cannot flow, thus the machine maintains its steering direction.

When steering occurs, as dictated by the rotation of the steering wheel, the control valve meters a portion of oil from port P to the L or R passage (dependent upon the direction the wheel is turned) and to the cylinder. The resultant stroking of the cylinder causes the machine to turn. As oil is admitted into one side of the cylinder, oil must discharge from the opposite side and return to the control valve. This return oil discharges to port T and returns through the filter and to the reservoir.

There are three relief valves built into the steering circuit. Steering work pressure is controlled at 2030 psi maximum (140 bar) by a relief valve in port P. Steering work pressure can be checked on port MP7 at the pressure test station. Two port safety reliefs, set at 2900 psi (200 bar), are built into cylinder ports L and R. The port relief valves protect the steering cylinder and work lines from being over pressurized while the oil is trapped by the steering hand valve (orbital motor).

STEERING SYSTEM DIAGNOSTICS If your steering system has poor performance, the first thing to do is check the pressure at test port MP7 while turning the steering in both directions until the pivot stops are reached. Steering work pressure will be slightly higher in one direction due to the area difference on the steering cylinder, but the system should not be operating at the 2030 psi level except when turning against the pivot stops.

If the pressure at test port MP7 is operating close to, or at 2030 psi, check for mechanical binding in the steering pivot pin.

If the pressure at test port MP7 is found to be low, cap the two steering cylinder lines and rerun the pressure test.

If the pressure reading is 2030 psi with the cap lines, check the steering cylinder for internal leakage.

If the pressure is low with the steering cylinder lines capped, the problem is in the steering valve (orbital motor) or the steering pump. The first place to check is the steering valve.

The steering pump can be tested by using a relief valve plumbed directly into the pump outlet line. Start the system with the relief valve backed completely out, then slowly increase the relief setting to 2030 PSI. If you can not develop steering pump pressure of 2030 psi, replace the steering pump.

4 - 15

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

HYDRAULIC RESERVOIR

4 - 16

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

HYDRAULIC OIL FILTER A cartridge type filter is used in the return line to the reservoir, filtering oil discharged from the vibration and steering circuits. The 10 micron filter is physically located in the top of the hydraulic reservoir. Included in the filter circuit is a 2 bar (30 PSI) filter bypass valve and a 1.2 bar (17.5 PSI) differential pressure switch to control an indicator light on the dash.

Oil supply to the charge pump is taken from the filter housing, immediately after the filter, providing filtration for charge oil.

HYDRAULIC OIL RESERVOIR The hydraulic oil reservoir is located in the lower left area of the rear chassis, below the operator’s platform. The reservoir has a capacity of 50 liter (13.2 gallons). A sight gauge is mounted on the side of the reservoir for visual oil level indication as well as oil temperature.

The top of the reservoir houses the hydraulic oil filter, supply and return hoses and a filler port with a breather cap.

4 - 17

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

BRAKE SYSTEM DRAWINGS

4 - 18

4 - 19

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

4 - 20

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

PARKING BRAKES A spring applied/ hydraulic release multidisk brake is built into each of the drum drive motors. Pilot pressure is used to release the brakes while removal of pilot pressure allows the springs to apply the brakes. The brakes may be applied by depressing a switch on the dash, depressing the emergency stop switch on the right hand operator’s console, turning the key switch “OFF�, or by stopping the engine.

When either of the switches is depressed to apply the brakes, a solenoid on the propulsion pump is deactivated removing the supply of charge oil to both brakes and the pump servo preventing forward or reverse movement. This feature makes it impossible to drive through the brakes.

When the emergency stop button is depressed the brakes apply, the machine returns to neutral and the engine stops.

PARKING BRAKE DIAGNOSTICS The parking brake is a spring applied hydraulic pressure released design.

When the brake/servo solenoid is activated, the pressure at the brake port should read 290 PSI and the brake should be released. If the brake does not release when hydraulic pressure is applied, check the brake for a mechanical lockup.

When the brake/servo solenoid valve is deactivated, the pressure at the brake port should drop to zero and the brake should spring apply. If the brake does not apply check for wear on the brake plates, a broken spring, or a mechanical lockup.

If the pressure at the brake port is less than 175 psi the brakes will not fully release.

Brake release pressure should be the same as the hydraulic charge pressure.

Check the charge pressure. If charge pressure is low check the hydraulic systems for excessive leakage.

A valve, located under the left side of the engine hood is used in conjunction with the brake hand pump to release the brakes on a disabled machine that must be moved.

Placing the valve in the tow position and actuating the pump provides sufficient oil pressure to release the brakes for towing.

Section six of this manual gives more detail on towing the machine.

4 - 21

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

HYDRAULIC TEST PORTS

4 - 22

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

4 - 23

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

MP1

Working pressure, forward travel, 345 bar maximum

MP2

Working pressure, reverse travel, 345 bar maximum

MP3

Charge system pressure, 20 bar

MP4

Not used

MP5

Working pressure, front vibration, 180 bar maximum

MP6

Working pressure, rear vibration, 180 bar maximum

MP7

Working pressure, steering, 140 bar maximum

4 - 24

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

NOTES

4 - 25

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

HYDRAULIC DRAINS

4 - 26

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

4 - 27

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

HYDRAULIC COOLING

4 - 28

4 - 29

HYDRAULIC COMPONENT LOCATIONS

P1 P2 P3 P4 P5 M1 M2 M3 M4 M5 M6 M7 LE

drive pump charge pump vibration pump steering pump brake hand pump rear drive motor front drive motor rear vibration motor front vibration motor steering cylinder spring applied brake, rear motor spring applied brake, front motor steering unit

F1 F2 VA VB1 VD1 VS VSp1 VW1 DS1 DS2 K B

4 - 30

hydraulic filter hydraulic tank filler/breather brake hand pump valve vibration control valve propulsion pump relief valves propulsion pump displacement propulsion flushing valve brake actuation valve pressure switch, hydraulic filter pressure switch, brake system hydraulic cooler hydraulic reservoir

HYDRAULIC SCHEMATIC

4 - 31

HYDRAULIC SCHEMATIC (“K” model)

4 - 32

“K” MODEL SYSTEMS

4 - 33

4 - 34

4 - 35

4 - 36

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

HYDRAULIC COMPONENTS

4 - 37

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

POCLAIN MC05 PROPULSION MOTOR

4 - 38

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

4 - 39

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

POCLAIN MC05 MOTOR

It is not the purpose of this manual to supersede the manufacturer’s repair instructions. For more detail on how to service this motor we recommend that you obtain a copy of Poclain Hydraulic’s repair manual IMG4/MCGB (677777 435Q) from your local Poclain distributor or order #V40098 from your Vibromax dealer.

4 - 40

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

SAUER/SUNDSTRAND SERIES 42 PROPULSION PUMP

4 - 41

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

This manual is not intended to supersede the service and repair instructions of the pump manufacturer. For minor repairs, we recommend that you obtain a copy of Sauer Sunstrand manual # BLN - 10093 from your local Sauer Sunstrand distributor or order #V40112 from your Vibromax dealer.

4 - 42

SM61005 - SECTION FOUR

HYDRAULIC OVERVIEW

4 - 43

4 - 44

SECTION FIVE

POWER TRAIN

5-1

SM61005 - SECTION FIVE

DRUM DRIVE

5-2

SM61005 - SECTION FIVE

DRUM DRIVE

5-3

SM61005 - SECTION FIVE

DRUM DRIVE

5-4

SM61005 - SECTION FIVE

DRUM DRIVE

5-5

5-6

SM61005 - SECTION FIVE

DRUM DRIVE

DRUM ASSEMBLY (right front side view)

5-7

5-8

SM61005 - SECTION FIVE

ITEM 1 1 2 2 3 3 4 5 5 6 6 7 8 10 11 13 14 15 17 24 25 26 27 28 29 30 32 33 34 35 36 37 38 40 42 43 47

PART # 07130/21100 07130/22100 07130/21200 07130/22200 07130/21300 07130/22300 07130/21400 87130/21500 87130/22500 07130/21550 07130/22550 07130/21700 07130/21800 07130/21010 07130/21011 07130/21013 07130/21014 04003/01019 06180/01033 06755/00026 02712/06081 02700/02180 02773/10513 02772/19530 02772/08030 02772/15930 02027/16040 02027/08025 02018/12035 02018/16040 02021/16045 02017/12090 02021/08012 02118/31600 02208/00116 02208/00012 02766/01215

DRUM DRIVE

QTY. 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 4 1 1 2 1 1 3 1 1 7 4 8 8 4 8 4 8 12 16 1

DESCRIPTION 255 Drum 1000mm 265 Drum 1200mm Suspension bracket, right side - model 255 Suspension bracket, right side - model 265 Suspension bracket, left side - model 255 Suspension bracket, left side - model 265 Support bracket Exciter shaft - model 255 Exciter shaft - model 265 Cover - model 255 Cover - model 265 Vibration gear motor Drum drive motor Flange, drive motor Support bracket Bearing plate Seal plate Buffer Screw plug Coupling sleeve Exciter shaft bearing Drum drive bearing Shaft seal O-ring seal O-ring seal O-ring seal Socket Capscrew, M16x40 DIN912 Socket Capscrew, M8x25 DIN912 Hex Capscrew, M12x1.5x35 DIN 961 Hex Capscrew, M16x1.5x40 DIN 961 Hex Capscrew, M16x45 DIN 933 Hex Capscrew, M12x1.5x90 DIN 961 Hex Capscrew, M8x12 DIN 933 Lock Nut, VM16 DIN 980 Washer Lock Washer Seal Ring, A12x15.5 DIN 7603

5-9

5 - 10

SM61005 - SECTION FIVE

DRUM DRIVE from under the machine. Jack the machine up to get the needed clearance and roll the drum from under the machine.

DRUM REMOVAL 1.

Block the machine before start of disassembly.

2.

Remove the front or rear drum scraper depending on which drum is to be removed.

3.

Remove the left and right cover plates (item #6) by removing the four M8x12 Hex. bolts (item # 38).

4.

Although it is not considered necessary to remove the water tank, it can make handling the hydraulic hoses easier. The tank is held in place with four buffer nuts and one water line connection.

5.

Disconnect, plug, and tag the hydraulic lines to the drive and vibration motors. The drain line for the front vibration motor can not be loosened until the left front support bracket (item #3) is ready for removal. A check valve located at the support bracket manifold prevents loosening the hose fitting because of a lack of wrench clearance. Removal of this hose connection requires loosening the four socket head capscrews holding the hose manifold. Once the support bracket is free of the drum and machine, the manifold can be pushed in enough to loosen the return hose fitting.

6.

Support the frame and remove the four buffer nuts (item #40) for the left and right buffers.

7.

Remove the right and left drum support brackets (items #2 & #3) by removing the eight M16x40 Hex. bolts (item #35).

8.

The drum is now free to be removed

DRIVE MOTOR REMOVAL CAUTION: The drum drive motor should not be removed until the drum is removed and sitting on end with the drive motor up. If this procedure is not followed, damage to the exciter shaft bearings may occur.

1.

Set the drum on its end with the drive motor facing up.

2.

Remove the buffer bracket (item #11) by removing the four M16x45 bolts (item #36).

3.

Remove the eight M12x35 bolts (item #34) holding the motor adapter flange.

4.

Install two of the M12x35 bolts in the two jacking bolt holes in the drive motor flange. Turn the two bolts in at an even rate to jack the motor flange out of the drum.

5.

Remove the flange and motor as one assembly. The bearing supporting the exciter shaft is also in the motor adapter flange. Motor removal should be done with caution to avoid damage to the exciter shaft and bearings.

6.

Remove the seven M16x40 socket head capscrews (item #32) to separate the motor and adapter flange.

5 - 11

5 - 12

SM61005 - SECTION FIVE

DRUM DRIVE 6.

DRIVE MOTOR REPAIR This manual is not intended to supersede Poclain Hydraulic’s repair instructions for the model MC05 motor. We strongly recommend that those wanting to rebuild the drive motor, obtain a copy of Poclain Hydraulic’s repair manual IMG4 / MCGB (677777 435Q) from their local Poclain distributor or from Vibromax under part number V40098.

Install the buffer bracket (item #11) by using the four M16x45 bolts (item #36) and Loctite 242. Torque the bolts to 140 ft lbs (190 Nm.).

DRUM DRIVE BEARING REMOVAL 1.

Set the drum on its end with the vibration motor facing up.

2.

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

Remove the vibration motor by loosening the four M8x25 socket head capscrews (item #33).

3.

Remove the vibration motor shaft coupling (item #24).

DRIVE MOTOR INSTALLATION

4.

Remove the drum support bracket (item #4) by using three long M12x1.75 bolts in the three threaded holes provided, to jack the bracket out of the drum bearing’s inner race.

5.

Remove the seal plate (item #14).

6.

Remove and discard the old shaft seal (item #27) from the seal plate.

7.

Using two long M12x1.5 bolts in two threaded holes provided, jack bearing plate (item #13) out of drum. Be careful when removing bearing plate to avoid damage of exciter shaft and bearings.

8.

Using an inside bearing puller, remove the drum drive bearing (item # 26) from the bearing plate.

1.

Replace O-ring seal (item #30) between the motor and adapter flange.

2.

Install the seven M16x40 socket head capscrews (item #32) to connect the motor and adapter flange. These bolts should be installed with Loctite 271 and torqued to 140 ft lbs (190 Nm).

3.

Replace O-ring seal (item #28) between the adapter flange and the drum.

4.

Lower the motor and flange assembly into place. Use caution to avoid damage of the exciter shaft bearings and the O-ring seal.

5.

Install the eight M12x35 bolts (item #34) and lock washers (item #43) holding the motor adapter flange.

Install the bolts with Loctite 242 and torque to 58 ft lbs (77 Nm).

5 - 13

the the the the the

5 - 14

SM61005 - SECTION FIVE

DRUM DRIVE

DRUM BEARING INSTALLATION

DRUM INSTALLATION

1.

Clean and dry all parts.

1.

2.

Install a new shaft seal (item #27) into the seal plate (item #14). The seal lip and spring should be facing toward the drive bearing. Grease the seal lip.

Jack the machine up to get the needed clearance and roll the drum under the machine.

2.

Lower and block the machine before starting reassembly.

3.

Install the right and left drum support brackets (items #2 & #3) by using the eight M16x40 capscrews (item #35) with lock washers (item #42). Torque the bolts to 140 ft lbs (190 Nm).

Remember to install the vibration motor return line before installation of the left support bracket. Hydraulic release of the brake might be needed to rotate for alignment.

4.

Install the four buffer nuts (item #40) for the left and right buffers.

5.

Fill the case drain port on the hydraulic motor.

6.

Connect the hydraulic lines to the drive and vibration motors. Care should be taken to avoid adding any contamination into the system.

7.

Install the cover plates (item #6) by using the four M8x12 capscrews (item # 38).

8.

Fill the hydraulic reservoir as needed.

9.

Block the engine fuel lever to allow the engine to crank but not start.

3.

Slide the seal plate assembly onto the shaft on the support bracket (item #4).

4.

Press the drive bearing (item #26) onto the shaft of the support bracket (Item #4).

5.

Install the outer O-ring seal (item # 28) into bearing plate (item #13).

Install the O-ring with grease to make sure it will stay in place.

6.

Install the support bracket (item #4) with bearing into the bearing plate (item #13). This can be done by using two short M12x1.5 bolts in the threaded holes provided in the bearing plate. Use the two bolts to draw the bearing into place.

7.

8.

9.

Install the inner O-ring seal (item # 28) into bearing plate (item #13).

Install the O-ring with grease to make sure it will stay in place.

Install the bearing plate and support assembly into the drum being extremely careful to avoid damaging the exciter shaft, bearing and O-ring seal.

Secure the bearing plate assembly to the drum using the eight M12x1.5x90 bolts with lock washers. Install the bolts with Loctite # 242 and torque to 57 ft lbs. (78 Nm).

10. Install the vibratory motor and coupling with the four M8x25 bolts and Loctite 242.

10. Crank the engine until a drive system charge pressure reading is obtained.

11. Start the engine, and slowly engage the drive system and allow it to run several minutes without loading to fill and flush.

5 - 15

PNEUMATIC TIRE DRIVE

5 - 16

SM61005 - SECTION FIVE

Item#

Part No.

DRUM DRIVE

Qty.

Description

1

7131/20010

1

suspension mount, right side

2

7131/20020

1

suspension mount, left side

3

4053/40503

2

tire mount flange

6

4053/40160

2

smooth tire including interior rim

7

4053/40170

2

smooth tire including outside rim

8

2021/12055

12

Hex. head bolt, M12x55 DIN933

9

2209/00012

12

12mm flat washer

10

2118/31200

34

12mm lock nut, VM12 DIN980

11

4053/40650

2

hydraulic drive motor

12

2026/12065

10

capscrew, M12x65 DIN912

13

2026/12050

12

bolt, M12x50 DIN912

14

2209/00013

22

flat washer

16

4053/40130

4

hose bracket

17

2027/10040

8

capscrew, M10x40 DIN912

19

4053/40020

2

air hose

20

2018/16050

8

Hex. capscrew, M16x1.5x50 DIN961

21

2200/00067

8

flat washer

22

7130/21553

2

step plate

23

2031/06016

4

countersunk screw, M6x16 DIN963

24

7131/20024

10

bushing

30

4053/40162

4

smooth tire

31

4053/40171

2

rim, interior

32

4053/40172

2

rim, outside

5 - 17

SM61005 - SECTION FIVE

DRUM DRIVE

NOTES

5 - 18

SECTION SIX

PARKING BRAKE SYSTEM

6-1

SM61005 - SECTION SIX

PARKING BRAKE SYSTEM

6-2

6-3

SM61005 - SECTION SIX

PARKING BRAKE SYSTEM

6-4

SM61005 - SECTION SIX

PARKING BRAKE SYSTEM

The 255/265 is equipped with a parking brake system. The brakes are designed into the Poclain MC05 drive motors. These brakes are spring applied and hydraulic pressure released. To make repairs to the brake disks requires removal of the drive motor. Information on diagnosing electrical or hydraulic problems in the brake system can be found in section #3 (electrical overview) and section #4 (hydraulic overview) of this manual.

CAUTION: The Poclain brake disks are installed under a spring load

PARK BRAKE TESTING Set the machine up on blocks. Disconnect and cap the brake release lines at the drive motor.

Install a 6,000 PSI (450 bar) gauge on each motor supply line (test ports MP1 & MP2). Start the engine and slowly engage the forward/reverse control. The brake should be able to stop drum rotation at the maximum system pressure of 5000 PSI (345 bar). If drum rotation occurs at or below this pressure, the brake discs must be adjusted or replaced.

This test should be run if the parking brake has been used as a safety brake on an emergency stop. Poclain further recommends that the brake discs be overhauled after such safety stops.

BRAKE RELEASE FOR TOWING

hand pump

hand pump valve

6-5

SM61005 - SECTION SIX

PARKING BRAKE SYSTEM

The two propulsion pump relief valves are accessible by opening the right side door. Depressing the button in the center of each valve allows the machine to be towed. The buttons will automatically reset when the engine is started.

TOWING PROCEDURE 1. The articulation lock should be in the “OPERATE� position. Chock the drum prior to releasing the parking brakes to avoid machine movement.

2. Turn the hand pump valve to the towing position. The valve is located under the air cleaner on the left side of the machine. To turn the valve it is necessary to remove the handle and rotate the lock plate. Reinstall the handle and rotate the valve.

3. Actuating the hand pump will build up enough pressure to release the brake. With the key switch in the ON position you will be able to see the brake light in the instrument cluster turn off when the brakes have released.

4. Depress the button on the end of each of the two relief valves on the propulsion pump (see drawing). The valves are accessible through the right side door.

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 after towing the machine. Remove the handle and reposition the handle lock into the operate position then reinstall the handle. The propulsion pump relief valves will reset themselves once the machine is started.

After towing a machine it is necessary to test the brake function prior to putting the machine back into operation.

6-6

6-7

SM61005 - SECTION SIX

PARKING BRAKE SYSTEM

BRAKE REPAIRS

BRAKE ASSEMBLY 1. Check the condition of the brake shaft and brake body splines. The splines should be free of nicks and burrs and must not show signs of heavy wear.

Brake disc wear on the MC05 style F05 brake can be checked prior to disassembly by measuring the piston stroke. Remove the plug from the cover plate and set up a dial indicator to measure piston stroke.

Supply oil to the motor brake port at 175 PSI (12 bar) to 435 PSI (30 bar). Piston stroke should measure .030 inch (0.75mm) + .013 inch (0.35mm) - .010 inch (0.25mm) or between .020 inch (0.50mm) and .043 inch (1.09mm). The longer the piston travel, the more the brake discs are worn.

2. Measure the total disc stack height, which should not be less than 1.125 inch (28.6mm).

NOTE: Do not remove the motor from the drum until the drum has been removed from the machine and setting on end with the drive motor up.

3. Coat all discs with oil and then install the discs alternately starting with one friction disc then one smooth disc.

BRAKE DISASSEMBLY 1. Remove the brake end cover and the cover O-ring.

4. Install the brake piston “WITHOUT� the Oring seals.

2. Use a press to compress the brake spring washer. Force applied should not exceed the recommended maximum of 15,737 pounds force (70,000 newtons).

5. Clean the snap ring and groove of burrs and install the snap ring.

6. Use a press to apply a force of 15,737 pounds (70,000 newtons) to the piston.

3. Remove the snap ring using an internal snap ring pliers.

4. Remove the spring washer, brake piston, shims, brake discs, and separator discs.

6-8

SM61005 - SECTION SIX

PARKING BRAKE SYSTEM

7. Measure the dimension X as shown. The amount of shims needed must be equal to the X measurement minus .421 inch (10.70mm) +/- .004 inch (0.1mm).

8. Remove the snap ring and piston.

9. Install the shim pack on the last disc with the thickest shim towards the piston.

10. Replace the piston seals and install the brake piston and spring washer.

11. Apply a force to the piston and install the snap ring making sure it seats properly.

12. Install a new cover seal and install the cover.

13. Supply oil to the motor brake port at 175 PSI (12 bar) to 435 PSI (30 bar). Piston stroke should measure .030 inch (0.75mm) + .013 inch (0.35mm) - .010 inch (0.25mm) or between .020 inch (0.50mm) and .043 inch (1.09mm). If you are unable to get the proper measurement the shim pack must be adjusted.

14. Check for signs of seal leakage by watching for pressure decay.

15. Install the cover plug and reinstall the motor assembly.

6-9

SM61005 - SECTION SIX

PARKING BRAKE SYSTEM

NOTES

6 - 10

SECTION SEVEN

VIBRATORY SYSTEM

7-1

SM61005 - SECTION SEVEN

VIBRATORY SYSTEM

7-2

7-3

SM61005 - SECTION SEVEN

VIBRATORY SYSTEM

7-4

7-5

7-6

SM61005 - SECTION SEVEN

ITEM 1 1 2 2 3 3 4 5 5 6 6 7 8 10 11 13 14 15 17 24 25 26 27 28 29 30 32 33 34 35 36 37 38 40 42 43 47

PART # 07130/21100 07130/22100 07130/21200 07130/22200 07130/21300 07130/22300 07130/21400 87130/21500 87130/22500 07130/21550 07130/22550 07130/21700 07130/21800 07130/21010 07130/21011 07130/21013 07130/21014 04003/01019 06180/01033 06755/00026 02712/06081 02700/02180 02773/10513 02772/19530 02772/08030 02772/15930 02027/16040 02027/08025 02018/12035 02018/16040 02021/16045 02017/12090 02021/08012 02118/31600 02208/00116 02208/00012 02766/01215

VIBRATORY SYSTEM

QTY. 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 4 1 1 2 1 1 3 1 1 7 4 8 8 4 8 4 8 12 16 1

DESCRIPTION 255 Drum 1000mm 265 Drum 1200mm Suspension bracket, right side - model 255 Suspension bracket, right side - model 265 Suspension bracket, left side - model 255 Suspension bracket, left side - model 265 Support bracket Exciter shaft - model 255 Exciter shaft - model 265 Cover - model 255 Cover - model 265 Vibration gear motor Drum drive motor Flange, drive motor Support bracket Bearing plate Seal plate Buffer Screw plug Coupling sleeve Exciter shaft bearing Drum drive bearing Shaft seal O-ring seal O-ring seal O-ring seal Socket Capscrew, M16x40 DIN912 Socket Capscrew, M8x25 DIN912 Hex Capscrew, M12x1.5x35 DIN 961 Hex Capscrew, M16x1.5x40 DIN 961 Hex Capscrew, M16x45 DIN 933 Hex Capscrew, M12x1.5x90 DIN 961 Hex Capscrew, M8x12 DIN 933 Lock Nut, VM16 DIN 980 Washer Lock Washer Seal Ring, A12x15.5 DIN 7603

7-7

7-8

SM61005 - SECTION SEVEN

VIBRATORY SYSTEM 13. Flip the drum to the opposite end with the drive motor facing upward.

VIBRATORY SHAFT REMOVAL 1.

2.

Remove the drum from the machine.

See the DRUM DRIVE section of this manual for proper instruction.

14. Remove the buffer bracket (item #11) by removing the four M16x45 bolts (item #36).

Rotate the drum so that the fill/drain plug is at the bottom and drain the vibration shaft oil.

3.

Set the drum on its end with the vibration motor facing up.

4.

Remove the vibration motor by loosening the four M8x12 socket head capscrews (item #33).

5.

Remove the vibration motor shaft coupling (item #24).

6.

Remove the drum support bracket (item #4) by using three long M12x1.75 bolts in the three threaded holes provided, to jack the bracket out of the drum bearing’s inner race.

7.

Remove the seal plate (item #14).

8.

Remove and discard the old shaft seal (item #27) from the seal plate.

9.

Using two long M12x1.5 bolts in the two threaded holes provided, jack the bearing plate (item #13) out and remove it from the drum.

15. Remove the eight M12x35 bolts (item #34) holding the motor adapter flange.

16. Install two of the M12x35 bolts in the two jacking bolt holes in the drive motor flange. Turn the two bolts in at an even rate to jack the motor flange out of the drum.

17. Remove the flange and motor as one assembly. The bearing supporting the exciter shaft is also in the motor adapter flange.

18. Using an inside bearing puller to remove the exciter shaft bearing (item #25) from the motor flange (item #10).

10. Using an inside bearing puller, remove the exciter shaft bearing outer race (item #25) from the bearing plate.

11. Carefully remove the exciter shaft (item #5).

12. Use an outside bearing puller to remove the inner bearing races from the exciter shaft.

7-9

7 - 10

SM61005 - SECTION SEVEN

VIBRATORY SYSTEM 11. Slide the seal plate assembly onto the shaft of the support bracket (item #4).

INSTALLING VIBRATORY SHAFT 1.

Press a new exciter bearing (item #25) into the drive motor flange (item #10).

NOTE: When replacing bearings both the inner and outer races must be replaced.

2.

Replace O-ring seal (item #28) between the adapter flange and the drum.

3.

Lower the motor and flange assembly into place. Use caution to avoid damage of the exciter shaft bearings and the O-ring seal.

4.

Install the eight M12x35 bolts (item #34) and lock washers (item #43) holding the motor adapter flange.

Install the bolts with Loctite 242 and torque to 58 ft lbs (77 Nm).

5.

13. Install the outer O-ring seal (item # 28) into bearing plate (item #13).

Install the O-ring with grease to make sure it will stay in place.

14. Install the support bracket (item #4) with bearing into the bearing plate (item #13). This can be done by using two short M12x1.5 bolts in the threaded holes provided in the bearing plate. Use the two bolts to draw the bearing into place.

15. Install the inner O-ring seal (item # 28) into bearing plate (item #13).

Install the O-ring with grease to make sure it will stay in place.

Install the buffer bracket (item #11) by using the four M16x45 bolts (item #36) and Loctite 242. Torque the bolts to 140 ft lbs (190 Nm.).

6.

Flip the drum to the opposite end to prepare for exciter shaft installation.

7.

Press the two exciter inner bearing races onto the exciter shaft.

8.

Carefully install the exciter shaft using caution to avoid exciter bearing damage.

9.

12. Press the drive bearing (item #26) onto the shaft of the support bracket (Item #4).

Press a new exciter shaft outer bearing race (item #25) into bearing plate (item #13).

16. Install the bearing plate and support assembly into the drum being extremely careful to avoid damaging the exciter shaft, bearing and O-ring seal.

17. Secure the bearing plate assembly to the drum using the eight M12x1.5x90 bolts. Install the bolts with Loctite # 242 and torque to 57 ft lbs. (78 Nm).

18. Check the exciter shaft for proper end play which is .023 to .078 inch (0.6 to 2.0 mm).

19. Install the vibration motor and coupling to finish drum assembly.

10. Install a new shaft seal (item #27) into seal plate (item #14). The seal lip with the spring should be facing toward the drive bearing. Grease seal lip.

7 - 11

SM61005 - SECTION SEVEN

VIBRATORY SYSTEM

NOTES

7 - 12

SECTION EIGHT

STEERING SYSTEM

8-1

SM61005 - SECTION EIGHT

STEERING SYSTEM

8-2

SM61005 - SECTION EIGHT

STEERING SYSTEM

8-3

SM61005 - SECTION EIGHT

STEERING SYSTEM

8-4

SM61005 - SECTION EIGHT

STEERING SYSTEM

ARTICULATION JOINTS

8-5

SM61005 - SECTION EIGHT

STEERING SYSTEM

ARTICULATION PARTS

8-6

SM61005 - SECTION EIGHT

ITEM 1 2 3 4 5 8 9 11 12 13 14 15 16 17 18 19 20 21 22 23

PART# 07130/40310 07130/40302 07130/40303 07130/40304 07130/40305 04050/22362 04050/22361 04054/15120 02241/11026 02242/23045 02806/00570 04054/15009 04029/20003 02806/00112 04054/15011 02445/20700 02018/16060 02940/02340 02021/10025 02021/08020

STEERING SYSTEM

QTY. 1 1 2 2 1 2 2 1 2 2 2 2 2 2 2 2 6 2 12 4

DESCRIPTION Articulation bearing support Support plate Bearing cap Bearing pin Transport safety bar Cylinder pin lock Pin Steering cylinder Swivel joint Articulation bearing, cup and cone Spring washer Seal ring Pivot bearing, cup and cone Spring washer Seal ring Pin Hex capscrew, M16x1.5x60 DIN961 Split pin Hex capscrew, M10x25 Hex capscrew, M8x20

8-7

SM61005 - SECTION EIGHT

STEERING SYSTEM

8-8

SM61005 - SECTION EIGHT

STEERING SYSTEM

HORIZONTAL PIVOT DISASSEMBLY

STEERING PIVOT DISASSEMBLY

1.

Park and block the machine.

2.

Remove the front drum using the instructions found in section five (DRUM DRIVE) of this manual.

11. Remove the steering cylinder rod pin (item #9).

3.

12. Block and support the articulation bearing support (item #1).

Remove the water tank by loosening the water hose clamps to remove the line to the water pump. Next loosen the four tank buffer nuts and lift the tank off of the front frame.

4.

Loosen the seven hydraulic clamps holding the hydraulic hoses to the front frame.

5.

Disconnect the water supply line to the front drum sprinkler tube.

6.

Disconnect the wire harness for the front lights at connector X5 located under the instrument column panel.

13. Remove the six M10x25 bolts (item #22) from the upper and lower bearing caps (item #3).

14. Remove the upper and lower bearing caps by using two M10 bolts in the threaded jacking holes provided in the bearing caps.

15. Remove and discard the old seal (item #15) rings from the upper and lower joints.

16. Remove the articulation bearing support from the machine.

7.

Sling support the front frame. Remove the six M16x1.5x60 bolts (item #20) holding the front bearing support plate (item # 2).

17. Remove the articulation bearing cups (item #13) from the rear frame by scratching the coating off and welding a bead around the inside of the bearing cup to shrink the cup.

8.

Carefully remove the bearing support plate (item #2) and move the front frame away from the articulation bearing support (item #1).

18. Remove the articulation bearing cones (item #13) from the bearing caps using and external bearing puller.

9.

Remove the pivot bearing cups (item #16) from the front frame using an internal bearing puller or scratch the coating off and weld a bead around the inside of the bearing cup to shrink the cup.

NOTE: The bearings used in the steering articulation and horizontal pivot joints are a maintenance free type. They do not require grease or oil lubrication.

DO NOT apply grease or oil lubricants during reassembly. Make sure the bearings are clean and dry when assembled.

10. Remove and discard the old seal ring (item # 18). Remove the pivot bearing cones (item #16) from bearing pins (item #4) using an external bearing puller. The bearing pins (item #4) are pressed into the support brackets.

CAUTION should be taken during reassembly to avoid damage to the coated surface in the bearing cups.

8-9

SM61005 - SECTION EIGHT

STEERING SYSTEM

8 - 10

SM61005 - SECTION EIGHT

STEERING SYSTEM installing the pin and pin lock.

STEERING PIVOT ASSEMBLY

1.

Install the spring washers (item #14) and bearing cups (item #13) into the rear frame support. Use only properly sized driving tools to avoid damage to the bearing cups. Note the following drawing for proper installation:

HORIZONTAL PIVOT INSTALLATION

1.

Install the spring washers (item #17) and bearing cups (item #16) into the front frame support. Use only properly sized driving tools to avoid damage to the bearing cups. Note the following drawing for proper installation:

Press the bearing cones (item #13) onto the upper and lower bearing caps (item #3).

2.

Slide the articulation joint support (item #1) over the rear frame support and block into a proper aligned position.

If the bearing pins (item #4) are being replaced, press the new pins into the support plate (item #2) and articulation bearing support (item #1).

3.

Install the bearing seal into the lower bore of the articulation joint support making sure it is properly seated.

Press the new bearing cones (item # 16) onto the bearing pins (item #4).

4.

Install the front and rear seal rings (item #18) over the bearing cones.

5.

Install the lower bearing cap assembly (items #3 & #13) into place.

5.

6.

Install the six M10x25 capscrews using Loctite 270. Evenly tighten the capscrews to draw the bearing cap into position.

Using proper slinging and support procedures lift the front frame assembly into the articulation joint support.

Caution must be used to avoid damage to the bearing cup coating.

6.

Install the support plate (item #2) into position and secure with the six M16x1.5x60 bolts (item #20) and Loctite 270.

7.

Evenly tighten and torque the plate bolts to 140 ft lbs. (190 Nm).

2.

3.

4.

7.

Torque the bearing cap capscrews to 32 ft lbs. (44 Nm).

8.

Repeat steps 4 through 7 to install the upper bearing cap.

9.

Connect the steering cylinder by

8 - 11

SM61005 - SECTION EIGHT

STEERING SYSTEM

STEERING CYLINDER

8 - 12

SECTION NINE

CHASSIS

9-1

SM61005 - SECTION NINE

CHASSIS

9-2

SM61005 - SECTION NINE

CHASSIS

FRAME

9-3

SM61005 - SECTION NINE

CHASSIS

HOOD & DOOR PANELS

9-4

SM61005 - SECTION NINE

CHASSIS

OPERATOR PLATFORM

9-5

SM61005 - SECTION NINE

CHASSIS

WATER TANK

9-6

SM61005 - SECTION NINE

CHASSIS

WATER TANK COATING INERTOL POXITAR

Interol Poxitar is a two part epoxy coating used for sealing the water tank on Vibromax rollers. The two part coating kit is available under Vibromax part # 9500/02106. This coating is mixed in a ratio that allows the coating to set up and maintain some flexibility. If too much hardener is used, the coating becomes rigid and brittle and will tend to crack due to machine vibration. The mix ratio is 7.3 parts Poxitar to 1 part hardener (by weight).

APPLICATION: •

Clean the inside of the tank, removing all rust, dirt, and old coating. Sand blasting may be required to achieve a clean surface.

•

Mix the Poxitar and hardener. Make sure that the two parts are thoroughly mixed. The tar is heavy and tends to settle and separate, even if properly mixed.

•

Apply the mixture to the cleaned surface of the tank using a stiff bristle brush.

•

Set up time is approximately one hour.

•

Full curing time is approximately three weeks. However, the tank can be used after 48 hours.

9-7

SM61005 - SECTION NINE

CHASSIS

ROLL OVER PROTECTIVE STRUCTURE (ROPS)

9-8

SM61005 - SECTION NINE

CHASSIS

ROPS MAINTENANCE

Before operating the machine, be certain the ROPS is fastened properly and has not been damaged in any way. The seat belt is an important part of the roll-over protective structure.

The operator must wear the seat belt at all times when operating the machine.

Perform the following checks every 500 hours.

Note that every ROPS is delivered with a certification tag.

•

Check the torque on the ROPS mounting bolts. If necessary retorque the bolts.

•

Check the operator’s seat and mounting parts for the seat belt. Be certain the seat and seat belt bolts are tight.

•

Keep the seat belt clean and dry. Check the seat belt buckle for proper operation. Seat belts should be cleaned with soap and water. Damage can occur if bleach or dye is used.

ROPS DAMAGE

Do not attempt to weld or straighten the ROPS. Do not modify the roll-over protective structure in any manner. Unauthorized modifications such as welding, drilling, cutting or attaching parts could weaken the ROPS structure.

If the ROPS has been damaged due to machine roll over, by striking an object, or by being hit by an object, the damaged parts must be REPLACED before placing the machine into operation. After such damage has occurred, check for the following: •

Check the ROPS for compression, bending, cracks, notches, etc.

•

Inspect the ROPS mounting bolts. Retorque the bolts.

•

Check the operator’s seat and seat belt along with all mounting hardware for signs of damage. Replace all damaged parts.

ROPS BOLT TORQUE

Twelve bolts with washers attach the ROPS to the machine’s rear frame. These 16mm grade 8.8 bolts are tightened to a torque of 140 ft. lbs. (190 Nm.).

The optional sunroof is fastened to the ROPS with 4 bolts and washers. Torque on these bolts is 16 ft. lbs. (22 Nm.).

9-9

SM61005 - SECTION NINE

CHASSIS

SUN ROOF

9 - 10

SECTION TEN

ATTACHMENTS

10 - 1

SM61005 - SECTION TEN

ATTACHMENTS

WATER SPRINKLER SYSTEM

10 - 2

SM61005 - SECTION TEN

ATTACHMENTS

SPRINKLER FUNCTION

The sprinkler system consists of a 12 volt impeller type water pump, solenoid shutoff valve, front and rear sprinkler tubes, front and rear regulator valves, system drain valve, and associated hoses and clamps. The purpose of the machine’s sprinkler system is to prevent asphalt from sticking to the drum. The most sticking occurs while the drum is cold. As the drum warms less water is required which is the reason for the regulator valves and variable sprinkler interval controls on the instrument panel.

The water pump is located behind the right side door directly behind the battery. The two black regulator valves are located on the right side of the operator platform. The drain valve is located between the front and rear frames in the area of the articulation joint.

Electrical components and function are described in detail in Section #3 which covers the machine’s electrical systems. This section should be reviewed for details on set up of the sprinkler interval times which are regulated through electrical components.

STORAGE PREPARATION

The water system should be drained when ambient air temperatures drop below freezing or when the machine is to be stored for 30 days or more.

1.

Drain the system and water tank using the drain valve located at the articulation joint.

2.

Open the system regulator valves to allow complete draining.

3.

Compressed air can be blown into the system at the air fitting located on the accumulator attached to the water pump to help clear the water from the system.

4.

Remove the water tank cover and clean the water tank.

5.

Check the condition of the Poxitar coating in the tank and make repairs as needed. For instructions on application of Poxitar coating refer to Water Tank in section #9.

1. water tank 2. drain valve 3. sprinkling pump 4. sprinkling valve, front 5. sprinkling valve, rear 6. sprinkling tube, front 7. sprinkling tube, rear 8. water filter screen Y5 shutoff solenoid valve

10 - 3

SM61005 - SECTION TEN

ATTACHMENTS

10 - 4

10 - 5

SM61005 - SECTION TEN

ATTACHMENTS

DRUM SCRAPERS

10 - 6

SM61005 - SECTION TEN

ATTACHMENTS

SCRAPER ADJUSTMENT

Each drum is equipped with front and rear mounted drum scrapers. These scrapers are spring loaded to maintain proper scraper tension against the drum.

Drive the machine forward and backwards with the vibration and sprinkler on. If the scrapers are adjusted properly against the drum, sprinkler water will spread evenly across the drum’s surface.

The scrapers can be moved away from the drum for operation on dirt and gravel.

10 - 7

SM61005 - SECTION TEN

ATTACHMENTS

ROAD LIGHT KIT 87130/20120

10 - 8

SM61005 - SECTION TEN

ITEM

PART #

ATTACHMENTS

QTY

DESCRIPTION

0

87130/20120

1

Kit, road lights

1

08102/02211

1

Switch, light S18

2

08102/02212

1

Switch, hazard warning S19

3

08102/02136

1

Switch, turning signal S20

4

08102/02121

1

Relay, flasher K9

5

08412/05100

3

Fuse, 10 amp, F5, F12, F13

6

08412/05050

2

Fuse, 5 amp, F14, F15

8

08424/01065

1

Light fixture, left front

9

08424/01070

1

Light fixture, right front

10

07130/20121

1

Cable harness, front

11

08424/01075

1

Light fixture, left rear

12

08424/01080

1

Light fixture, right rear

13

07130/20122

1

Cable harness, rear

14

02023/04016

8

Capscrew, M4x16

15

02204/00004

8

Lockwasher, M4

16

08420/03008

4

Bulb, flasher

17

08420/03009

4

Bulb, working light

18

02322/00021

15

Plastic tie strap

ROAD LIGHT KIT INSTALLATION

larger bulb is for the turn signal.

Install the front and rear harnesses making sure to string them through the support tubes welded onto the frame. The front harness will plug into connector X5 located in the instrument panel column. The rear harness will plug into connector X9 located in the right side of the engine compartment.

Install the three instrument panel switches in their proper locations (see drawing)

Install the front and rear light fixtures into their proper locations (left or right, etc.).

Lt. front = black/white to turn signal, yellow/ white to headlamp.

Rt. front = green/black to turn signal, yellow to headlamp.

Lt. rear = black/white to turn signal, yellow/ white to tail lamp.

Rt. rear = green/black to turn signal, yellow to tail lamp.

Install the bulbs into the light fixtures. The

Install the K9 relay in the proper location under the right side panel.

Install 10 amp fuses in locations F5, F12, and F13 on the fuse rack.

Install 5 amp fuses in locations F14 and F15 on the fuse rack.

Use the plastic tie straps to secure wire harnesses as required.

Test all lights and switches for proper operation.

10 - 9

SM61005 - SECTION TEN

ATTACHMENTS

WORK LIGHT KIT 87130/20100

10 - 10

SM61005 - SECTION TEN

ITEM 0 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18

PART # 87130/20100 08424/01060 08420/03025 08302/02010 08366/02004 08364/01147 08364/01148 04058/11053 08321/03314 07130/20101 02200/00510 2910/00600 02322/00021 07130/20102 02021/08016 02200/00008 08366/02001 08300/02060

ATTACHMENTS

QTY 1 2 2 2 2 2 2 2 3 1 4 2 7 1 2 4 1 1

DESCRIPTION Kit, work spotlight front and rear Spotlight Bulb Electrical cable Quick connect plug Wire terminal Wire terminal Wire Wire connector Mounting bracket, front Washer Wing nut Plastic tie strap Mounting bracket, rear Hex capscrew, M8x16 Washer Plug socket Wire, 2000mm length

WORK LIGHT KIT INSTALLATION

Attach the wire harness [item #18] to plug socket [item #17] and install the socket and wire into the hole provided in the ROPS frame. The harness will plug into socket X16 located along the right side under the ROPS. The ground for the plug socket is provided through the ROPS and chassis.

Attach bracket [item #9] to the water tank using two tank cover bolts.

Attach bracket [item #14] to the ROPS with two capscrews and washers [items #15 and #16].

Attach wire harness [item #3] to the rear spotlight and plug the light into the ROPS socket.

Attach wire harness [item #4] to the front spotlight and plug the light into the accessory socket on the left side of the instrument column.

10 - 11

SM61005 - SECTION TEN

ATTACHMENTS

NOTES

10 - 12

index A access panels ............................................................................ 9 - 3, 9 - 4 accessory sockets............................................................................ 3 - 37 alternator voltage checks ................................................................ 3 - 23 alternators explained........................................................................ 3 - 21 articulation joints................................................................................. 8 - 5 articulation parts ................................................................................. 8 - 6 auxillary power socket ....................................................................... 3 - 3

B back-up alarm circuit........................................................................ 3 - 42 batteries explained ........................................................................... 3 - 19 battery diagnostics ........................................................................... 3 - 20 bolt torque chart................................................................................ 1 - 13 brake repairs ....................................................................................... 6 - 8 brake tow valve ................................................................................. 4 - 21

C California Proposition 65 ................................................................... 1 - 2 charge system diagnostics.............................................................. 3 - 22 charging circuit.................................................................................. 3 - 19 cleaning parts.................................................................................... 1 - 12 combination indicator.............................................................. 3 - 4, 3 - 32 console lever control........................................................................ 3 - 17

D diesel fuel specification.................................................................... 1 - 18 directional switch ................................................................................ 3 - 5 drive bearing removal ...................................................................... 5 - 13 drive lever ................................................................................. 3 - 6, 3 - 33 drive system specifications ............................................................. 1 - 16 drum installation ................................................................................ 5 - 15 drum parts list...................................................................................... 5 - 9 drum removal .................................................................................... 5 - 11 drum scrapers ................................................................................... 10 - 6

1

index E electrical schematics........................................................................ 3 - 59 electrical schematics explained...................................................... 3 - 11 electrical, general ............................................................................... 3 - 8 emergency off switch .............................................................. 3 - 6, 3 - 33 emergency stop circuit..................................................................... 3 - 17 engine description .............................................................................. 1 - 3 engine oil specification .................................................................... 1 - 19 engine specifications........................................................................ 1 - 16

F fluid specifications ............................................................................ 1 - 17 frame, modular.................................................................................... 9 - 3 fuse location chart .............................................................................. 3 - 9

H hazard warning switch ....................................................................... 3 - 5 horn switch .......................................................................................... 3 - 5 hydraulic filter circuit ........................................................................ 4 - 17 hydraulic reservoir ............................................................................ 4 - 16 hydraulic reservoir capacity ............................................................ 4 - 17 hydraulic test ports ........................................................................... 4 - 22

I instrument panel ...................................................................... 3 - 2, 3 - 31 instrument panel cover ...................................................................... 3 - 2

K key switch ............................................................................................ 3 - 5

L light kit ................................................................................................ 10 - 8 light switch ........................................................................................... 3 - 5

2

index M machine components......................................................................... 1 - 6 machine description ........................................................................... 1 - 3 machine specifications .................................................................... 1 - 15 metric conversions ........................................................................... 1 - 14

N neutral switch control ....................................................................... 3 - 29

O operating data ................................................................................... 1 - 16 operator platform ................................................................................ 9 - 5

P park brake circuit .............................................................................. 3 - 35 park brake diagnostics..................................................................... 4 - 21 park brake explained........................................................................ 4 - 21 park brake switch................................................................................ 3 - 5 park brake test .................................................................................... 6 - 5 pivot disassembly ............................................................................... 8 - 9 Poxitar .................................................................................................. 9 - 7 preheat indicator light ........................................................................ 3 - 5 propulsion motor............................................................................... 4 - 38 propulsion motor installation........................................................... 5 - 13 propulsion motor removal................................................................ 5 - 11 propulsion motor repair.................................................................... 5 - 13 propulsion pump ............................................................................... 4 - 41 propulsion system diagnostics ......................................................... 4 - 5 propulsion system explained ............................................................ 4 - 5 pump servo control............................................................................. 4 - 6

R relay location chart............................................................................. 3 - 9 relays, understanding ...................................................................... 3 - 14 relays, Vibromax types .................................................................... 3 - 15 ROPS maintenance ........................................................................... 9 - 9

3

index S safety, electrical rules ........................................................................ 1 - 9 safety, general .................................................................................... 1 - 7 safety, machine operation................................................................. 1 - 8 safety, maintenance......................................................................... 1 - 10 safety, personal .................................................................................. 1 - 7 serial numbers .................................................................................... 1 - 5 spark arrester ...................................................................................... 1 - 7 sprinkler circuit ........................................................... 3 - 36, 3 - 37, 3 - 38 sprinkler switches ............................................................................... 3 - 3 starter diagnostics ............................................................................ 3 - 25 starter motor test .............................................................................. 3 - 27 starters explained ............................................................................. 3 - 24 steering cylinder................................................................................ 8 - 12 steering diagnostics ......................................................................... 4 - 15 steering system description ............................................................ 4 - 15 steering system explained .............................................................. 4 - 15 storage preparation.......................................................................... 10 - 3 sun roof .............................................................................................. 9 - 10

T torque data ........................................................................................ 1 - 13 towing the machine ............................................................................ 6 - 5

V vibration control circuit..................................................................... 3 - 35 vibration frequency........................................................................... 4 - 11 vibration switches ............................................................................... 3 - 3 vibration system diagnostics........................................................... 4 - 11 vibration system explained.............................................................. 4 - 10 vibratory shaft installation................................................................ 7 - 11 vibratory shaft removal ...................................................................... 7 - 9

W water sprinkler system..................................................................... 10 - 2 water tank ............................................................................................ 9 - 6 water tank coating .............................................................................. 9 - 7 work light kit..................................................................................... 10 - 10

4

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