JCB Vibromax VM 106 Single Drum Roller Service Manual – PDF Download

SINGLE DRUM ROLLER SERVICE MANUAL SM96106 July 2004

Model VM 106

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

SECTION ONE GENERAL INFORMATION MACHINE DESCRIPTION ............................................................................... 1 - 3 SERIAL NUMBERS............................................................................... 1 - 5 IDENTIFYING MACHINE COMPONENTS ........................................... 1 - 6 FLUID SPECIFICATIONS................................................................................ 1 - 7 MACHINE SPECIFICATIONS.......................................................................... 1 - 8 STANDARD TORQUE DATA.............................................................. 1 - 10 DIESEL FUEL SPECIFICATION......................................................... 1 - 12 ENGINE OIL SPECIFICATION ...................................................................... 1 - 13 SAFETY, GENERAL ...................................................................................... 1 - 14 SPARK ARRESTER ...................................................................................... 1 - 14 PERSONAL.................................................................................................... 1 - 15 MACHINE OPERATION ................................................................................ 1 - 16 MAINTENANCE ............................................................................................. 1 - 19 MAINTENANCE SCHEDULE ........................................................................ 1 - 23

SECTION TWO ENGINE CUMMINS ENGINE WARRANTY.................................................................... 2 - 2

SECTION THREE ELECTRICAL GENERAL INFORMATION.............................................................................. 3 - 3 FUSES ............................................................................................................. 3 - 4 RELAYS ........................................................................................................... 3 - 5 INSTRUMENT PANEL..................................................................................... 3 - 6 UNDERSTANDING ELECTRICAL SCHEMATICS ........................................ 3 - 11 UNDERSTANDING RELAYS......................................................................... 3 - 14 STARTER/CHARGING CIRCUIT .................................................................. 3 - 17 EMERGENCY STOP ..................................................................................... 3 - 17 UNDERSTANDING BATTERIES................................................................... 3 - 17 UNDERSTANDING ALTERNATORS ............................................................ 3 - 19 UNDERSTANDING STARTERS.................................................................... 3 - 22 INSTRUMENTATION PANEL........................................................................ 3 - 27 BRAKE SWITCH............................................................................................ 3 - 29 HIGH SPEED CIRCUIT ................................................................................. 3 - 31 VIBRATION CIRCUIT .................................................................................... 3 - 33 ROAD LIGHTING CIRCUIT ........................................................................... 3 - 35

1

WORK LIGHTS & ACCESSORY PLUG ........................................................ 3 - 37 CAB CIRCUITS.............................................................................................. 3 - 39 ELECTRICAL SCHEMATICS ........................................................................ 3 - 40 PLUG CONNECTORS................................................................................... 3 - 48 INSTRUMENT HARNESS 7242/80435 ......................................................... 3 - 49 WIRE CHART 7242/80435 ............................................................................ 3 - 51 RELAY/FUSE HARNESS 7242/80415 .......................................................... 3 - 54 WIRE CHART 7242/80415 ............................................................................ 3 - 56 REAR HARNESS 7222/80510....................................................................... 3 - 60 WIRE CHART 7222/80510 ............................................................................ 3 - 62

SECTION FOUR HYDRAULIC HYDRAULIC COOLER LINES......................................................................... 4 - 2 HYDRAULIC DRAIN LINES............................................................................. 4 - 5 HYDRAULIC CHARGE SYSTEM .................................................................... 4 - 7 HYDRAULIC TEST STATION.......................................................................... 4 - 9 HYDRAULIC TEST FITTINGS....................................................................... 4 - 10 PROPULSION SYSTEM................................................................................ 4 - 11 PROPULSION SCHEMATIC ......................................................................... 4 - 13 PROPULSION SYSTEM DIAGNOSTICS ...................................................... 4 - 15 VIBRATION SYSTEM .................................................................................... 4 - 17 VIBRATORY SYSTEM DIAGNOSTICS......................................................... 4 - 19 VIBRATION SYSTEM SCHEMATIC.............................................................. 4 - 20 STEERING SYSTEM ..................................................................................... 4 - 21 STEERING SYSTEM SCHEMATIC............................................................... 4 - 23 PARKING BRAKE SYSTEM .......................................................................... 4 - 25 PARKING BRAKE SCHEMATIC.................................................................... 4 - 27 TOWING YOUR MACHINE ........................................................................... 4 - 29 TOWING PROCEDURE...................................................................... 4 - 30 PUMP CONTROL VALVE.............................................................................. 4 - 31 HYDRAULIC COMPONENTS........................................................................ 4 - 33 HYDRAULIC SCHEMATIC ............................................................................ 4 - 34

SECTION FIVE POWER TRAIN DRUM ASSEMBLY .......................................................................................... 5 - 2 DRUM REMOVAL............................................................................................ 5 - 6 DRUM INSTALLATION.................................................................................... 5 - 6 RIGHT SIDE BEARING COVER...................................................................... 5 - 7 DRUM DRIVE BEARING REMOVAL............................................................... 5 - 7

2

DRUM DRIVE BEARING ASSEMBLY ............................................................. 5 - 9 DRUM DRIVE MOTOR REPAIRS ................................................................. 5 - 10 DRUM DRIVE GEARBOX.............................................................................. 5 - 11 GFT 17 T2/312 2 GEARBOX ......................................................................... 5 - 13

SECTION SIX PARKING BRAKE SYSTEM PARKING BRAKE SYSTEM ............................................................................ 6 - 2 PARKING BRAKE SCHEMATIC...................................................................... 6 - 4 TOWING YOUR MACHINE ............................................................................. 6 - 6 TOWING PROCEDURE........................................................................ 6 - 7

SECTION SEVEN VIBRATION SYSTEM LIFTING DEVICE ............................................................................................. 7 - 2 DRUM EXCITER SHAFT ................................................................................. 7 - 3 VIBRATION SYSTEM ...................................................................................... 7 - 4 VIBRATION SYSTEM SCHEMATIC................................................................ 7 - 5 VIBRATION FREQUENCY .............................................................................. 7 - 6 VIBRATION AMPLITUDE ................................................................................ 7 - 7 VIBRATORY SYSTEM DIAGNOSTICS........................................................... 7 - 8 DRUM DRAWING ............................................................................................ 7 - 9 DRUM - LEFT SIDE ....................................................................................... 7 - 10 DRUM - RIGHT SIDE..................................................................................... 7 - 11 DRUM REMOVAL.......................................................................................... 7 - 13 DRUM INSTALLATION.................................................................................. 7 - 13 RIGHT SIDE BEARING COVER.................................................................... 7 - 14 EXCITER BEARING REMOVAL.................................................................... 7 - 15 EXCITER BEARING ASSEMBLY .................................................................. 7 - 17

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

3

SECTION NINE CHASSIS

SECTION TEN ATTACHMENTS ROLL OVER PROTECTION STRUCTURE (ROPS) ..................................... 10 - 2 ROPS TIGHTENING TORQUES ........................................................ 10 - 2

4

SECTION ONE GENERAL INFORMATION

July 2004

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1-2

July 2004

SM96106 - SECTION ONE

GENERAL INFORMATION

MACHINE DESCRIPTION This book introduces the new Vibromax 6 series single drum rollers. Included within the pages of the book are materials covering the Model VM106.

The new roller uses the Cummins 3.9 liter 4 cylinder engine.

The engine is turbocharged and tuned to meet the latest EPA emissions standards.

A Mannesman Rexroth variable displacement, axial piston hydrostatic pump, used for machine propulsion, is mounted to the flywheel end of the engine.

It provides oil to a Rexroth 2 speed drum drive motor and a 2 speed axle drive motor in a parallel path. The Rexroth drum motor is mounted on the left side of the drum, drives through a L&S planetary gearbox and is isolated from the drum by rubber buffers. This arrangement is used in the heavy roller models with a great deal of success. The axle drive motor is attached directly to the intermediate gearbox incorporated into the rear axle.

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SM96106 - SECTION ONE

GENERAL INFORMATION

The vibration system on the VM106 uses a Rexroth hydrostatic pump mounted directly behind the propulsion pump. It is similar in design to the propulsion pump. The vibratory pump supplies oil to a Rexroth hydrostatic motor mounted at the right side of the drum. This operates at frequencies of 1860 or 2160 vibrations per minute on both the smooth drum and pad foot versions.

This machine comes standard with parking brakes at both the front drum and the rear axle. A spring applied-hydraulically released multi disc brake is part of the drum drive motor gearbox. The axle uses a spring applied hydraulically released multiple disc brake at each axle shaft.

Pressure testing has been made easier by placing all the test ports at a centrally located test station under the engine hood.

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

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

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July 2004

SM96106 - SECTION ONE

GENERAL INFORMATION

SERIAL NUMBERS 1

Model / Serial Number

2

Front Drum Drive Motor S/N

3

Steering Unit S/N

4

Axle S/N

5

Vibratory Motor S/N

6

Hydraulic Pumps S/N

7

Axle Drive Motor S/N

8

Engine S/N

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SM96106 - SECTION ONE

GENERAL INFORMATION

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

Articulation joint Smooth drum Lifting and towing eyes Operator’s platform Battery Hydraulic tank Engine Axle Air filter Drum drive motor

11 12 13 14 15 16 17 18 19

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Isolation buffer Scraper Engine exhaust Fuel tank Cooling system Vibration motor Steering cylinder Hydraulic pumps Axle drive motor

July 2004

SM96106 - SECTION ONE

GENERAL INFORMATION

FLUID SPECIFICATIONS MACHINE PART

CAPACITY USA (metric)

SPECIFICATIONS

Fuel tank

79.3 gal (300 l)

see diesel fuel

Engine crankcase

11.5 qts(11.0 l)

engine oil API classification API-CI-4 multigrade engine oil (see oil chart)

Hydraulic system

21.1 gal (80 l)

Reservoir only

15.9 gal (60 l)

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

Input Gearbox Differential gear Planetary (each)

1.8 qts (1.75 l) 10.0 qts (9.5 l) 2.1 qts (2.0 l)

Drum gearbox

1.4 qts (1.3 l)

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

Vibration system

3.7 qts (3.5 l)

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

Battery

as required

Distilled water

Grease

as required

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

Engine coolant

14.8 qts (14 l)

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

Tire ballast

see tire ballast

Calcium Chloride (77%CaCl2)

July 2004

SAE 90 API GL-5 gear lubricant Alternate SAE 85/140 API GL-5 gear lubricant

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SM96106 - SECTION ONE

GENERAL INFORMATION

MACHINE SPECIFICATIONS MODEL VM106

in. a b c d1 d2 d3 d4 h h1 k l o s w e1 e2

mm

112.0 2846 88.6 2250 60.0 1523 59.8 1520 59.1 1500 55.1 1400 63 1600 115.6 2935 86.0 2185 17.6 447 214.3 5444 3 75 1 25 82.7 2100 41 degrees 32 degrees

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July 2004

SM96106 - SECTION ONE ENGINE Make/Model/Type/Displacement - cu. in. (cc)

GENERAL INFORMATION

HP, SAE net (kW) @2200 rpm Air Cleaner / Fuel filter Fuel capacity - gal (ltr)

Cummins 3.9 125C, 4 cylinder turbo diesel (water cooled), 239 cu.in. (3920cc) with charge air cooler 125 (93) Dual replaceable elements, Spin-on cartridge 79.3 (300) VM106D

VM106PD

Operating weight max. -lb (kg)

24912 (11300)

25574 (11600)

Weight, front-lb (kg)

13228 (6000)

13889 (6300)

Weight, rear axle - lb (kg)

11684 (5300)

11684 (5300)

Static applied linear drum load lb/in (kg/cm)

160 (28.6)

-----------

Articulation/oscillation-degrees

35/15

35/15

Turning radius-inside-ft. (m)

11.16 (3.4)

11.16 (3.4)

Drum shell thickness-in. (mm)

1.0 (25)

1.0 (25)

Number of pad feet/height of foot - in. (mm)

132/ 3.9 (100)

Contact area of foot-sq. in. (cm)

64 sq.in.(413 sq. cm)

Tire size

23.1 - 26 8PR diamond tread

23.1 - 26 8PR tractor tread

Travel speed - 1st range mph (km/hr)

0 - 2.8 (0 - 4.5)

0 - 2.8 (0 - 4.5)

0 - 6.5 (0 - 10.5)

0 - 6.5 (0 - 10.5)

- 2nd range mph (km/hr) Theoretical gradeability up to - %

60

65

Brakes - front drum

disc

disc

- rear axle

disc - input shaft

disc - input shaft

1st Stage

2nd Stage

1st Stage

Max compaction depth up to - in. (cm)

35 (90)

------------

28 (70)

------------

Frequency - vpm (Hz)

1860 (31)

2160 (36)

1860 (31)

2160 (36)

Amplitude - in. (mm)

.077 (1.95)

.035 (0.9)

.077 (1.95)

.035 (0.9)

Centrifugal force - lbf (kN)

58675 (261)

36644 (163)

63396 (282)

39566 (176)

Centrifugal force/drum width - lb/in. (N/cm)

710 (1243)

443 (776)

767 (1343)

479 (838)

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2nd Stage

SM96106 - SECTION ONE

GENERAL INFORMATION

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

Threads should be lubricated with engine oil or grease.

STANDARD TORQUE SPECIFICATIONS +/- 10% GRADE 8.8

GRADE 10.9

GRADE 12.9

SIZE

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

5mm

4

5.5

5.5

7.5

6.6

9

6mm

6.6

9

9.2

12.5

11

15

8mm

16.5

22.5

23

31.5

26.5

36

10mm

32

44

45

62

55

75

12mm

57

77.5

81

110

95

130

14mm

88

120

125

170

155

210

16mm

140

190

195

265

236

320

18mm

192

260

269

365

320

435

20mm

273

370

383

520

457

620

22mm

369

500

516

700

619

840

24mm

471

640

665

900

796

1080

27mm

702

950

996

1350

1195

1620

30mm

955

1300

1328

1800

1593

2160

NUTS FOR TUBES AND HOSES DIAMETER & PITCH

NEWTONS/METER

POUNDS/FOOT

16MM X 1.5

20

14.5

18MM X 1.5

35

26

20MMX1.45

45

33.2

24MM X 1.5

60

44

FITTINGS, CONNECTIONS AND PLUGS DIAMETER & PITCH

NEWTONS/METER

POUNDS/FOOT

10MM X 1

20

14.5

12MM X 1.5

35

26

14MM X 1.5

45

33.2

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July 2004

SM96106 - SECTION ONE

GENERAL INFORMATION

FITTINGS, CONNECTIONS AND PLUGS DIAMETER & PITCH

NEWTONS/METER

POUNDS/FOOT

16MM X 1.5

60

44

18MM X 1.5

70

51

22MM X 1.5

100

73

27MM X 2

200

147

33MM X 2

280

207

42MM X 2

380

281

FLANGES

July 2004

DIAMETER & PITCH

NEWTONS/METER

POUNDS/FOOT

8MM X 1.5

28

21

10MM X 1.5

55

41

12MM X 1.75

90

67

14MM X 2

145

107

16MM X 2

230

170

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SM96106 - 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 blend.

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

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

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

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

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

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

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

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

2.0 to 4.3 32 to 40 No 3 ASTM 30

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July 2004

SM96106 - SECTION ONE

GENERAL INFORMATION

ENGINE OIL SPECIFICATION Use multigrade engine oil with API engine oil service classification CI-4.

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 ranges.

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SM96106 - SECTION ONE

GENERAL INFORMATION

SAFETY, GENERAL The information in this manual does not replace any safety rules and laws used in your area. Before operating this machine, learn the rules and laws for your area and make sure your machine has the correct equipment according to these rules and regulations. Before starting the engine study the operator’s manual.

•

Know the location and function of all machine controls.

•

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

•

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

•

Understand the limits of the machine.

•

Do not try to do too much too fast.

•

Keep the machine under control at all times.

The following decal is located on the left side of the machine on the fuse box door. Check the decal daily. Clean or replace as needed.

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

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July 2004

SM96106 - SECTION ONE

GENERAL INFORMATION

PERSONAL

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

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

Make sure cab windows are clean and unobstructed.

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

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

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

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

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

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

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

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

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SM96106 - SECTION ONE

GENERAL INFORMATION

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

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

The following decal is located on the instrument panel on machines without cabs. Check the decal daily. Clean or replace as needed.

MACHINE OPERATION

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

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July 2004

SM96106 - SECTION ONE

GENERAL INFORMATION

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

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

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

Sparks from the electrical system or engine exhaust can cause a fire or explosion.

Before you operate this machine in an area with flammable dust or vapors, use good ventilation to remove the flammable dust or vapors.

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

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

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

The following decal is located on each side of the machine’s front frame in the articulation joint area.

Check the decals daily. Clean or replace as needed.

July 2004

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SM96106 - SECTION ONE

GENERAL INFORMATION

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

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

Adjust machine operation accordingly.

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

NOTE: IF THE CLEARANCES IN THE SPECIFICATIONS BELOW ARE LESS THAN THE CLEARANCES GIVEN IN THE RULES AND LAWS OF YOUR AREA, YOU MUST FOLLOW THE RULES AND LAWS OF YOUR AREA! Table 1: Electrical Safety Rules Minimum Clearance From Cable When Machine is Working

Minimum Clearance From Cable When Transporting Machine

50,000 volts or less

10 feet (3 meters)

4 feet (1.2 meters)

50,000 volts to 345,000 volts

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

10 feet (3 meters)

345,000 volts to 750,000 volts

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

16 feet (5 meters)

Cable Voltage

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July 2004

SM96106 - SECTION ONE

GENERAL INFORMATION

MAINTENANCE

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

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

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

Flammable cleaning solvents can cause a fire hazard. Use nonflammable cleaning solvents for cleaning purposes.

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

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

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

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

July 2004

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SM96106 - SECTION ONE

GENERAL INFORMATION

Batteries produce explosive gases. Protect from and keep flames away. Ventilate when charging. Always wear eye protection when working near batteries. Do not wear jewelry or watch bands when working on batteries.

The following decal is located inside the battery box door. Check the decal daily. Clean or replace as needed.

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

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

The following decal is located inside the battery box door and shows that this machine has a 12 volt electrical system. Check the decal daily. Clean or replace as needed.

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July 2004

SM96106 - SECTION ONE

GENERAL INFORMATION

The following decal is located in six places on the machine at the lift and anchor points. Check the decals daily. Clean or replace as needed

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

July 2004

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SM96106 - SECTION ONE

GENERAL INFORMATION

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July 2004

SM96106 - SECTION ONE

GENERAL INFORMATION

MAINTENANCE SCHEDULE The intervals given in this maintenance schedule must not be exceeded. If the machine is operated under severe conditions (high temperature, dust, water, etc.) shorten the interval.

As Required Clean the machine Fill the fuel tank Service the air cleaner if warning light is lit Service the hydraulic oil filter if warning light is lit Check the torque of the wheel nuts Every 10 hours or daily Complete a daily walk around inspection Check the condition of the machine’s seat belt Check air and water hoses Clean or replace decals that cannot be read Check the engine oil level Check the hydraulic reservoir oil level Check the drum scrapers Check tire condition and pressure Check the condition of the engine belts Clean the rubber dust valve on air cleaner Check the wheel nuts Check the coolant reservoir fluid level After the first 250 hours of operation Change the oil in the drum gearbox Change engine oil Replace the engine oil filter Every 250 hours of operation Check axle oil levels Check engine mounts Check charge air cooler system Check fuel injection pump mounting Clean battery and check fluid level Check the oil in the drum gearbox Check the rubber buffers on the drum After the first 500 hours of operation Change oil in the rear axle

July 2004

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SM96106 - SECTION ONE

GENERAL INFORMATION

Every 500 hours of operation Change engine oil * * Engine oil change intervals are based on normal use with API CI-4 oil . Change intervals should be shortened to 250 hours during extreme operating conditions.

Replace the engine oil filter Drain the water from the fuel tank Clean the fuel filler inlet strainer Every 1000 hours of operation or once each year Replace the fuel filters Check the ROPS Check the operator’s seat Check drum vibration frequency Change the vibration system oil Change the hydraulic oil filter Change the hydraulic oil Clean the hydraulic oil filler screen Change oil in the rear axle Check and clean cooling system (outside) Change the oil in the drum gearbox Complete a Cummins service check Every 2000 hours of operation Clean and flush cooling system Change engine coolant

1 - 24

July 2004

SECTION TWO ENGINE

July 2004

2-1

SM96106 - SECTION TWO

ENGINE

CUMMINS ENGINE WARRANTY All Cummins Engines manufactured by Cummins Diesel and installed in Vibromax products are covered by Cummins warranty and are to be serviced by an Authorized Cummins Servicing Dealer and/or Distributor. The engines used in Vibromax equipment have a two (2) year or 2000 hour warranty period.

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

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

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

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

It is not the intent or purpose of this manual to supersede the manufacturer’s technical instruction for repair or overhaul of this engine. After the expiration of warranty, those wishing to do their own engine service work should obtain the Cummins Shop Manual for the “B 3.9” series engine from their local Cummins distributor.

2-2

July 2004

SECTION THREE

ELECTRICAL

July 2004

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SM96106 - SECTION THREE

ELECTRICAL

3-2

July 2004

SM96106 - SECTION THREE

ELECTRICAL

GENERAL INFORMATION The electrical system is a 12 volt, negative ground system. A solenoid controlled, gear driven, engine starter is standard along with a belt driven alternator. The battery is located in an enclosure at the rear of the machine.

A compartment under the operator’s seat contains the fuses and relays. The fuses are positioned at the left side of the compartment and accessible through a removable panel on the left side of the seat box.

Cab fuses The cab fuses are located on the top panel of the cab.

FK1 FK2

July 2004

15A 10A

cab fan and lights (option) windshield wipers and washers (option)

3-3

SM96106 - SECTION THREE

ELECTRICAL

FUSES The fuses for the machine are located in the panel on the left side below the operator’s seat. A hex bit is required to open the panel.

NOTE: Before changing fuses, be sure the key switch is in the OFF position. To change a fuse, remove the fuse box cover, remove the fuse, insert a new fuse of the same rating and replace the cover. .

location F0 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19

rating 100A 15A 10A 10A 10A 10A 5A 10A 15A 10A 10A 20A 10A 20A 10A 10A 10A 10A 10A 60A

fuse circuit main fuse (in battery compartment) instrument panel and horns alternator parking brake vibration two speed drive radio (option) emergency off switch cab heating and air conditioning (option) instrument and road lighting (option) accessory socket work lights (option) directional lights (option) road lighting system (option) hazard warning lights (option) road lights, left (option) road lights, right (option) road lights, left (option) road lights, right (option) cab functions (option)

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ELECTRICAL

RELAYS There are 14 relays used on the machine. The relays are located in the compartment under the operator’s seat except for K0 which is located on the engine.

Relay function K0 K1 K2 K3 K4 K5 K6 K7 K9 K10 K11 K12 K13 K14

July 2004

engine starter (located on engine) anti-restart brake monitor and alternator brake monitor and neutral position drive lever neutral position brake control vibration control vibration off in high speed travel emergency off road light system (option) reverse travel alarm (option) automatic vibration directional flasher (option) cab functions (option)

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ELECTRICAL

INSTRUMENT PANEL

The above picture is an overview of the complete instrument panel. On the following pages you will find a detailed break down of the panel.

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SM96106 - SECTION THREE 1

ELECTRICAL

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 oil temperature indicator light (not used) Engine coolant temperature indicator Sprinkler pump “ON” indicator light (not used) Air filter indicator light Fuel level indicator light (not used) Neutral position indicator light Directional light indicator (optional equipment)

2

Fuel level gauge This gauge indicates the fuel level in the fuel tank.

3

Engine temperature gauge This gauge registers engine temperature. While the engine is operating in the normal temperature range, the gauge will register in the green area. DO NOT OPERATE THE MACHINE WITH GAUGE REGISTERING IN THE RED.

July 2004

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ELECTRICAL 9

Travel speed selector

Vibration switch (low frequency) This switch operates the exciter shaft at low frequency and high amplitude.

10 Horn switch This switch actuates the machine’s horn.

Note: The horn will sound automatically if the engine operating temperature is too high or if the machine is driven with the parking brake engaged.

11 Lighting system switch This is a two position ON and OFF switch which controls the dash panel lights and also actuates a master relay for the optional road lights. This switch must be ON to operate the optional road lights using switch #12.

NOTE: This machine is designed so vibration will not function when the machine is in HIGH speed travel. Vibration at high travel speeds will produce poor compaction results.

12 Road lights switch This switch operates the front headlights and the rear tail lights. It has three positions, OFF, LOW BEAM, and HIGH BEAM. (optional equipment)

Uphill forward = drum in high speed and axle in low speed Uphill reverse = axle in high speed and drum in low speed 5

Key switch This is a three position switch; OFF, ON, and START. Rotate the switch clockwise to the ON position to actuate the electrical system. Continued clockwise rotation of the switch to the START position will engage the starter motor. Releasing the key will return the switch to the ON (run) position.

To stop the engine, rotate the key counterclockwise to the OFF position.

6

Auxiliary power socket This socket provides a 12 volt 10 amp. power source.

7

Vibration switch (high frequency) This switch operates the exciter shaft at high frequency and low amplitude.

8

Automatic vibration system switch This is a two position ON and OFF switch.

The automatic vibration system is designed to stop vibration when the machine’s forward/reverse lever is in neutral.

13 Front working headlight switch This is a two position ON and OFF switch which operates the front working lights. (optional equipment) 14 Rear working headlight switch This is a two position ON and OFF switch which operates the rear working lights. (optional equipment) 15 Hazard warning light switch This is a two position ON and OFF switch which controls the warning system lights. (optional equipment) 16 Parking brake switch This is a two position ON and OFF switch which engages and disengages the parking brake. The parking brake circuit is hooked into the horn circuit which will sound if the machine is driven with the parking brake engaged.

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ELECTRICAL

17 Clock or Compaction meter (optional equipment) The compaction meter gives a relative measurement of the compaction effort.

1) The relative compaction of the subsoil.

2) The vibration frequency expressed in Hertz (cycle per second).

3) The relative measurement of the drum jump height.

Menu position #1 (press M once) sets the meter brightness with the +/- buttons Menu position #2 (press M twice) sets the meter contrast with +/- buttons.

18 Flasher and directional light switch This is a switch which is mounted on the steering column when a machine is equipped with the optional road lights.

19 Steering column adjustment

To change the steering column height pull the lever upwards.

To change the steering column pitch push the lever down.

July 2004

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ELECTRICAL

UNDERSTANDING ELECTRICAL SCHEMATICS

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SM96106 - SECTION THREE

ELECTRICAL

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

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

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

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

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

Shown between the contacts, in parentheses, is the number (5).

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

July 2004

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

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

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

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

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ELECTRICAL

UNDERSTANDING ELECTRICAL SCHEMATICS

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SM96106 - SECTION THREE

ELECTRICAL All drawings are shown without power

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

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

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

Resistor Switch Diode Connector Solenoid control valve

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

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

Power to control the relay is always terminal #86 Ground is always terminal #85

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

Other items which may help you understand the diagram:

July 2004

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ELECTRICAL 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 and a simple switch. When the control circuit switch is closed, a magnetic field is produced by the electromagnet. This magnetic force is used to pull the relay work circuit contacts closed.

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

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

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SM96106 - SECTION THREE

ELECTRICAL

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

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

The numbering system mentioned earlier will apply.

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

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

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

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

Relay terminal #85 is always ground.

July 2004

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.

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ELECTRICAL

Starter/Charge Circuit

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SM96106 - SECTION THREE

ELECTRICAL

STARTER/CHARGING CIRCUIT

EMERGENCY STOP

Power to the S1 key switch [line 1] comes from the battery through fuse F0 [line 1]. To start the machine emergency stop switch S23 [line 24] must be closed. Additionally S2 neutral start switch [line 11] must be closed, energizing the coil of the K4 relay [line 11]. This closes the contacts of the K4 relay [line 8]. Current flows through the emergency stop circuit [line 24] and through K4 contacts, providing power to H2 neutral indicator light [line 9] and K1 relay coil [line 8]. K1 coil will be energized because of 12 volts at terminal 86 and ground at terminal 85 through the alternator regulator [line 3].

K1 relay contacts [line 2] close, providing a current path to the control coil of relay K0 [line 0] and to ground at control coil terminal 85.

Activating emergency stop switch S23 [line 24] removes power from K9 relay coil [line 24] opening the contacts of K9 [line 25].

Opening the K9 contacts drops power to the brake, vibration and travel circuits plus the engine fuel solenoid. Note that power for the start circuit relay K4 is also cut off when the emergency stop switch is activated [line 24] to prevent restart of the engine.

UNDERSTANDING BATTERIES 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.

K0 relay contacts [line2] close, providing a current path to the starter motor terminal 50. Power for the engine fuel solenoid Y6 [line 6] comes through fuse F3 [line 26].

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

Contacts K0 [line 2] open removing power to the starter. Holding power for the Y6 fuel solenoid is provided through fuse F3.

July 2004

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.

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SM96106 - SECTION THREE

ELECTRICAL BATTERY DIAGNOSTICS

Batteries produce explosive gases.

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

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

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

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

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

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

4) Keep the electrolyte level topped off.

5) Keep the alternator belt tight.

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SM96106 - SECTION THREE

ELECTRICAL

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

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

Measure the voltage just before removing the load.

STATE OF CHARGE VOLTAGE READING

SPECIFIC GRAVITY

% CHARGE

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

12.66

1.260

100

12.60

1.250

91

12.54

1.240

83

Temp C

21

16

10

4

-1

12.48

1.230

75

Temp F

70

60

50

40

30

12.42

1.220

62*

Min-voltage

9.6

9.5

9.4

9.3

9.1

12.36

1.210

58

12.30

1.200

0**

UNDERSTANDING TORS

* = 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.

July 2004

ALTERNA-

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SM96106 - SECTION THREE

ELECTRICAL

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

the B+ terminal to the positive terminal of the starter solenoid.

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

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

As the rotor is turned by the shaft, the magnetic field of the rotor (C) will pass through the windings of the stator (B) and produce an electrical current in the stator windings. The amount of current produced will vary depending on the speed of the rotor and the strength of the magnetic field.

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

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

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

CHARGING SYSTEM DIAGNOSTICS Normal warning lamp operation.

KEY

ENGINE

LAMP

OFF

OFF

OFF

ON

OFF

ON

ON

ON

OFF

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

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

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SM96106 - SECTION THREE

ELECTRICAL

VOLTAGE CHECKS AT ALTERNATOR

going to ground. This will eventually discharge the battery.

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

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

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

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

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

SYSTEM LEAKAGE Remove the ground cable from the battery.

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

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

July 2004

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ELECTRICAL

MEASURING ALTERNATOR OUTPUT

UNDERSTANDING STARTERS

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

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

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

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

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

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

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

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ELECTRICAL

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

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

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

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

STARTER SYSTEM DIAGNOSTICS SOLENOID CIRCUIT TEST CAUTION: Fasten the manual shut off lever on the injection pump in the “OFF” position prior to this test.

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

Turn the key switch to the start position.

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

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SM96106 - SECTION THREE

ELECTRICAL

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

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

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

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

NOTE: A clicking from the solenoid indicates the following: 1) Poorly charged battery 2) Corroded cables 3) Bad connection 4) Poor ground 5) Bad solenoid If the reading was 0.5 or less, the ground is satisfactory. If the reading is more than 0.5 volts, the starter is poorly grounded.

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

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July 2004

SM96106 - SECTION THREE

ELECTRICAL

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

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

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

July 2004

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ELECTRICAL

INSTRUMENT PANEL

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July 2004

SM96106 - SECTION THREE

ELECTRICAL

INSTRUMENTATION PANEL The instrumentation panel receives power from terminal 15/54 of the key switch. Power flows from Fuse F1 and is available to the panel when the key switch is in the ON position.

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

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

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

July 2004

The current path when brake pressure is insufficient is through the horn, through K2 relay contacts [line 16] (contacts close if engine is running), Diode V2, K3 relay contacts [lines 16] (closed whenever the machine is not in neutral) and through the brake pressure switch S3 [line 15] to ground.

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

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

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

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

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ELECTRICAL

BRAKE SWITCH

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July 2004

SM96106 - SECTION THREE

ELECTRICAL

BRAKE SWITCH The brake solenoid Y5 [line 26] receives power to release the brakes provided the key switch is in the ON position, the normally closed contacts of brake switch S17 [line 26] are closed, and the normally closed contacts of the K5 [line 26] relay are closed .

The brakes are released by hydraulic pressure so the engine must be running for the brakes to release.

Solenoid Y8 [line 25] receives power whenever brake solenoid Y5 is energized. When

July 2004

de-energized this valve connects both sides of the pump servo cylinder so the pump will stroke back to a neutral position whenever the brakes are applied.

The brakes will apply if (1) the key switch is turned off so the engine has stopped running, (2) brake switch S17 is depressed, (3) there is insufficient brake pressure at Switch S3 [line 15] causing the switch to close, energizing the coil of the K5 relay [line 16] causing the contacts of relay K5 [line 26] to open.

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ELECTRICAL

FRONT AND REAR HIGH SPEED

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ELECTRICAL

HIGH SPEED CIRCUIT Power for the high speed control circuit is available through Fuse F5 [line 35] if the key switch is in the ON position and the emergency stop switch is not depressed.

Solenoids Y3 and Y7 [lines 35 and 36] provide the high speed operation and are controlled by Selector Switch S8. Switch S8 also controls the K7 relay coil [line 37] which will not allow vibration in HIGH speed travel.

“D” “B”

“A”

“C”

NOTE: This machine is designed so vibration will not function when the machine is in HIGH speed travel. Vibration at high travel speeds will produce poor compaction results.

Low speed = drum and axle in low speed range High speed = drum and axle in high speed range Uphill reverse = axle in high speed and drum in low speed Uphill forward = drum in high speed and axle in low speed

July 2004

When Selector Switch S8 is in the center position or is actuated to the “A” position no power is supplied to either solenoid and the hydraulic motors remain at full displacement which is the low speed range.

When Selector Switch S8 is actuated to the “B” position power is supplied to solenoids Y3 and Y7 as well as the control coil of relay K7. Relay K7 contacts [line 29] will open preventing vibratory operation in high travel speed. With power to the solenoids the hydraulic motor displacements are reduced resulting in a higher speed operation of the axle and drum. The S20 switch [line 35] is located on the machines fuse panel and must be in the “ON” position for the drum to operate in a high speed mode.

The S20 switch can be shut off for some padfoot drum applications.

When Selector Switch S8 is actuated to the “C” position solenoid Y3 [line 36] is energized causing the axle drive motor to reduce displacement which results in the axle operating at high speed. At the same time solenoid Y7 [line 35] was not energized so it continues to operate the drum in low range mode.

When Selector Switch S8 is actuated to the “D” position solenoid Y7 [line 35] is energized causing the drum drive motor to reduce displacement which results in the drum operating at high speed. At the same time solenoid Y3 [line 36] was not energized so it continues to operate the axle in low range mode.

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ELECTRICAL

VIBRATION CIRCUIT

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SM96106 - SECTION THREE

ELECTRICAL

VIBRATION CIRCUIT The smooth drum and padfoot drum models are both equipped with a high and low frequency vibratory system.

Power for the vibration control circuit is available through Fuse F4 and relay K7 [line 29] if the key is on and the emergency stop switch is not depressed and the machine is not in HIGH speed travel. When the machine is in HIGH speed travel the contacts of K7 relay will stay open preventing operation of the vibration system.

Power from the fuse is available at both Switch S7B [line 29] and S24 [line 33]. In manual mode the manual/automatic selector switch S7B passes current through the manual mode contacts [8] to terminal 2 of the K6 latching relay [line 33]. When the momentary push button, switch S24 [line 33] on the forward/reverse lever, is depressed and released, K6 latches contacts 2 and 5, allowing current to flow to the S7 (high frequency) and S7A (low frequency) vibration control switches. Activating switch

July 2004

S7 or S7A allows current to solenoids Y1 or Y2 on the vibration control valve. When switch S24 is depressed and released a second time K6 unlatches, removing power from terminal 5 of the K6 relay, and shuts off vibration. Switches S7 and S7A work independently once K6 relay is latched, however it is recommended that the vibration system be shut down by using S24 before changing between high and low frequency with switches S7 and S7A. In the automatic vibration mode, current passes through switch S7B [line 29], through the contacts of relay K12 [line29], and onto terminal 1 of switches S7 and S7A. Switch S24 and relay K6 are not part of the active circuit so the button on the forward/reverse lever has no effect on vibration operations in the automatic mode. The automatic vibration off in neutral is controlled through relay K12. The contacts of K12 open whenever the forward/reverse lever is moved into the neutral position.

3 - 33

SM96106 - SECTION THREE

ELECTRICAL

ROAD LIGHTING CIRCUIT

3 - 34

July 2004

SM96106 - SECTION THREE

ELECTRICAL

ROAD LIGHTING CIRCUIT The lighting circuit includes the instrument panel lighting, optional headlights and taillights, optional directional and hazard lighting.

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

If the optional park and tail light circuit is provided, the instrument panel Switch S11 also energizes the coil of Relay K10 [line 53]. The optional circuit receives power from Terminal 30 (battery +) of the key switch but key control is maintained through relay K10. There is power to Fuse F13 but not to Switch 25 until the K10 Relay Contacts are closed. Switch S25 is a three position rocker switch for operating the dimmed or high beam headlights and the tail lights. Separate fuses are used for each pair of park/tail lights.

July 2004

Fuse F12 [line 63] receives power from the key switch ON position and provides current to the optional directional light circuit.

Current enters Switch S27 passes through Relay K13 and enters the Directional Switch S26, Terminal A. When the lever is moved left or right, it energizes the proper lights. As the current passes through the K13 Flasher Relay, intermittent output occurs.

Fuse F14 [line 62] receives power from Terminal 30 and does not need the key switch on. It provides power to the optional Hazard Light Switch S27. When the switch is activated, power is passed through the K13 Relay as well as to all four directional lights.

E1 = temperature gauge light E2 = fuel gauge light E7 = left front dimmed headlight E8 = left rear tail light E9 = right front dimmed headlight E10 = right rear tail light E11 = left high beam headlight E12 = right high beam headlight H21 = left front flasher light H22 = left rear flasher light H23 = right front flasher light H24 = right rear flasher light

3 - 35

SM96106 - SECTION THREE

ELECTRICAL

WORK LIGHTS / ACCESSORY PLUG

3 - 36

July 2004

SM96106 - SECTION THREE

ELECTRICAL

WORK LIGHTS & ACCESSORY PLUG The optional work light circuit is a key switch controlled circuit, protected by Fuse F11 and controlled by Switch S28 [line 70] for the front work lights and Switch S28a [line 73] for the rear work lights. Indicator Lights illuminate the light switches when activated.

The accessory plug circuit [line 75] is a key switch controlled circuit, protected by Fuse F10 and provides a 12 volt 15 amp. power source.

E3 = left front light E4 = right front light E5 = left rear light E6 = left front light

July 2004

3 - 37

SM96106 - SECTION THREE

ELECTRICAL

CAB CIRCUITS

3 - 38

July 2004

SM96106 - SECTION THREE

ELECTRICAL

CAB CIRCUITS Cab power comes directly from the battery through fuse F19 [line 79]. To maintain key switch control relay K14 [lines 79 and 83] has been inserted after the fuse. K14 relay coil is powered through fuse F1 and the relay contacts close when the key switch is in the on position.

The cab fan motor is powered through fuse FK1 [line 80] and controlled by switch S15 [line 80]. The cab lights are also powered through fuse FK1 and controlled by switch S10 [line 81].

Power for the front and rear window wipers and washers comes through fuse FK2 [line 76]. Switch S12 [line 76] controls the front window wiper motor and washer pump.

Switch S13 [line 78] controls the rear window wiper motor and washer pump.

Fuse F8 [line 82] is used for air conditioner applications. Fuse F6 [line 84] is used for a radio application.

July 2004

3 - 39

3 - 40

July 2004

84

24

82

52

75

70

63

56a

62

56

57

59

60

79

80

75

F6

F7

F8

F9

F10

F11

F12

F13

F14

F15

F16

F17

F18

F19

FK1

FK2

18

35

F5

17

29

F4

H5

26

F3

H4

3

F2

15

2

F1

9

1

F0

H3

81

E13

H2

60

E12

4

59

E11

H1

58

E10

3

57

E9

G2

56

E8

1

55

E7

G1

72

70

E4

73

69

E3

E6

52

E2

E5

51

E1

ITEM LINE

INDICATOR LIGHT, ENG. TEMP.

HORN

INDICATOR LIGHT, BRAKE

INDICATOR LIGHT, NEUTRAL

INDICATOR LIGHT, ALTERNATOR

ALTERNATOR

BATTERY

FUSE, CAB WINDOW WIPER & WASHER

FUSE, CAB FAN & LIGHTS

FUSE, CAB FUNCTIONS

FUSE, RIGHT DIM LIGHT

FUSE, LEFT DIM LIGHT

FUSE, RIGHT ROAD LIGHTS

FUSE, LEFT ROAD LIGHTS

FUSE, HAZARD LIGHTS

FUSE, LIGHTING

FUSE, DIRECTIONAL LIGHTS

FUSE, WORK LIGHTS

FUSE, PLUG SOCKET

FUSE, LIGHTING

FUSE, CAB AIR CONDITIONER

FUSE, EMERGENCY OFF

FUSE, CAB RADIO

FUSE, TWO SPEED / COMPACTOMETER

FUSE, VIBRATION

FUSE, BRAKE

FUSE, ALTERNATOR

FUSE, INSTRUMENTATION CIRCUIT 15

FUSE, MAIN POWER FROM BATTERY

LIGHT, CAB

LIGHT, RIGHT DIM

LIGHT, LEFT DIM

LIGHT, RIGHT TAIL

LIGHT, FRONT RIGHT PARK

LIGHT, LEFT TAIL

LIGHT, FRONT LEFT PARK

LIGHT, REAR RIGHT WORK

LIGHT, REAR LEFT WORK

LIGHT, FRONT RIGHT WORK

LIGHT, FRONT LEFT WORK

LIGHT, FUEL GAUGE

LIGHT, TEMPERATURE GAUGE

DESCRIPTION

ELECTRICAL SCHEMATICS

S5

S4

S3

S2

S1

R2

R1

P3

P2

P1

M6

M5

M4

M3

M2

M1

K14

K13

K12

K11

K10

K9

K7

K6

K5

K4

K3

K2

K1

K0

H24

H23

H22

H21

H16

H15

H14

H13

H10

H9

H8

H6

18

17

15

11

1

22

21

22

21

4

79

80

77

78

76

2

79-83

64

28-29

13-14

54-56

24-25

29-37

32-33

16-26

8-11

10-16

5-16

2-8

0-2

66

65

64

63

68

65

64a

53

23

19

14

20

ITEM LINE

SWITCH, HIGH ENGINE TEMP.

SWITCH, HORN BUTTON

SWITCH, BRAKE RELEASE PRESSURE

SWITCH, NEUTRAL POSITION

SWITCH, KEY

SENSOR, FUEL LEVEL

SENSOR, ENGINE TEMPERATURE

GAUGE, FUEL LEVEL

GAUGE, ENGINE TEMPERATURE

HOUR METER

MOTOR, WASHER PUMP REAR

MOTOR, FAN

MOTOR, WASHER PUMP FRONT

MOTOR, REAR WIPER

MOTOR, FRONT WIPER

MOTOR, STARTER

RELAY, CAB FUNCTIONS

RELAY, DIRECTIONAL FLASHER

RELAY, AUTOMATIC VIBRATION

RELAY, BACK UP ALARM

RELAY, LIGHTING SYSTEM

RELAY, EMERGENCY OFF

RELAY, VIBRATION OFF IN HIGH SPEED

RELAY, VIBRATION MANUAL CONTROL

RELAY, BRAKE RELEASE

RELAY, NEUTRAL POSITION

RELAY, BRAKE MONITOR, NEUTRAL

RELAY, BRAKE MONITOR, ALTERNATOR

RELAY, ANTI-RESTART

RELAY, ENGINE START

LIGHT, REAR RIGHT DIRECTIONAL

LIGHT, FRONT RIGHT DIRECTIONAL

LIGHT, REAR LEFT DIRECTIONAL

LIGHT, FRONT LEFT DIRECTIONAL

INDICATOR LIGHT, DIRECTION ARROW

INDICATOR LIGHT, HAZARD LIGHTS

INDICATOR LIGHT, DIRECTIONALS

INDICATOR LIGHT, LIGHTS

INDICATOR LIGHT, AIR FILTER

INDICATOR LIGHT, HYDRAULIC FILTER

BACK UP ALARM

INDICATOR LIGHT, ENG. OIL PSI.

DESCRIPTION

V5

V4

V3

V2

V1

Y8

Y7

Y6

Y5

Y3

Y2

Y1

S28A

S28

S27

S26

S25

S24

S23

S20

S19

S18

S17

S16

S15

S13

S12

S11

S10

S8

S7B

S7A

S7

S6

36

36

7

16

17

25

35

6

26

36

30

29

73

70

64

64

56

33

24

35

13

19

26

23

80

78

76

52

81

38

29

29

29

20

ITEM LINE

DIODE, ISOLATION

DIODE, ISOLATION

DIODE, ISOLATION

DIODE, ISOLATION

DIODE, ISOLATION

SOLENOID, PUMP CONTROL

SOLENOID, 2 SPEED DRUM

SOLENOID, ENGINE SHUT DOWN

SOLENOID, BRAKE/SERVO

SOLENOID, 2 SPEED AXLE

SOLENOID, VIBRATION LOW FREQ.

SOLENOID, VIBRATION HIGH FREQ.

SWITCH, REAR WORK LIGHTS

SWITCH, FRONT WORK LIGHTS

SWITCH, HAZARD LIGHTS

SWITCH, DIRECTIONAL LIGHTS

SWITCH, LIGHTING

SWITCH, THUMB,VIBRATION ON/OFF

SWITCH, EMERGENCY OFF

SWITCH, DISABLE DRUM TWO SPEED

SWITCH, BACK UP ALARM

SWITCH, HYDRAULIC FILTER PSI.

SWITCH, HYDRAULIC BRAKE

SWITCH, AIR FILTER

SWITCH, FAN

SWITCH, REAR WIPER

SWITCH, FRONT WIPER

SWITCH, LIGHTING SYSTEM

SWITCH, CAB LIGHTING

SWITCH, TRAVEL SPEED

SWITCH, AUTO/MANUAL VIBRATION

SWITCH, VIBRATION LOW FREQ.

SWITCH, VIBRATION HIGH FREQ.

SWITCH, ENGINE OIL PRESSURE

DESCRIPTION

3 - 42

July 2004

72

73

55

56

57

58

59

60

81

1

2

3

26

E5

E6

E7

E8

E9

E10

E11

E12

E13

F0

F1

F2

F3

9

15

17

18

H2

H3

H4

H5

4

80

FK1

3

79

F19

H1

60

F18

G2

59

F17

75

57

F16

1

56

F15

G1

62

F14

FK2

56a

F13

F10

70

75

F9

63

52

F8

F12

82

F7

F11

84

24

F6

29

70

E4

35

69

E3

F5

52

E2

F4

51

E1

ITEM LINE

INDICATOR LIGHT, ENG. TEMP.

HORN

INDICATOR LIGHT, BRAKE

INDICATOR LIGHT, NEUTRAL

INDICATOR LIGHT, ALTERNATOR

ALTERNATOR

BATTERY

FUSE, CAB WINDOW WIPER & WASHER

FUSE, CAB FAN & LIGHTS

FUSE, CAB FUNCTIONS

FUSE, RIGHT DIM LIGHT

FUSE, LEFT DIM LIGHT

FUSE, RIGHT ROAD LIGHTS

FUSE, LEFT ROAD LIGHTS

FUSE, HAZARD LIGHTS

FUSE, LIGHTING

FUSE, DIRECTIONAL LIGHTS

FUSE, WORK LIGHTS

FUSE, PLUG SOCKET

FUSE, LIGHTING

FUSE, CAB AIR CONDITIONER

FUSE, EMERGENCY OFF

FUSE, CAB RADIO

FUSE, TWO SPEED / COMPACTOMETER

FUSE, VIBRATION

FUSE, BRAKE

FUSE, ALTERNATOR

FUSE, INSTRUMENTATION CIRCUIT 15

FUSE, MAIN POWER FROM BATTERY

LIGHT, CAB

LIGHT, RIGHT DIM

LIGHT, LEFT DIM

LIGHT, RIGHT TAIL

LIGHT, FRONT RIGHT PARK

LIGHT, LEFT TAIL

LIGHT, FRONT LEFT PARK

LIGHT, REAR RIGHT WORK

LIGHT, REAR LEFT WORK

LIGHT, FRONT RIGHT WORK

LIGHT, FRONT LEFT WORK

LIGHT, FUEL GAUGE

LIGHT, TEMPERATURE GAUGE

DESCRIPTION

S5

S4

S3

S2

S1

R2

R1

P3

P2

P1

M6

M5

M4

M3

M2

M1

K14

K13

K12

K11

K10

K9

K7

K6

K5

K4

K3

K2

K1

K0

H24

H23

H22

H21

H16

H15

H14

H13

H10

H9

H8

H6

18

17

15

11

1

22

21

22

21

4

79

80

77

78

76

2

79-83

64

28-29

13-14

54-56

24-25

29-37

32-33

16-26

8-11

10-16

5-16

2-8

0-2

66

65

64

63

68

65

64a

53

23

19

14

20

ITEM LINE

SWITCH, HIGH ENGINE TEMP.

SWITCH, HORN BUTTON

SWITCH, BRAKE RELEASE PRESSURE

SWITCH, NEUTRAL POSITION

SWITCH, KEY

SENSOR, FUEL LEVEL

SENSOR, ENGINE TEMPERATURE

GAUGE, FUEL LEVEL

GAUGE, ENGINE TEMPERATURE

HOUR METER

MOTOR, WASHER PUMP REAR

MOTOR, FAN

MOTOR, WASHER PUMP FRONT

MOTOR, REAR WIPER

MOTOR, FRONT WIPER

MOTOR, STARTER

RELAY, CAB FUNCTIONS

RELAY, DIRECTIONAL FLASHER

RELAY, AUTOMATIC VIBRATION

RELAY, BACK UP ALARM

RELAY, LIGHTING SYSTEM

RELAY, EMERGENCY OFF

RELAY, VIBRATION OFF IN HIGH SPEED

RELAY, VIBRATION MANUAL CONTROL

RELAY, BRAKE RELEASE

RELAY, NEUTRAL POSITION

RELAY, BRAKE MONITOR, NEUTRAL

RELAY, BRAKE MONITOR, ALTERNATOR

RELAY, ANTI-RESTART

RELAY, ENGINE START

LIGHT, REAR RIGHT DIRECTIONAL

LIGHT, FRONT RIGHT DIRECTIONAL

LIGHT, REAR LEFT DIRECTIONAL

LIGHT, FRONT LEFT DIRECTIONAL

INDICATOR LIGHT, DIRECTION ARROW

INDICATOR LIGHT, HAZARD LIGHTS

INDICATOR LIGHT, DIRECTIONALS

INDICATOR LIGHT, LIGHTS

INDICATOR LIGHT, AIR FILTER

INDICATOR LIGHT, HYDRAULIC FILTER

BACK UP ALARM

INDICATOR LIGHT, ENG. OIL PSI.

DESCRIPTION

V5

V4

V3

V2

V1

Y8

Y7

Y6

Y5

Y3

Y2

Y1

S28A

S28

S27

S26

S25

S24

S23

S20

S19

S18

S17

S16

S15

S13

S12

S11

S10

S8

S7B

S7A

S7

S6

36

36

7

16

17

25

35

6

26

36

30

29

73

70

64

64

56

33

24

35

13

19

26

23

80

78

76

52

81

38

29

29

29

20

ITEM LINE

DIODE, ISOLATION

DIODE, ISOLATION

DIODE, ISOLATION

DIODE, ISOLATION

DIODE, ISOLATION

SOLENOID, PUMP CONTROL

SOLENOID, 2 SPEED DRUM

SOLENOID, ENGINE SHUT DOWN

SOLENOID, BRAKE/SERVO

SOLENOID, 2 SPEED AXLE

SOLENOID, VIBRATION LOW FREQ.

SOLENOID, VIBRATION HIGH FREQ.

SWITCH, REAR WORK LIGHTS

SWITCH, FRONT WORK LIGHTS

SWITCH, HAZARD LIGHTS

SWITCH, DIRECTIONAL LIGHTS

SWITCH, LIGHTING

SWITCH, THUMB,VIBRATION ON/OFF

SWITCH, EMERGENCY OFF

SWITCH, DISABLE DRUM TWO SPEED

SWITCH, BACK UP ALARM

SWITCH, HYDRAULIC FILTER PSI.

SWITCH, HYDRAULIC BRAKE

SWITCH, AIR FILTER

SWITCH, FAN

SWITCH, REAR WIPER

SWITCH, FRONT WIPER

SWITCH, LIGHTING SYSTEM

SWITCH, CAB LIGHTING

SWITCH, TRAVEL SPEED

SWITCH, AUTO/MANUAL VIBRATION

SWITCH, VIBRATION LOW FREQ.

SWITCH, VIBRATION HIGH FREQ.

SWITCH, ENGINE OIL PRESSURE

DESCRIPTION

3 - 44

July 2004

72

73

55

56

57

58

59

60

81

1

2

3

26

E5

E6

E7

E8

E9

E10

E11

E12

E13

F0

F1

F2

F3

9

15

17

18

H2

H3

H4

H5

4

80

FK1

3

79

F19

H1

60

F18

G2

59

F17

75

57

F16

1

56

F15

G1

62

F14

FK2

56a

F13

F10

70

75

F9

63

52

F8

F12

82

F7

F11

84

24

F6

29

70

E4

35

69

E3

F5

52

E2

F4

51

E1

ITEM LINE

INDICATOR LIGHT, ENG. TEMP.

HORN

INDICATOR LIGHT, BRAKE

INDICATOR LIGHT, NEUTRAL

INDICATOR LIGHT, ALTERNATOR

ALTERNATOR

BATTERY

FUSE, CAB WINDOW WIPER & WASHER

FUSE, CAB FAN & LIGHTS

FUSE, CAB FUNCTIONS

FUSE, RIGHT DIM LIGHT

FUSE, LEFT DIM LIGHT

FUSE, RIGHT ROAD LIGHTS

FUSE, LEFT ROAD LIGHTS

FUSE, HAZARD LIGHTS

FUSE, LIGHTING

FUSE, DIRECTIONAL LIGHTS

FUSE, WORK LIGHTS

FUSE, PLUG SOCKET

FUSE, LIGHTING

FUSE, CAB AIR CONDITIONER

FUSE, EMERGENCY OFF

FUSE, CAB RADIO

FUSE, TWO SPEED / COMPACTOMETER

FUSE, VIBRATION

FUSE, BRAKE

FUSE, ALTERNATOR

FUSE, INSTRUMENTATION CIRCUIT 15

FUSE, MAIN POWER FROM BATTERY

LIGHT, CAB

LIGHT, RIGHT DIM

LIGHT, LEFT DIM

LIGHT, RIGHT TAIL

LIGHT, FRONT RIGHT PARK

LIGHT, LEFT TAIL

LIGHT, FRONT LEFT PARK

LIGHT, REAR RIGHT WORK

LIGHT, REAR LEFT WORK

LIGHT, FRONT RIGHT WORK

LIGHT, FRONT LEFT WORK

LIGHT, FUEL GAUGE

LIGHT, TEMPERATURE GAUGE

DESCRIPTION

S5

S4

S3

S2

S1

R2

R1

P3

P2

P1

M6

M5

M4

M3

M2

M1

K14

K13

K12

K11

K10

K9

K7

K6

K5

K4

K3

K2

K1

K0

H24

H23

H22

H21

H16

H15

H14

H13

H10

H9

H8

H6

18

17

15

11

1

22

21

22

21

4

79

80

77

78

76

2

79-83

64

28-29

13-14

54-56

24-25

29-37

32-33

16-26

8-11

10-16

5-16

2-8

0-2

66

65

64

63

68

65

64a

53

23

19

14

20

ITEM LINE

SWITCH, HIGH ENGINE TEMP.

SWITCH, HORN BUTTON

SWITCH, BRAKE RELEASE PRESSURE

SWITCH, NEUTRAL POSITION

SWITCH, KEY

SENSOR, FUEL LEVEL

SENSOR, ENGINE TEMPERATURE

GAUGE, FUEL LEVEL

GAUGE, ENGINE TEMPERATURE

HOUR METER

MOTOR, WASHER PUMP REAR

MOTOR, FAN

MOTOR, WASHER PUMP FRONT

MOTOR, REAR WIPER

MOTOR, FRONT WIPER

MOTOR, STARTER

RELAY, CAB FUNCTIONS

RELAY, DIRECTIONAL FLASHER

RELAY, AUTOMATIC VIBRATION

RELAY, BACK UP ALARM

RELAY, LIGHTING SYSTEM

RELAY, EMERGENCY OFF

RELAY, VIBRATION OFF IN HIGH SPEED

RELAY, VIBRATION MANUAL CONTROL

RELAY, BRAKE RELEASE

RELAY, NEUTRAL POSITION

RELAY, BRAKE MONITOR, NEUTRAL

RELAY, BRAKE MONITOR, ALTERNATOR

RELAY, ANTI-RESTART

RELAY, ENGINE START

LIGHT, REAR RIGHT DIRECTIONAL

LIGHT, FRONT RIGHT DIRECTIONAL

LIGHT, REAR LEFT DIRECTIONAL

LIGHT, FRONT LEFT DIRECTIONAL

INDICATOR LIGHT, DIRECTION ARROW

INDICATOR LIGHT, HAZARD LIGHTS

INDICATOR LIGHT, DIRECTIONALS

INDICATOR LIGHT, LIGHTS

INDICATOR LIGHT, AIR FILTER

INDICATOR LIGHT, HYDRAULIC FILTER

BACK UP ALARM

INDICATOR LIGHT, ENG. OIL PSI.

DESCRIPTION

V5

V4

V3

V2

V1

Y8

Y7

Y6

Y5

Y3

Y2

Y1

S28A

S28

S27

S26

S25

S24

S23

S20

S19

S18

S17

S16

S15

S13

S12

S11

S10

S8

S7B

S7A

S7

S6

36

36

7

16

17

25

35

6

26

36

30

29

73

70

64

64

56

33

24

35

13

19

26

23

80

78

76

52

81

38

29

29

29

20

ITEM LINE

DIODE, ISOLATION

DIODE, ISOLATION

DIODE, ISOLATION

DIODE, ISOLATION

DIODE, ISOLATION

SOLENOID, PUMP CONTROL

SOLENOID, 2 SPEED DRUM

SOLENOID, ENGINE SHUT DOWN

SOLENOID, BRAKE/SERVO

SOLENOID, 2 SPEED AXLE

SOLENOID, VIBRATION LOW FREQ.

SOLENOID, VIBRATION HIGH FREQ.

SWITCH, REAR WORK LIGHTS

SWITCH, FRONT WORK LIGHTS

SWITCH, HAZARD LIGHTS

SWITCH, DIRECTIONAL LIGHTS

SWITCH, LIGHTING

SWITCH, THUMB,VIBRATION ON/OFF

SWITCH, EMERGENCY OFF

SWITCH, DISABLE DRUM TWO SPEED

SWITCH, BACK UP ALARM

SWITCH, HYDRAULIC FILTER PSI.

SWITCH, HYDRAULIC BRAKE

SWITCH, AIR FILTER

SWITCH, FAN

SWITCH, REAR WIPER

SWITCH, FRONT WIPER

SWITCH, LIGHTING SYSTEM

SWITCH, CAB LIGHTING

SWITCH, TRAVEL SPEED

SWITCH, AUTO/MANUAL VIBRATION

SWITCH, VIBRATION LOW FREQ.

SWITCH, VIBRATION HIGH FREQ.

SWITCH, ENGINE OIL PRESSURE

DESCRIPTION

3 - 46

July 2004

72

73

55

56

57

58

59

60

81

1

2

3

26

E5

E6

E7

E8

E9

E10

E11

E12

E13

F0

F1

F2

F3

9

15

17

18

H2

H3

H4

H5

4

80

FK1

3

79

F19

H1

60

F18

G2

59

F17

75

57

F16

1

56

F15

G1

62

F14

FK2

56a

F13

F10

70

75

F9

63

52

F8

F12

82

F7

F11

84

24

F6

29

70

E4

35

69

E3

F5

52

E2

F4

51

E1

ITEM LINE

INDICATOR LIGHT, ENG. TEMP.

HORN

INDICATOR LIGHT, BRAKE

INDICATOR LIGHT, NEUTRAL

INDICATOR LIGHT, ALTERNATOR

ALTERNATOR

BATTERY

FUSE, CAB WINDOW WIPER & WASHER

FUSE, CAB FAN & LIGHTS

FUSE, CAB FUNCTIONS

FUSE, RIGHT DIM LIGHT

FUSE, LEFT DIM LIGHT

FUSE, RIGHT ROAD LIGHTS

FUSE, LEFT ROAD LIGHTS

FUSE, HAZARD LIGHTS

FUSE, LIGHTING

FUSE, DIRECTIONAL LIGHTS

FUSE, WORK LIGHTS

FUSE, PLUG SOCKET

FUSE, LIGHTING

FUSE, CAB AIR CONDITIONER

FUSE, EMERGENCY OFF

FUSE, CAB RADIO

FUSE, TWO SPEED / COMPACTOMETER

FUSE, VIBRATION

FUSE, BRAKE

FUSE, ALTERNATOR

FUSE, INSTRUMENTATION CIRCUIT 15

FUSE, MAIN POWER FROM BATTERY

LIGHT, CAB

LIGHT, RIGHT DIM

LIGHT, LEFT DIM

LIGHT, RIGHT TAIL

LIGHT, FRONT RIGHT PARK

LIGHT, LEFT TAIL

LIGHT, FRONT LEFT PARK

LIGHT, REAR RIGHT WORK

LIGHT, REAR LEFT WORK

LIGHT, FRONT RIGHT WORK

LIGHT, FRONT LEFT WORK

LIGHT, FUEL GAUGE

LIGHT, TEMPERATURE GAUGE

DESCRIPTION

S5

S4

S3

S2

S1

R2

R1

P3

P2

P1

M6

M5

M4

M3

M2

M1

K14

K13

K12

K11

K10

K9

K7

K6

K5

K4

K3

K2

K1

K0

H24

H23

H22

H21

H16

H15

H14

H13

H10

H9

H8

H6

18

17

15

11

1

22

21

22

21

4

79

80

77

78

76

2

79-83

64

28-29

13-14

54-56

24-25

29-37

32-33

16-26

8-11

10-16

5-16

2-8

0-2

66

65

64

63

68

65

64a

53

23

19

14

20

ITEM LINE

SWITCH, HIGH ENGINE TEMP.

SWITCH, HORN BUTTON

SWITCH, BRAKE RELEASE PRESSURE

SWITCH, NEUTRAL POSITION

SWITCH, KEY

SENSOR, FUEL LEVEL

SENSOR, ENGINE TEMPERATURE

GAUGE, FUEL LEVEL

GAUGE, ENGINE TEMPERATURE

HOUR METER

MOTOR, WASHER PUMP REAR

MOTOR, FAN

MOTOR, WASHER PUMP FRONT

MOTOR, REAR WIPER

MOTOR, FRONT WIPER

MOTOR, STARTER

RELAY, CAB FUNCTIONS

RELAY, DIRECTIONAL FLASHER

RELAY, AUTOMATIC VIBRATION

RELAY, BACK UP ALARM

RELAY, LIGHTING SYSTEM

RELAY, EMERGENCY OFF

RELAY, VIBRATION OFF IN HIGH SPEED

RELAY, VIBRATION MANUAL CONTROL

RELAY, BRAKE RELEASE

RELAY, NEUTRAL POSITION

RELAY, BRAKE MONITOR, NEUTRAL

RELAY, BRAKE MONITOR, ALTERNATOR

RELAY, ANTI-RESTART

RELAY, ENGINE START

LIGHT, REAR RIGHT DIRECTIONAL

LIGHT, FRONT RIGHT DIRECTIONAL

LIGHT, REAR LEFT DIRECTIONAL

LIGHT, FRONT LEFT DIRECTIONAL

INDICATOR LIGHT, DIRECTION ARROW

INDICATOR LIGHT, HAZARD LIGHTS

INDICATOR LIGHT, DIRECTIONALS

INDICATOR LIGHT, LIGHTS

INDICATOR LIGHT, AIR FILTER

INDICATOR LIGHT, HYDRAULIC FILTER

BACK UP ALARM

INDICATOR LIGHT, ENG. OIL PSI.

DESCRIPTION

V5

V4

V3

V2

V1

Y8

Y7

Y6

Y5

Y3

Y2

Y1

S28A

S28

S27

S26

S25

S24

S23

S20

S19

S18

S17

S16

S15

S13

S12

S11

S10

S8

S7B

S7A

S7

S6

36

36

7

16

17

25

35

6

26

36

30

29

73

70

64

64

56

33

24

35

13

19

26

23

80

78

76

52

81

38

29

29

29

20

ITEM LINE

DIODE, ISOLATION

DIODE, ISOLATION

DIODE, ISOLATION

DIODE, ISOLATION

DIODE, ISOLATION

SOLENOID, PUMP CONTROL

SOLENOID, 2 SPEED DRUM

SOLENOID, ENGINE SHUT DOWN

SOLENOID, BRAKE/SERVO

SOLENOID, 2 SPEED AXLE

SOLENOID, VIBRATION LOW FREQ.

SOLENOID, VIBRATION HIGH FREQ.

SWITCH, REAR WORK LIGHTS

SWITCH, FRONT WORK LIGHTS

SWITCH, HAZARD LIGHTS

SWITCH, DIRECTIONAL LIGHTS

SWITCH, LIGHTING

SWITCH, THUMB,VIBRATION ON/OFF

SWITCH, EMERGENCY OFF

SWITCH, DISABLE DRUM TWO SPEED

SWITCH, BACK UP ALARM

SWITCH, HYDRAULIC FILTER PSI.

SWITCH, HYDRAULIC BRAKE

SWITCH, AIR FILTER

SWITCH, FAN

SWITCH, REAR WIPER

SWITCH, FRONT WIPER

SWITCH, LIGHTING SYSTEM

SWITCH, CAB LIGHTING

SWITCH, TRAVEL SPEED

SWITCH, AUTO/MANUAL VIBRATION

SWITCH, VIBRATION LOW FREQ.

SWITCH, VIBRATION HIGH FREQ.

SWITCH, ENGINE OIL PRESSURE

DESCRIPTION

July 2004

3 - 47

SM96106 - SECTION THREE

ELECTRICAL

PLUG CONNECTORS PLUG #

DESCRIPTION

X1

OPERATOR STAND MAIN

X2

DRIVE LEVER

X3

ON-BOARD AUXILIARY SOCKET

X4

HYDRAULIC FILTER

X5

CAB

X6

CAB

X7

LIGHTING SYSTEM FRONT

X8

LIGHTING SYSTEM REAR

X9

WORK LIGHTING FRONT

X10

COMPACTION METER

X11

BACK UP ALARM

X12

CAB AIR CONDITIONING

X13

DRUM HIGH SPEED TRAVEL

X14

INSTRUMENT PANEL GAUGE CLUSTER

X15

TRAVEL SPEED CONTROL

X16

STEERING COLUMN

X17

STEERING COLUMN

X18

STEERING COLUMN

X19

FLASHER SWITCH

X20

WINDSHIELD WIPER, FRONT

X21

EMERGENCY OFF

3 - 48

July 2004

SM96106 - SECTION THREE

ELECTRICAL

INSTRUMENT HARNESS 7242/80435

July 2004

3 - 49

SM96106 - SECTION THREE

ELECTRICAL

INSTRUMENT HARNESS 7242/80435

3 - 50

July 2004

SM96106 - SECTION THREE

ELECTRICAL

WIRE CHART 7242/80435 INSTRUMENT PANEL HARNESS WIRE

COLOR

FROM

TO

1

red

plug X16/1

key switch S1/30

2

black/red

plug X16/15

key switch S1/15

3

black

plug X16/10

key switch S1/50a

4

black/red

plug X16/2

engine temp gauge P2/+

5

blue

plug X16/3

alternator indicator H1 plug X14/7

6

violet

plug X16/4

neutral indicator H2 plug X14/9

7

black/yellow

plug X16/5

brake indicator H3 plug X14/6

8

black/yellow

plug X16/6

horn switch S4/1

9

red/white

plug X16/8

engine temp indicator H5 plug X14/14

10

green/red

plug X16/9

hyd. filter indicator H9 plug X14/12

11

green

plug X16/11

eng. oil psi. indicator plug X14/8

12

black

plug X16/12

engine temp gauge P2/G

13

white

plug X16/13

fuel gauge P3/G

14

brown/red

plug X16/14

air filter indicator H10 plug X14/1

15

black/yellow

plug X17/1

brake switch S17/1

16

black/yellow

plug X17/2

brake switch S17/4

17

blue/yellow

plug X17/3

travel speed switch S8/13

18

black/gray

plug X17/4

light switch S11/1

19

blue/yellow

plug X17/5

flasher indicator H16 plug X14/5

20

gray

plug X17/6

front work light switch S28/1

21

gray/black

plug X17/7

front work light switch S28/5

22

gray/black

plug X17/8

front work light switch S28/6

23

gray/black

plug X17/9

rear work light switch S28A/5

24

gray/black

plug X17/10

rear work light switch S28A/6

25

black

plug X17/11

plug X3/+

26

gray

plug X17/12

rear work light switch S28A/1

27

blue/yellow

plug X15/1

travel speed switch S8/14

28

blue/yellow

plug X15/2

travel speed switch S8/24

29

blue/yellow

plug X15/3

travel speed switch S8/34

30

blue/yellow

plug X15/4

travel speed switch S8/44

31

red

plug X15/5

travel speed switch S8/43

32

black/red

engine temp gauge P2/+

fuel gauge P3/+

33

black/red

fuel gauge P3/+

cluster gauge plug X14/13

34

black/gray

light switch S11/5

engine temp gauge P2 light E1/+

35

gray

front work light switch S28/1

front work light switch S28/2

July 2004

3 - 51

SM96106 - SECTION THREE

ELECTRICAL

INSTRUMENT PANEL HARNESS WIRE

COLOR

FROM

TO

36

gray/black

front work light switch S28/6

front work light switch S28/9

37

gray

rear work light switch S28A/1

rear work light switch S28A/2

38

gray/black

rear work light switch S28A/6

rear work light switch S28A/9

39

black/gray

temp gauge P2 light E1/+

fuel gauge P3 light E2/+

40

black/gray

light switch S11/9

light switch S11/5

41

black/gray

plug X18/7

light switch S11/9

42

red

plug X18/1

hazard light switch S27/2

43

black/red

plug X18/2

hazard light switch S27/8

44

black

plug X18/3

hazard light switch S27/6

45

hb

plug X17/13

Sub-D

46

black/yellow

plug X18/4

hazard light switch S27/5

47

black/yellow

hazard light switch S27/5

plug X19/1

49

black/white

hazard light switch S27/1

plug X19/2

50

black/white

plug X18/5

hazard light switch S27/1

51

black/green

plug X18/6

hazard light switch S27/3

52

black/green

hazard light switch S27/3

plug X19/3

55

red

plug X18/8

light switch S25/8

56

red

57

red

light switch S25/1

light switch S25/6

58

red

plug X18/9

light switch S25/2

59

white/black

plug X18/10

light switch S25/3

60

black/red

plug X18/18

plug X10/1

61

gray

plug X18/11

auto vib switch S7B/5

62

gray

auto vib switch S7B/5

auto vib switch S7B/6

63

gray

plug X18/12

auto vib switch S7B/1

64

gray

auto vib switch S7B/1

auto vib switch S7B/9

65

gray

plug X18/17

auto vib switch S7B/8

66

gray

plug X18/13

high vib switch S7/1

67

gray

plug X18/16

low vib switch S7A/1

68

gray

high vib switch S7/1

low vib switch S7A/1

69

gray/white

high vib switch S7/5

low vib switch S7A/8

70

gray/red

high vib switch S7/8

low vib switch S7A/5

71

gray/white

plug X18/14

low vib switch S7A/6

72

gray/red

plug X18/15

high vib switch S7/6

73

red

travel speed switch S8/43

travel speed switch S8/33

74

red

travel speed switch S8/33

travel speed switch S8/23

75

red

travel speed switch S8/23

travel speed switch S8/13

76

black

key switch S1/2

fuse F20

3 - 52

July 2004

SM96106 - SECTION THREE

ELECTRICAL

INSTRUMENT PANEL HARNESS WIRE

COLOR

FROM

TO

77

black

fuse F20

clock P4/+

78

black/gray

fuel gauge P3 light E2/+

clock P4 light E3/+

79

gray

auto vib switch S7B/6

auto vib switch S7B/8

90

brown

horn switch S4/5

ground

91

brown

engine temp gauge P2/-

fuel gauge P3/-

92

brown

gauge cluster plug X14/5

ground

93

brown

fuel gauge P3/-

ground

94

brown

95

brown

rear work light switch S28A/10

hazard light switch S27/10

97

brown

plug X16/7

ground

98

brown

clock P4/-

ground

100

brown

plug X15/6

ground

101

brown

light switch S11/10

ground

102

brown

light switch S11/10

front work light switch S28/10

103

brown

front work light switch S28/10

rear work light switch S28A/10

104

brown

horn switch S4/5

auto vib switch S7B/10

105

brown

hazard light switch S27/10

plug X10/2

107

brown

plug X19/4

ground

July 2004

3 - 53

SM96106 - SECTION THREE

ELECTRICAL

RELAY/FUSE HARNESS 7242/80415

3 - 54

July 2004

July 2004

3 - 55

SM96106 - SECTION THREE

ELECTRICAL

WIRE CHART 7242/80415 RELAY AND FUSE HARNESS WIRE

COLOR

FROM

TO

1

red

panel terminal block

fuse F13/1

2

red

plug X16/1

fuse F13/1

3

black/red

plug X16/15

fuse F1/1

4

black/red

fuse F1/1

fuse F10/4

5

black/red

fuse F1/A

plug X16/2

6

black/red

fuse F1/A

relay K11/30

7

black/red

relay K11/30

plug X2/1

8

black/red

relay K11/30

horn H4/+

9

black

relay K1/30

plug X16/10

10

black

plug X1/1

relay K1/87

11

blue

fuse F2/2

plug X1/3

12

blue

fuse F2/B

plug X16/3

13

blue

fuse F2/B

relay K2/86

14

blue

relay K2/86

diode V3

15

violet

diode V3

relay K1/85

16

violet

relay K1/86

relay K3/86

17

violet

relay K1/86

relay K4/87

18

violet

relay K4/87

plug X16/4

19

violet

relay K3/86

relay K12/86

20

black/red

relay K4/30

relay K9/86

21

black/yellow

relay K9/86

plug X21/2

22

black/yellow

fuse F7/A

plug X21/1

23

black yellow

fuse F7/A

relay K5/86

24

black/red

fuse F3/C

plug X1/6

25

violet

relay K4/86

plug X2/2

26

brown/green

relay K11/86

plug X2/4

27

brown/white

relay K11/87

plug X1/4

28

black/yellow

relay K3/30

plug X1/17

29

black/yellow

relay K3/30

plug X16/5

30

black

relay K3/87a

diode V2

31

black

relay K5/85

relay K3/87a

32

black

relay K2/30

diode V2

33

black/yellow

relay K2/87

horn H4/-

34

black/yellow

relay K2/87

plug X16/6

35

black/yellow

relay K2/87

diode V1

36

red/white

plug X16/8

diode V1

37

red/white

plug X1/7

diode V1

38

green/red

plug X1/18

plug X16/9

3 - 56

July 2004

SM96106 - SECTION THREE

ELECTRICAL

RELAY AND FUSE HARNESS WIRE

COLOR

FROM

TO

39

green

plug X1/8

plug X16/11

40

black

plug X1/9

plug X16/12

41

white

plug X1/10

plug X16/13

42

brown/red

plug X1/5

plug X16/14

43

red

panel terminal block

fuse F19/1

44

black/red

fuse F7/1

relay K9/30

45

black/red

fuse F3/3

relay K9/87

46

black/yellow

plug X17/1

fuse F3/C

47

black/yellow

plug X17/2

relay K5/87a

48

black/yellow

relay K5/30

plug X1/16

49

gray

relay K7/87a

plug X18/11

50

gray

relay K7/87a

plug X2/5

51

gray

relay K12/87a

plug X18/12

52

gray

relay K12/30

plug X18/13

53

black/red

fuse F1/A

plug X1/2

54

hb

relay K11/87a

plug X17/13

55

black/red

fuse F7/1

fuse F9/1

56

gray/white

plug X18/14

plug X1/11

57

gray/red

plug X18/15

plug X1/12

58

gray

relay K6/87

plug X18/16

59

gray

relay K6/30

plug X18/17

60

gray

relay K6/15

plug X2/6

61

blue/yellow

fuse F5/E

plug X17/3

62

blue/yellow

switch S20/1

plug X15/1

63

blue/yellow

switch S20/2

plug X13/1

64

blue/yellow

plug X15/2

plug X1/13

65

black/gray

fuse F9/C

plug X17/4

66

black/gray

fuse F6/F

plug X6/6

67

black/gray

relay K10/86

plug X18/7

68

red

fuse F13/A

relay K10/30

69

red

relay K10/87

plug X18/8

70

red

fuse F15/3

plug X18/9

71

yellow/white

fuse F15/C

plug X7/1

72

yellow/white

fuse F15/C

plug X1/20

73

yellow

fuse F16/D

plug X7/2

74

yellow

fuse F16/D

plug X1/21

75

white/black

fuse F17/5

plug X18/10

76

yellow/black

fuse F17/E

plug X7/3

77

yellow/red

fuse F18/F

plug X7/4

78

red

fuse F14/B

plug X18/1

79

black/red

fuse F12/F

plug X18/2

July 2004

3 - 57

RELAY AND FUSE HARNESS WIRE

COLOR

FROM

TO

80

black

relay K13/49

plug X18/3

81

red

fuse F8/2

fuse F20/1

82

blue/yellow

relay K13/C

plug X17/5

83

black/yellow

relay K13/49a

plug X18/4

84

red

fuse F6/6

fuse F14/1

85

black/red

fuse F21/B

relay K15/30

86

black/red

fuse F7/1

fuse F9/3

87

black/red

relay K8/87

plug X24/2

88

black/red

fuse F20/A

relay K8/30

89

black/white

plug X18/5

plug X7/5

90

black/white

plug X18/5

plug X1/22

91

black/green

plug X18/6

plug X1/23

92

black/green

plug X18/6

plug X7/6

93

gray

fuse F11/E

plug X17/6

94

gray/black

plug X9/3

plug X17/7

95

gray/black

plug X17/8

plug X9/1

96

gray/black

plug X5/2

plug X9/1

97

gray/black

plug X1/19

plug X5/5

98

gray/black

plug X1/24

plug X5/6

99

gray/black

plug X9/3

plug X5/4

100

black/red

fuse F5/E

plug X18/18

101

black/red

fuse F8/B

plug X12/1

102

gray/black

fuse F10/D

plug X17/11

103

gray/black

fuse F10/D

plug X3A/+

104

blue/yellow

diodes V4 and V5

plug X15/3

105

red

plug X25/1

relay K8/86

106

red

fuse F19/2

relay K14/30

107

red

plug X5/1

relay K14/87

108

black/red

fuse F1/A

relay K14/86

109

gray

fuse F11/E

plug X17/12

110

red

fuse F8/2

relay K14/87 (SP1)

111

black/red

fuse F4/D

relay K7/30

112

gray

relay K7/86

plug X15/3

113

gray/black

plug X17/9

plug X5/5

114

gray/black

plug X17/10

plug X5/6

115

hb

plug X25/4

plug X12/2

116

hb

plug X12/4

plug X25/2

117

hb

plug X25/3

relay K15/85

118

red

plug X23

relay K15/87

119

brown

relay K16/87a

plug X24/1

120

brown

plug X16/7

ground

3 - 58

July 2004

SM96106 - SECTION THREE

ELECTRICAL

RELAY AND FUSE HARNESS WIRE

COLOR

FROM

TO

121

brown

plug X13/3

ground

122

brown

plug X1/31

ground

123

brown

plug X3A/-

ground

124

brown

plug X7/8

ground

125

brown

plug X9/2

ground

126

brown

plug X12/3

ground

127

hb

relay K16/86

plug X12/4

128

hb

relay K15/86

relay K16/86

129

brown

plug X2/3

ground

130

brown

plug X5/3

ground

131

brown

plug X24/3

ground

132

brown

relay K16/85

ground

134

brown

relay K16/85

relay K8/85

135

brown

relay K2/85

ground

136

brown

relay K2/85

relay K3/85

137

brown

relay K3/85

relay K4/85

138

brown

relay K4/85

relay K6/31

139

brown

relay K6/31

relay K7/85

140

brown

relay K8/85

relay K9/85

141

brown

relay K9/85

relay K10/85

142

brown

relay K10/85

relay K11/85

143

brown

relay K11/85

relay K12/85

144

brown

relay K12/85

relay K13/31

145

brown

relay K13/31

relay K14/85

146

brown

plug X7/7

plug X7/8

July 2004

3 - 59

SM96106 - SECTION THREE

ELECTRICAL

REAR HARNESS 7222/80510

3 - 60

July 2004

SM96106 - SECTION THREE

July 2004

ELECTRICAL

3 - 61

SM96106 - SECTION THREE

ELECTRICAL

WIRE CHART 7222/80510 REAR MACHINE HARNESS WIRE

COLOR

FROM

TO

1

red

alternator B+

starter terminal 30

2

black

engine start relay K0/86

plug X1/1

3

blue

alternator D+

plug X1/3

4

white

fuel sender R2

plug X1/10

5

gray

engine temp switch S5

plug X1/7

6

gray

fuel solenoid Y6

plug X1/6

7

green

engine oil pressure switch S6/4

plug X1/8

8

black

engine temp sender R1

plug X1/9

9

brown/white

backup alarm plug X11/1

plug X1/4

10

brown

backup alarm plug X11/2

plug X1/ground

11

blue/yellow

axle 2 speed solenoid Y3/1

plug X1/13

12

brown

axle 2 speed solenoid Y3/2

plug X1/ground

13

black/gray

lighting system plug X8/5

plug X1/19

14

black/red

alternator G2/L

plug X1/2

15

gray/white

high freq. vib. solenoid Y1/1

plug X1/11

16

brown

high freq. vib. solenoid Y1/2

plug X1/ground

17

gray/red

low freq. vib. solenoid Y2/1

plug X1/12

18

brown

low. freq. vib. solenoid Y2/2

plug X1/ground

19

brown

lighting system plug X8/8

plug X1/ground

20

black/gray

lighting system plug X8/7

plug X1/24

21

green

heater pump motor M7/1

plug X22/1

22

green

heater pump motor M7/2

plug X22/2

23

brown

engine oil pressure switch S6/3

plug X1/ground

24

black/yellow

pump control solenoid Y8/1

plug X1/16

25

black/green

lighting system plug X8/4

plug X1/23

26

black/white

lighting system plug X8/3

plug X1/22

27

yellow

lighting system plug X8/2

plug X1/21

28

white

lighting system plug X8/1

plug X1/20

29

brown

brake/servo solenoid Y5/2

plug X1/ground

30

black/yellow

brake/servo solenoid Y5/1

plug X1/16

31

brown

lighting system plug X8/6

plug X1/ground

33

red

engine start relay K0/30

starter motor M1/30

34

black

engine start relay K0/87

starter motor M1/50

35

white

fuel solenoid Y6

starter motor M1/F

36

brown

fuel solenoid Y6

plug X1/ground

37

brown

engine start relay K0/85

plug X1/ground

38

black/yellow

brake pressure switch S3

plug X1/17

39

brown

brake pressure switch S3

plug X1/ground

3 - 62

July 2004

SM96106 - SECTION THREE

ELECTRICAL

REAR MACHINE HARNESS WIRE

COLOR

FROM

TO

40

green/red

hyd. filter switch plug X4/1

plug X1/18

41

brown

hyd. filter switch plug X4/2

plug X1/ground

44

brown

pump control solenoid Y8/2

plug X1 ground

45

brown

fuel sender R2/ground

plug X1/ground

46

brown/red

air filter switch S16

plug X1/5

47

brown

air filter switch S16

plug X1/ground

49

brown

battery -

panel ground post

50

red

main fuse F0

panel terminal block

51

red

battery +

main fuse F0

July 2004

3 - 63

SM96106 - SECTION THREE

ELECTRICAL

3 - 64

July 2004

SECTION FOUR

HYDRAULIC

July 2004

4-1

HYDRAULIC COOLER LINES

4-2

July 2004

SM96106 - SECTION FOUR

July 2004

HYDRAULICS

4-3

4-4

July 2004

HYDRAULIC DRAIN LINES

July 2004

4-5

4-6

July 2004

HYDRAULIC CHARGE SYSTEM

July 2004

4-7

4-8

July 2004

SM96106 - SECTION FOUR

HYDRAULICS

HYDRAULIC TEST STATION

July 2004

4-9

SM96106 - SECTION FOUR

HYDRAULICS

HYDRAULIC TEST FITTINGS

A hydraulic pressure test station is located on the rear of the machine, inside the engine hood. All hydraulic pressures can be measured from this location by using either a VT8002 gauge set or a VT8004 adapter fitting.

4 - 10

July 2004

PROPULSION SYSTEM

July 2004

4 - 11

4 - 12

July 2004

PROPULSION SCHEMATIC

July 2004

4 - 13

SM96106 - SECTION FOUR

HYDRAULICS

The propulsion components for these units are manufactured by Rexroth. The propulsion pumps are Rexroth piston type A10VG. The drum and axle motors are variable displacement for two speed operation. The axle motors are Rexroth A10VM and the drum motors which also drive through a L&S planetary gearbox are Rexroth A10VE. The Rexroth pumps do not have a “built in” brake/servo valve as seen on Sundstrand systems. To obtain the needed pump control during braking operations the system is designed with an additional valve (VW2) controlled by solenoid Y8. When the brakes are applied with the Rexroth system, solenoid Y8 is de-energized shifting Valve (VW2) and connecting both sides of the pump’s servo control cylinder. With both sides connected the servo is spring returned to the neutral position destroking the pump. This feature eliminates driving through the brakes.

The pumps have pressure controls similar to all hydrostatic systems to control maximum system pressure and pump destroking. The pumps are also designed with bypass valves if the machine needs to be towed.

For towing the bypass screws are turned in until flush with the lock nut. After towing the bypass screws are returned to the full out position.

4 - 14

July 2004

SM96106 - SECTION FOUR

HYDRAULICS

PROPULSION SYSTEM DIAGNOSTICS INTERNAL LEAKAGE

All hydrostatic systems require charge pressure to function properly. This is because a hydrostatic system cannot operate at a negative pressure. The charge pump provides a positive pressure to the hydrostatic pump inlet. The VM106 uses the steering return oil to charge the hydrostatic systems. On these models, normal charge pressure is about 350 PSI and can be checked at port #1 on the test station located at the rear of the machine. Hydrostatic systems are designed to leak a small amount of oil from the pumps and motors for lubrication of parts and cooling, and in some instances, leakage is strictly due to operating clearances while in others a flushing valve may be designed into the system. A flushing valve is designed into the drum drive motor on the model VM106. The greater the system pressure the higher the leakage rate. Fresh charge oil will make up for normal system losses including the oil discharged through the flushing valve.

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

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

One method of isolating the component is to measure the motor case drain flows with the hydrostatic system at no load and maximum load at high engine idle. The component with high internal leakage will have a significantly higher case drain flow when the system is loaded. This method is not recommended with the Vibromax system because of the flushing valve in the drum drive motor.

July 2004

4 - 15

SM96106 - SECTION FOUR

HYDRAULICS

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.

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

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

4 - 16

July 2004

VIBRATION SYSTEM

July 2004

4 - 17

SM96106 - SECTION FOUR

HYDRAULICS

4 - 18

July 2004

SM96106 - SECTION FOUR

HYDRAULICS

VIBRATORY SYSTEM DIAGNOSTICS The smooth and padfoot drum versions are equipped with two overturning weights. The vibration shaft is bi-directionally rotated to obtain a vibration frequency of 1860 vibrations per minute (31 Hz) in one rotational direction and 2160 vibrations per minute (36 Hz) with the opposite direction of rotation.

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

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

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

July 2004

4 - 19

VIBRATION SYSTEM SCHEMATIC The vibration circuit consists of a pump providing oil to a vibration motor. The pump is a variable displacement axial piston design with bi-directional flow. The motor is a fixed displacement axial piston style with a built in flushing valve.

The model VM106 smooth and padfoot drums have two frequency ranges. When high frequency is desired, the solenoid controlled pump is stroked to provide oil to the vibration motor. This results in a vibration frequency of 2160 vibrations per minute, rotating the vibration shaft in a clockwise direction. When low frequency is desired, the solenoid controlled pump is stroked in the opposite direction, to provide oil to the vibration motor. This results in a vibration frequency of 1860 vibrations per minute, rotating the shaft in a counter clockwise direction. In either case the actual shaft RPM is controlled by the amount the pump is set to stroke.

Two pressure relief valves in the vibration pump, set at 350 bar (5075 PSI), protect the vibration circuit from excessive pressure in the same manner as in the propulsion circuit. The pump is also designed with a 320 bar pressure limiting valve. Start up pressure may be as high as 350 bar but will drop to 100 to 150 bar once the operating speed is obtained.

4 - 20

July 2004

STEERING SYSTEM

July 2004

4 - 21

4 - 22

July 2004

SM96106 - SECTION FOUR

HYDRAULICS

STEERING SYSTEM SCHEMATIC

July 2004

4 - 23

SM96106 - SECTION FOUR

HYDRAULICS

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

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

4 - 24

July 2004

PARKING BRAKE SYSTEM

July 2004

4 - 25

4 - 26

July 2004

PARKING BRAKE SCHEMATIC

July 2004

4 - 27

SM96106 - SECTION FOUR

HYDRAULICS

A spring applied, hydraulically released, multi-disc brake is built into the drum drive motor gearbox. The rear axle has a multi-disc brake at each axle shaft. Charge pressure is used to release the brake. Without charge pressure, the springs keep the brakes applied.

The brakes are controlled by a push button on the dash or by the emergency stop button on the drive lever console. When the brake switch on the dash is depressed, hydraulic pressure is removed from the brake valve VW1 and the brakes become applied through spring force.

At the same time power is removed from pump control valve VW2 which puts the pump into neutral stroke. When the emergency stop switch is activated, the brake solenoid is de-energized removing hydraulic pressure allowing the springs to apply the brakes, the vibration circuit is turned off, and the engine is stopped.

The pump control valve VW2 solenoid Y8 controls the pump by looping the two servo cylinder ports on the propulsion pump when the brake valve solenoid is de-energized. With the ports looped the pressure is equal on both sides of the servo cylinder allowing spring pressure to stroke the pump to neutral.

The pressure used to release the brakes is tapped off the charge system. Maximum brake release pressure should be charge pressure at 25 bar (355 psi).

4 - 28

July 2004

TOWING YOUR MACHINE

The brake release valve is located under the engine hood on the air cleaner bracket.

The brake release hand pump is located under the engine hood in the area of the fuel fill tube.

Propulsion Pump (the propulsion pump is the first pump coupled to the engine)

July 2004

4 - 29

SM96106 - SECTION FOUR

HYDRAULICS

TOWING PROCEDURE

1

The articulation lock should be in the drive position. Secure the machine with wheel and drum chocks prior to releasing the brakes.

2

Turn the brake release valve to the towing position. The brake release valve is located under the engine hood below the air cleaner. To turn the valve it is necessary to remove the valve handle and rotate the lock plate, then reinstall the handle and turn the valve to the tow position.

3

Turn the two propulsion pump bypass screws in until they are flush with the retaining nuts. This will disengage the hydrostatic drive system.

4

Disengage the parking brake by actuating the hand pump located near the fuel fill tube. This will build up enough hydraulic pressure to release the brake. With the key switch on you will be able to see the brake light in the instrument cluster turn off when the brakes have released.

5

Tow the machine.

NOTE: Do not tow the machine faster than 1.2 miles per hour (2km/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 to avoid drive system damage.

6

Return the brake release valve to the operate position after towing. Remove the valve handle and reposition the lock plate to lock the valve in the operate position. This is necessary to prevent unintended actuation which could cause brake drag.

7

Reset the two propulsion pump bypass valves by turning the bypass screws out until they stop.

Tighten the lock nuts.

4 - 30

July 2004

SM96106 - SECTION FOUR

HYDRAULICS

PUMP CONTROL VALVE

The pump control valve VW2 puts the propulsion pump in neutral whenever the brakes are applied. This is accomplished by looping both sides of the pumps servo together. With pressure equal on both sides of the servo cylinder the servo is spring loaded to return to neutral.

July 2004

4 - 31

SM96106 - SECTION FOUR

HYDRAULICS

4 - 32

July 2004

SM96106 - SECTION FOUR

HYDRAULICS

HYDRAULIC COMPONENTS

P1 P2 P3 P5 M1 M2 M3 M4 M5 M7 M12/13 LE F1 F2

July 2004

Propulsion pump (axial piston) Vibration pump (axial piston) Steering pump (gear) Brake release pump Axle drive motor (piston) Drum drive motor (piston) Vibration motor (piston) Steering cylinder Steering cylinder Drum gearbox brake Axle brakes Steering hand pump Hydraulic filter Hydraulic tank breather filter

B K VW2 VW4 VW6 VW7 DS1 DS2 VA1 VR2 S VSp1 VSp2

4 - 33

Hydraulic tank Heat exchanger Propulsion pump control valve Brake valve Axle high speed valve Drum high speed valve Hydraulic filter pressure switch Brake pressure switch Brake tow valve Heat exchanger bypass valve Hydraulic return oil manifold Drum drive flushing valve Vibration drive flushing valve

HYDRAULIC SCHEMATIC

SECTION FIVE

POWER TRAIN

July 2004

5-1

DRUM ASSEMBLY

5-2

July 2004

July 2004

5-3

5-4

July 2004

SM96106 - SECTION FIVE

July 2004

FINAL DRIVES

5-5

SM96106 - SECTION FIVE

FINAL DRIVES

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

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

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

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

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

6. Remove the front scraper bar and roll or lift the drum out of the front frame.

Smooth drum = 9372 lbs (4250 kg) Padfoot drum = 10848 lbs (4920 kg.)

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

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

NOTE: To complete alignment of the left side gearbox and plate might require hooking up the machine’s brake system and using the hand pump to release the brake on the gearbox. (see the brake section of this manual on releasing the brakes for towing) 3. Install the front scraper bar.

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

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

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

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

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

5-6

July 2004

RIGHT SIDE BEARING COVER

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

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

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

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

Smooth drum = 9372 lbs (4250 kg) Padfoot drum = 10848 lbs (4920 kg.)

4. Remove the vibration motor and motor coupling.

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

6. Remove capscrews (#5) from the bearing flange (#8) and use two jacking screws to remove

July 2004

5-7

SM96106 - SECTION FIVE

FINAL DRIVES

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

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

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

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

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

5-8

July 2004

SM96106 - SECTION FIVE

FINAL DRIVES

DRUM DRIVE BEARING ASSEMBLY 10. Add the proper amount of oil to the exciter housing. CLP DIN 51517/3 (Mobil Gear 629).

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

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

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

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

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

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

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

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

July 2004

5-9

SM96106 - SECTION FIVE

FINAL DRIVES

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

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

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

22. Reinstall the drum into the machine.

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

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

5 - 10

July 2004

SM96106 - SECTION FIVE

FINAL DRIVES

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

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

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

Oil Level 1

Remove the control plug (a).

2

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

3

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

4

Reinstall the plugs and check for leaks.

July 2004

5 - 11

SM96106 - SECTION FIVE

FINAL DRIVES

Gearbox oil change Change the oil after the first 250 hours of operation, then change oil after every 1000 operating hours or annually.

1

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

2

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

3

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

4

Reinstall the fill and control plugs and check for leaks.

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

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

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

The VM106 uses a GFT 17 T2/312 2 gearbox.

5 - 12

July 2004

SM96106 - SECTION FIVE

FINAL DRIVES

GFT 17 T2/312 2 GEARBOX

July 2004

5 - 13

SM96106 - SECTION FIVE

FINAL DRIVES

5 - 14

July 2004

SECTION SIX

PARKING BRAKE SYSTEM

July 2004

6-1

PARKING BRAKE SYSTEM

6-2

July 2004

July 2004

6-3

PARKING BRAKE SCHEMATIC

6-4

July 2004

SM96106 - SECTION SIX

PARKING BRAKE SYSTEM

A spring applied, hydraulically released, multi-disc brake is built into the drum drive motor gearbox. The rear axle has a multi-disc brake at the input shaft of the intermediate gear box.

Charge pressure is used to release the brake. Without charge pressure, the spring keeps the brake applied.

The brakes are controlled by a push button on the dash or by the emergency stop button on the drive lever console. When the brake switch on the dash is depressed, hydraulic pressure is removed from the brake circuit and the brakes become applied through spring force. The brake switch also removes electrical power to the pump control valve which puts the pump into neutral stroke. When the emergency stop switch is activated, the brake solenoid is deenergized removing hydraulic pressure allowing the springs to apply the brakes, the vibration circuit is turned off, and the drive system stops with the pump stroked to neutral. The fuel solenoid is de-energized and the engine stops.

The pressure used to release the brakes is tapped off the charge system. Maximum brake release pressure should be the 25 bar (355 psi) charge pressure limit.

The pump control valve VW2 solenoid Y8 controls the pump by looping the two servo cylinder ports on the propulsion pump when the brake and pump valve solenoids are de-energized.

With the ports looped the pressure is equal on both sides of the servo cylinder allowing spring pressure to stroke the pump to neutral.

July 2004

6-5

SM96106 - SECTION SIX

PARKING BRAKE SYSTEM

TOWING YOUR MACHINE

The brake release valve is located under the engine hood on the air cleaner bracket.

The brake release hand pump is located under the engine hood in the area of the fuel fill tube.

Propulsion Pump (the propulsion pump is the first pump coupled to the engine)

6-6

July 2004

SM96106 - SECTION SIX

PARKING BRAKE SYSTEM

TOWING PROCEDURE

1

The articulation lock should be in the drive position. Secure the machine with wheel and drum chocks prior to releasing the brakes.

2

Turn the brake release valve to the towing position. The brake release valve is located under the engine hood on the air cleaner bracket. To turn the valve it is necessary to remove the valve handle and rotate the lock plate, then reinstall the handle and turn the valve to the tow position.

3

Turn the two propulsion pump bypass screws in until they are flush with the retaining nuts. This will disengage the hydrostatic drive system.

4

Disengage the parking brake by actuating the hand pump located near the fuel fill tube. This will build up enough hydraulic pressure to release the brake. With the key switch on you will be able to see the brake light in the instrument cluster turn off when the brakes have released.

5

Tow the machine.

NOTE: Do not tow the machine faster than 1.2 miles per hour (2km/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 to avoid drive system damage.

6

Return the brake release valve to the operate position after towing. Remove the valve handle and reposition the lock plate to lock the valve in the operate position. This is necessary to prevent unintended actuation which could cause brake drag.

7

Reset the two propulsion pump bypass valves by turning the bypass screws out until they stop.

Tighten the lock nuts.

July 2004

6-7

SM96106 - SECTION SIX

PARKING BRAKE SYSTEM

6-8

July 2004

SECTION SEVEN

VIBRATION SYSTEM

July 2004

7-1

LIFTING DEVICE

7-2

July 2004

SM96106 - SECTION SEVEN

VIBRATION SYSTEM

DRUM EXCITER SHAFT

The following drawing shows a typical exciter shaft with overturning weights as would be found in the model VM106.

July 2004

7-3

SM96106 - SECTION SEVEN

VIBRATION SYSTEM

VIBRATION SYSTEM

7-4

July 2004

SM96106 - SECTION SEVEN

VIBRATION SYSTEM

VIBRATION SYSTEM SCHEMATIC The vibration circuit consists of a pump providing oil to a vibration motor. The pump is a variable displacement axial piston design with bi-directional flow. The motor is a fixed displacement axial piston style.

Both smooth and padfoot drums have two frequency ranges. When high frequency is desired, the solenoid controlled pump is stroked to provide oil to the vibration motor. This results in a vibration frequency of 2160 vibrations per minute, rotating the vibration shaft in a clockwise direction. When low frequency is desired, the solenoid controlled pump is stroked in the opposite direction, to provide oil to the vibration motor. This results in a vibration frequency of 1860 vibrations per minute, rotating the shaft in a counter clockwise direction. In either case the actual shaft RPM is controlled by the amount the pump is set to stroke.

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

Two pressure relief valves in the vibration pump, set at 350 bar (5075 PSI), protect the vibration circuit from excessive pressure in the same manner as in the propulsion circuit. The 605/ 606 pump is also designed with a 320 bar pressure limiting valve. Start up pressure may be as high as 350 bar but will drop to 100 to 150 bar once the operating speed is obtained.

July 2004

7-5

SM96106 - SECTION SEVEN

VIBRATION SYSTEM

VIBRATION FREQUENCY

This drawing illustrates a typical exciter shaft and the two overturning weights.

The shaft rotation can be faster in one direction and slower in the other direction. These two speeds create the two frequencies. The amplitude is changed by the use of overturning weights. In one direction the overturning weights are opposite the shaft counterweight and create a low amplitude vibration. When the shaft is rotated in the opposite direction the overturning weights are transferred to the same side as the shaft counterweight causing an increase in amplitude. This design allows for a LOW amplitude when the frequency is HIGH and a HIGH amplitude when the frequency is LOW. The models which offer only one frequency do not reverse the direction of shaft rotation nor do they use the overturning weight design.

7-6

July 2004

SM96106 - SECTION SEVEN

VIBRATION SYSTEM

VIBRATION AMPLITUDE

HIGH AMPLITUDE LOW FREQUENCY

AMPLITUDE

h1

TIME in seconds

h2

LOW AMPLITUDE HIGH FREQUENCY

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

JUMPING HEIGHT

July 2004

AMPLITUDE

7-7

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

VIBRATORY SYSTEM DIAGNOSTICS The model VM106 smooth and padfoot drum versions are equipped with two overturning weights. The vibration shaft is bi-directionally rotated to obtain a vibration frequency of 1860 vibrations per minute (31 Hz) in one rotational direction and 2160 vibrations per minute (36 Hz) with the opposite direction of rotation.

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

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

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

7-8

July 2004

DRUM DRAWING

July 2004

7-9

DRUM - LEFT SIDE

7 - 10

July 2004

DRUM - RIGHT SIDE

July 2004

7 - 11

SM96106 - SECTION SEVEN

VIBRATION SYSTEM

7 - 12

July 2004

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

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

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

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

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

6. Remove the front scraper bar and roll or lift the drum out of the front frame.

Smooth drum = 9372 lbs (4250 kg) Padfoot drum = 10848 lbs (4920 kg.)

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

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

NOTE: To complete alignment of the left side gearbox and plate might require hooking up the machine’s brake system and using the hand pump to release the brake on the gearbox. (see the brake section of this manual on releasing the brakes for towing) 3. Tighten and torque the motor bracket and buffer bracket bolts.

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

5. Start the machine engine and allow the hydraulic systems to develop charge pressure. Allow the engine to run at low idle for several minutes without loading to fill and flush the system.

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

July 2004

7 - 13

SM96106 - SECTION SEVEN

VIBRATION SYSTEM

RIGHT SIDE BEARING COVER

7 - 14

July 2004

SM96106 - SECTION SEVEN

VIBRATION SYSTEM

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

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

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

Smooth drum = 9372 lbs (4250 kg) Padfoot drum = 10848 lbs (4920 kg.)

4. Remove the vibration motor and motor coupling.

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

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

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

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

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

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

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

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

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

July 2004

7 - 15

SM96106 - SECTION SEVEN

VIBRATION SYSTEM

7 - 16

July 2004

SM96106 - SECTION SEVEN

VIBRATION SYSTEM

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

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

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

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

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

6. Add the proper amount of oil to the exciter housing. CLP DIN 51517/3 (Mobil Gear 629).

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

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

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

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

July 2004

7 - 17

SM96106 - SECTION SEVEN

VIBRATION SYSTEM

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

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

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

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

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

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

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

18. Reinstall the drum into the machine.

7 - 18

July 2004

SECTION EIGHT

STEERING SYSTEM

July 2004

8-1

SM96106 - SECTION EIGHT

STEERING SYSTEM

SPECIAL TOOLS

8-2

July 2004

SM96106 - SECTION EIGHT

STEERING SYSTEM

ARTICULATION JOINTS

July 2004

8-3

SM96106 - SECTION EIGHT

STEERING SYSTEM

8-4

July 2004

SM96106 - SECTION EIGHT

STEERING SYSTEM

JOINT DISASSEMBLY 1.

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

2.

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

3.

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

4.

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

5.

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

6.

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

7.

Remove the cylinder pivot pins (#7).

8.

Sling the front roller frame in preparation for removal. The roller frame weight is 10,827 lbs (4910 Kg).

9.

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

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

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

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

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

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

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

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

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

18. Remove the bearing cover (#3) by removing capscrews (#1).

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

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

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

July 2004

8-5

SM96106 - SECTION EIGHT

STEERING SYSTEM

8-6

July 2004

SM96106 - SECTION EIGHT

STEERING SYSTEM

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

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

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

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

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

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

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

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

July 2004

8-7

SM96106 - SECTION EIGHT

STEERING SYSTEM

8-8

July 2004

SM96106 - SECTION EIGHT

STEERING SYSTEM

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

1.

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

2.

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

3.

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

4.

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

5.

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

6.

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

7.

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

8.

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

9.

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

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

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

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

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

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

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

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

17. Move the roller frame into position in the steering link. Roller frame weight = 10,827 lbs (4910 Kg). Be careful not to damage the bearing parts.

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

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

July 2004

8-9

SM96106 - SECTION EIGHT

STEERING SYSTEM

8 - 10

July 2004

SM96106 - SECTION EIGHT

STEERING SYSTEM

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

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

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

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

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

24. Install the front drum.

25. Remove all jack stands.

July 2004

8 - 11

SM96106 - SECTION EIGHT

STEERING SYSTEM

8 - 12

July 2004

SECTION NINE

CHASSIS

July 2004

9-1

SM96106 - SECTION NINE

CHASSIS

9-2

July 2004

SECTION TEN

ATTACHMENTS

July 2004

10 - 1

SM96106 - SECTION TEN

ATTACHMENTS

ROLL OVER PROTECTION STRUCTURE (ROPS) Before operating the machine, be certain that the ROPS is fastened properly and has not been damaged in any way. The seat belt is an important part of the roll-over protection structure. The operator must wear the seat belt at all times when operating the machine.

ROPS Maintenance Perform the following checks every 1000 hours of operation: 1

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

2

Check the operators seat and the mounting parts for the seat belt. Be certain that all bolts are tight.

3

Keep the seat belts clean and dry. Clean with soap and water. Do not use bleach or dye.

Damage to the belt may occur. Replace the seat belt if signs of wear are noted.

ROPS Damage If the ROPS has been damaged due to the machine rolling over, by striking an obstruction during transport etc., the damaged parts must be REPLACED before the machine is placed in operation.

After such damage has occurred, check the following: 1

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

2

Inspect the mounting bolts on the ROPS. If necessary, retorque the bolts.

3

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

4

Do not attempt to weld or straighten the ROPS.

ROPS TIGHTENING TORQUES The ROPS shown here is standard equipment and comes without the ROPS cab option.

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

Use only the recommended parts. Never modify or repair ROPS parts! Always replace damaged parts with the proper new parts!

Grade 8.8 bolt torque 520 ft. lbs (710 Nm.)

10 - 2

July 2004

A accessory plug ...................................................................................................................... 3 - 37 alternator voltage checks .................................................................................................... 3 - 21 alternators explained ........................................................................................................... 3 - 19

B batteries explained ............................................................................................................... 3 - 17 battery diagnostics ............................................................................................................... 3 - 18 bolt torque chart .................................................................................................................... 1 - 10 brake release valve .....................................................................................................4 - 29, 6 - 6 brake switch .......................................................................................................................... 3 - 29

C California Proposition 65 ....................................................................................................... 1 - 2 charge system diagnostics ................................................................................................. 3 - 20 combination indicator ............................................................................................................. 3 - 7

D diesel fuel specification ....................................................................................................... 1 - 12 drive motor .............................................................................................................................. 1 - 3 drum assembly ....................................................................................................................... 5 - 2 drum drive bearings ............................................................................................................... 5 - 7 drum drive gearbox .............................................................................................................. 5 - 11 drum motor repairs ............................................................................................................... 5 - 10

E engine oil specification ........................................................................................................ 1 - 13 engine temperature gage ...................................................................................................... 3 - 7 engine warranty ...................................................................................................................... 2 - 2

F fluid specifications .................................................................................................................. 1 - 7 fuel level gage ......................................................................................................................... 3 - 7 fuses ......................................................................................................................................... 3 - 4

H hazard warning switch ........................................................................................................... 3 - 8 headlight, front switch ............................................................................................................ 3 - 8 headlight, rear switch ............................................................................................................. 3 - 8

1

high speed circuit ................................................................................................................. 3 - 31 horn push button .................................................................................................................... 3 - 8 hydraulic brake lines ............................................................................................................ 4 - 25 hydraulic cooler lines ............................................................................................................. 4 - 2 hydraulic drain lines ............................................................................................................... 4 - 5 hydraulic propulsion lines .................................................................................................... 4 - 11 hydraulic steering lines ........................................................................................................ 4 - 21 hydraulic system identification ........................................................................................... 4 - 33 hydraulic test fittings ............................................................................................................ 4 - 10 hydraulic test station ...................................................................................................4 - 9, 4 - 10 hydraulic vibration lines ....................................................................................................... 4 - 17 hydrostatic pump .................................................................................................................... 1 - 3

I instrument panel .......................................................................................................... 3 - 6, 3 - 27

K key switch ................................................................................................................................ 3 - 8

L light switch ............................................................................................................................... 3 - 8 lighting circuit ........................................................................................................................ 3 - 35

M machine components ............................................................................................................ 1 - 6 machine specifications .......................................................................................................... 1 - 8 maintenance schedule ........................................................................................................ 1 - 23

P park brake switch ................................................................................................................... 3 - 8 parking brake system .................................................................................................4 - 27, 6 - 4 propulsion system diagnostics ........................................................................................... 4 - 15

R relays ........................................................................................................................................ 3 - 5 relays, understanding .......................................................................................................... 3 - 14 relays, Vibromax types ........................................................................................................ 3 - 15 ROPS bolt torque ................................................................................................................. 10 - 2 ROPS damage ...................................................................................................................... 10 - 2

2

ROPS maintenance ............................................................................................................. 10 - 2

S safety, during maintenance ................................................................................................ 1 - 19 safety, electrical rules .......................................................................................................... 1 - 18 safety, general ...................................................................................................................... 1 - 14 safety, machine operation ................................................................................................... 1 - 16 safety, personal .................................................................................................................... 1 - 15 serial numbers ........................................................................................................................ 1 - 5 spark arrester ........................................................................................................................ 1 - 14 starter diagnostics ................................................................................................................ 3 - 23 starter motor test .................................................................................................................. 3 - 25 starters explained ................................................................................................................. 3 - 22 steering joints .......................................................................................................................... 8 - 3 steering pump ......................................................................................................................... 1 - 4

T torque data ............................................................................................................................ 1 - 10 towing your machine ...................................................................................................4 - 29, 6 - 6 travel speed selector .............................................................................................................. 3 - 8

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

V vibration amplitude explained ............................................................................................... 7 - 7 vibration circuit ..................................................................................................3 - 33, 4 - 20, 7 - 5 vibration frequency ................................................................................................................. 7 - 6 vibration pump ........................................................................................................................ 1 - 4 vibration shaft .......................................................................................................................... 7 - 3 vibration shaft bearings .............................................................................................. 5 - 7, 7 - 15 vibration switch, automatic .................................................................................................... 3 - 8 vibration switch, high ............................................................................................................. 3 - 8 vibration switch, low ............................................................................................................... 3 - 8

W work lights .............................................................................................................................. 3 - 37

3

4

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

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

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