JCB Vibromax W1500 Trench Roller Service Repair Manual SM35002 – PDF Download

W1500 TRENCH ROLLER

SERVICE MANUAL SM35002 starting at S/N JKC4200800 October 2003

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 IDENTIFICATION ................................................................ 1 - 2 MACHINE DESCRIPTION .................................................................... 1 - 3 MACHINE SERIAL NUMBERS ............................................................. 1 - 4 COMPONENT IDENTIFICATION ......................................................... 1 - 5 SAFETY ................................................................................................ 1 - 6 SPARK ARRESTER .................................................................. 1 - 6 PERSONAL ................................................................................ 1 - 6 MACHINE OPERATION............................................................. 1 - 7 MAINTENANCE ......................................................................... 1 - 9 GENERAL INFORMATION ................................................................. 1 - 10 STANDARD TORQUE DATA.............................................................. 1 - 11 METRIC/USA CONVERSIONS........................................................... 1 - 13 MACHINE SPECIFICATIONS............................................................. 1 - 14 FLUID CAPACITY ............................................................................... 1 - 14 ENGINE DATA ......................................................................... 1 - 15 OPERATING DATA.................................................................. 1 - 15 DIESEL FUEL SPECIFICATION......................................................... 1 - 16 ENGINE OIL SPECIFICATION ........................................................... 1 - 17 MACHINE CONTROLS, MANUAL...................................................... 1 - 18 MACHINE CONTROLS, WITH REMOTE ........................................... 1 - 20 REMOTE BATTERY CHARGER ........................................................ 1 - 22 STARTING THE ENGINE ................................................................... 1 - 23 PARKING BRAKE ............................................................................... 1 - 23 MACHINE OPERATION...................................................................... 1 - 24 PARKING ............................................................................................ 1 - 24 TURNING OFF THE ENGINE ............................................................. 1 - 24 MAINTENANCE SCHEDULE.............................................................. 1 - 25 As Required.............................................................................. 1 - 25 Every 10 hours or daily............................................................. 1 - 25 Every 100 hours of operation ................................................... 1 - 25 Every 150 hours ....................................................................... 1 - 25 Every 500 hours of operation ................................................... 1 - 26 Every 1000 hours of operation or annually ............................... 1 - 26

SECTION TWO ENGINE ENGINE OVERHAUL............................................................................ 2 - 2 KUBOTA ENGINE WARRANTY ........................................................... 2 - 2 Oil and filter change .............................................................................. 2 - 5 AIR FILTER SYSTEM ........................................................................... 2 - 6 Dust collector.............................................................................. 2 - 6 Replacing the filter elements ...................................................... 2 - 7

1

Cleaning the primary filter element............................................. 2 - 7 ENGINE COOLING SYSTEM ............................................................... 2 - 8 Inspection ................................................................................... 2 - 8 Check coolant level .................................................................... 2 - 8 Cleaning ..................................................................................... 2 - 9 Filling the cooling system ........................................................... 2 - 9 ENGINE FUEL SYSTEM..................................................................... 2 - 10 Venting the fuel system ............................................................ 2 - 11 Replacing the fuel filter ............................................................. 2 - 11

SECTION THREE ELECTRICAL CIRCUITS ELECTRICAL SYSTEM ........................................................................ 3 - 2 Battery ........................................................................................ 3 - 2 Battery fluid level ........................................................................ 3 - 2 Fuses and Relays....................................................................... 3 - 3 UNDERSTANDING ELECTRICAL SCHEMATICS .............................. 3 - 5 UNDERSTANDING RELAYS................................................................ 3 - 8 ENGINE ELECTRICAL CIRCUITS ..................................................... 3 - 11 UNDERSTANDING BATTERIES ........................................................ 3 - 12 UNDERSTANDING ALTERNATORS....................................... 3 - 14 STARTER SYSTEM DIAGNOSTICS .................................................. 3 - 18 MACHINE ELECTRICAL CIRCUITS................................................... 3 - 21 ELECTRICAL LAYOUT....................................................................... 3 - 22 ELECTRICAL SCHEMATICS.............................................................. 3 - 26 WIRE HARNESS 5731/82110............................................................. 3 - 30 WIRE CHART 5731/82110.................................................................. 3 - 31 WIRE HARNESS 5731/82505............................................................. 3 - 32 WIRE CHART 5731/82505.................................................................. 3 - 33 WIRE HARNESS 5731/82121............................................................. 3 - 34 WIRE CHART 5731/82121.................................................................. 3 - 35 WIRE HARNESS 5731/82105............................................................. 3 - 37 WIRE CHART 5731/82105.................................................................. 3 - 38 WIRE HARNESS 5731/82175............................................................. 3 - 40

SECTION FOUR HYDRAULIC SYSTEMS IDENTIFYING HYDRAULIC COMPONENTS ....................................... 4 - 2 SUCTION LINES................................................................................... 4 - 3 PROPULSION SYSTEM DRAWINGS .................................................. 4 - 4 PROPULSION SYSTEM FUNCTION......................................... 4 - 7 VIBRATION SYSTEM DRAWINGS ...................................................... 4 - 8 HIGH SPEED TRAVEL DRAWINGS .................................................. 4 - 10 VIBRATION SYSTEM FUNCTION........................................... 4 - 13

2

HIGH SPEED TRAVEL FUNCTION ......................................... 4 - 13 BRAKE SYSTEM DRAWINGS............................................................ 4 - 14 DRAIN LINE DRAWINGS ................................................................... 4 - 16 HYDRAULIC TEST PORTS ................................................................ 4 - 18 HYDRAULIC SCHEMATIC ................................................................. 4 - 20

SECTION FIVE CHASSIS LOWER FRAME.................................................................................... 5 - 2 UPPER FRAME .................................................................................... 5 - 3 VIBRATION SHAFT .............................................................................. 5 - 4 VIBRATION SYSTEM ........................................................................... 5 - 6 Oil change .................................................................................. 5 - 6

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SECTION ONE

GENERAL INFORMATION

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SM35002 - SECTION ONE

GENERAL INFORMATION

MACHINE IDENTIFICATION

The terms “left”, “right”, “front”, “rear” used in this manual refer to the sides of the machine as seen from the operator’s position at the controls.

1) 2) 3) 4)

Front Rear Right Left

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SM35002 - SECTION ONE

GENERAL INFORMATION

MACHINE DESCRIPTION

The hydrostatic drive system is designed for two ground speeds. The hydrostatic drive system consists of two gear pumps, left and right drum drive motors with hydraulic brakes, and the system control valves. The left side drums are independently operated from the right side. This feature allows the machine to be steered.

The Vibromax Model W1500 Trench Roller is a 1.5 metric ton tandem drum roller with hydrostatic propulsion and a hydrostatic vibratory system. The machine is available with either a 24.8 inch (630 mm) or a 33.5 inch (850 mm) drum.

All models include pressure test ports for quick and easy diagnostics of the various hydraulic systems.

The machines can be ordered with manual or remote controls.

Power is provided by a 61 cubic inch (1000 cc) Kubota, three cylinder water cooled diesel engine, Model D1005/-BB-EC, rated at 22.5 hp (16.8 kW) at 3000 RPM.

Remote controlled units are operated either manually or by using the radio controlled remote system. Remote controlled machines are equipped with an auxiliary battery for the remote controller and a battery charger to insure a fully charged battery is always available.

The W1500 trench roller operates at a vibration frequency of 1860 vibrations per minute (31 Hz). The machine is designed with a single vibratory shaft mounted between the front and rear drum.

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SM35002 - SECTION ONE

GENERAL INFORMATION

MACHINE SERIAL NUMBERS Enter the machine and components serial numbers on the following lines. When ordering spare parts or requesting information on the machine, have these numbers available for your dealer.

Make a copy of these numbers and keep them in a safe place. If the machine is stolen, these numbers should be made available to the investigating authorities. #1

Model and Serial Number

#2

Engine ID. Numbers

#3

Remote Control Serial Number (numbers located on control under remote battery)

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SM35002 - SECTION ONE

GENERAL INFORMATION

COMPONENT IDENTIFICATION

1

drum

13

drum motor

2

drum scraper

14

drum motor with brake

3

diesel engine

15

lifting point

4

radiator

16

safety strap

5

vibratory shaft

17

engine oil dipstick

6

fuel tank

18

engine hood

7

hydraulic oil tank

19

rear hood

8

battery

20

control panel cover

9

instrument panel

21

remote transmitter (option)

10

emergency stop bar

22

remote receiver (option)

11

platform buffers

23

antenna for receiver (option)

12

air filter

24

remote actuation switch (option)

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SM35002 - SECTION ONE

GENERAL INFORMATION

SAFETY 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.

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.

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 machine can cause accidents and injury.

Keep the machine clear at all times.

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

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

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

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SM35002 - SECTION ONE

GENERAL INFORMATION

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 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 control panel to the right side of the main gauge cluster. 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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SM35002 - SECTION ONE

GENERAL INFORMATION

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.

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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SM35002 - 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 injury or death. Use nonflammable cleaning solvents for cleaning purposes.

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

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

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

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

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

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

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

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SM35002 - SECTION ONE

GENERAL INFORMATION

GENERAL INFORMATION

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

INSPECTION Check all parts as they are disassembled. Replace all parts that have wear or damage.

Small scoring or grooves can be removed with a hone or crocus cloth. Complete visual inspection for indications of wear and pitting. Replacement of bad parts will prevent early failure.

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

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

GEARS Check and replace all gears that have wear or damage.

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

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SM35002 - SECTION ONE

GENERAL INFORMATION

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

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

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

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

Threads should be lubricated with engine oil or grease. Loctite products also act as a lubricant.

STANDARD TORQUE SPECIFICATIONS +/- 10% GRADE 8.8

GRADE 10.9

GRADE 12.9

SIZE

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

5mm

4

5.5

5.5

7.5

6.6

9

6mm

6.6

9

9.2

12.5

11

15

8mm

16.5

22.5

23

31.5

26.5

36

10mm

32

44

45

62

55

75

12mm

57

77.5

81

110

95

130

14mm

88

120

125

170

155

210

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SM35002 - SECTION ONE

GENERAL INFORMATION

STANDARD TORQUE SPECIFICATIONS +/- 10% GRADE 8.8

GRADE 10.9

GRADE 12.9

SIZE

ft-lbs

Nm

ft-lbs

Nm

ft-lbs

Nm

16mm

140

190

195

265

236

320

18mm

192

260

269

365

320

435

20mm

273

370

383

520

457

620

22mm

369

500

516

700

619

840

24mm

471

640

665

900

796

1080

27mm

702

950

996

1350

1195

1620

30mm

955

1300

1328

1800

1593

2160

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

NEWTONS/METER 20 35 45 60

POUNDS/FOOT 14.5 26 33.2 44

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

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

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

SM35002 - SECTION ONE

GENERAL INFORMATION

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

NEWTONS/METER 28 55 90 145 230

POUNDS/FOOT 21 41 67 107 170

METRIC/USA CONVERSIONS

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

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

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

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

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

cubic centimeters (cm3)

cubic inches (in3)

cm3 x .061 = in3

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

SM35002 - SECTION ONE

GENERAL INFORMATION

MACHINE SPECIFICATIONS

in.

33.5 65 73.6 19.7 24.8 50.4 6.7 24.8/33.5

a b c d e h k w

mm 850 1650 1870 500 630 1280 170 630/850

FLUID CAPACITY MACHINE PART

CAPACITY USA (metric)

SPECIFICATIONS

Fuel tank

5.8 gal (22 l)

see diesel fuel

Engine crankcase

4.2 qts(4 l)

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

Hydraulic system

18.5 gal (70 l)

cold weather hot weather

(see oil chart) (see oil chart)

HLP 46 DIN 51524 HLP 68 DIN 51524

Mobil DTE 25,26 Shell Tellus OL 46,68 Amoco Rykon HD 46,68 Texaco Rando HD 46,68 Vibration system

0.53 qts (0.5 l)

15W-40

Battery

as required

Distilled water

Engine coolant

1.32 gal (5 l)

50% ethylene glycol and 50% water SAE J814c

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SM35002 - SECTION ONE

GENERAL INFORMATION

ENGINE DATA Make / Model / Type Cooling Displacement - cu.in. (cc) HP, SAE net (kW) Operating speed (rpm) Air Cleaner Fuel filter Fuel Consumption - gal/hr. (liter/hr.)

Fuel capacity - gal (liter) Electrical system Battery, amp hours/alternator amps Injector pump timing Injector pop off pressure Valve clearance (intake \ exhaust)

D1005-BB-EC Kubota, 3 cylinder, diesel Water 61 (1000) 16.8 (22.5) 3000 Dry replaceable element Inline and Spin-on 0.7 (2.57) 5.8 (22) 12 volt 66/40 17 to 19 degrees 1991 to 2133 PSI .018 \ .022 mm (cold)

OPERATING DATA Operating Weight , max - lbs (kg) Operating axle load, front - lbs (kg) Operating axle load, rear - lbs (kg) Frequency - vpm (Hz) Nominal Amplitude - in. (mm) Centrifugal force - lbs (kN) Compaction depth - inch (cm) Propulsion - front and rear Travel speed - mph (km/hr) Theoretical gradeability, with vibration - % Theoretical gradeability, without vibration - %

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3307 (1500) 1654 (750) 1654 (750) 3300(55) .020 (0.51) 18878 (84) 31.5 (80) Infinitely variable hydrostatic 1st gear 0 - 0.7 (0-1.1) 2nd gear 0 - 1.6 (0-2.5) 45 55

SM35002 - SECTION ONE

GENERAL INFORMATION

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

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

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

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

MINIMUM REQUIREMENTS FOR #2 DIESEL FUEL: Maximum cloud point Maximum pour point

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

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

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SM35002 - SECTION ONE

GENERAL INFORMATION

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

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

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

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SM35002 - SECTION ONE

GENERAL INFORMATION

MACHINE CONTROLS, MANUAL

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SM35002 - SECTION ONE

GENERAL INFORMATION

S1

Key Switch - The switch has four positions; OFF, ON, PREHEAT and START. Place the switch in the ON position to turn on the electrical system and indicator lamps H2 and H3 will illuminate. Place the switch in preheat position and hold until the preheat indicator light (item H1) goes out. Place the switch in the start position. When engine starts, release the switch and it will return to the ON position. To stop the engine, place the switch in the OFF position. Remove the key

H1

Preheat Indicator Lamp - illuminates for a predetermined length of time when the key switch is placed in the preheat position.

H2

Alternator Indicator Lamp - illuminates to indicate charge circuit problems.

H3

Engine Oil Pressure Indicator Lamp - illuminates if engine oil pressure is low.

H4

Engine Temperature Indicator Lamp - illuminates if engine overheats.

Bh

Hourmeter - tracks operating time when the key switch is in the “ON� position.

S6

Travel Speed Switch - turns on high speed travel when pressed in. Vibratory operation is not available in high.

S7

Vibration Control Switch - has three positions: Forward/Off/Reverse. Push switch forward for vibratory operation in forward travel and push switch to the rear for vibratory operation in reverse travel.

FR

Travel control - right side manual operation.

FL

Travel control - left side manual operation

MD

Engine throttle control.

AS

Emergency stop lever.

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SM35002 - SECTION ONE

GENERAL INFORMATION

MACHINE CONTROLS, WITH REMOTE

S5

Remote actuation switch - turns on remote control circuits. If this switch is in the REMOTE mode the machine can not be started with the key switch.

FR

Travel control - right side manual operation.

FL

Travel control - left side manual operation

MD

Engine throttle control.

AS

Emergency stop lever.

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SM35002 - SECTION ONE

GENERAL INFORMATION

The machine can be controlled by radio remote when equipped with the remote option. Activate the remote with the S5 switch on the machine’s instrument panel. It must be noted that the radio transmitters and receivers are matched units and are not interchangeable.

S1

Master Switch - toggle the switch forward to activate the remote and back to shut off the remote. If this switch is left on the battery will discharge. Stand a minimum of 10 feet (2.5 meters) away from the machine when starting remote operations to allow the remote to lock onto a good operating frequency.

L1

Indicator Light - transmitter check

L2

Indicator Light - remote battery, illuminates when battery has a low charge.

T1

Engine Start Switch - after activating the remote with switch S1, toggle switch T1 back then full forward to start the engine. Switch S3 must be OFF.

T2/T3 Frequency Control Switch - This feature allows changing the frequency in cases of radio interference. Press and hold switch T2 on the left side of the remote control unit then press and release switch T3 on the right side of the unit to change the radio frequency in 25 mhz steps up to about a 434 mhz range.

FLF

Left Travel Control - push the lever forward or reverse to control left side travel.

FRF

Right Travel Control - push the lever forward or reverse to control right side travel.

S2

Travel Speed Switch - turns on high speed travel when toggled left. Vibratory operation is not available in high.

S3

Vibration Control Switch - has three positions: Forward/Off/Reverse. Push switch forward for vibratory operation in forward travel and push switch to the rear for vibratory operation in reverse travel. Vibration will not work if travel switch S2 is in high range.

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SM35002 - SECTION ONE

GENERAL INFORMATION

REMOTE BATTERY CHARGER

The battery charger is attached to the remote receiver and is located under the engine hood to the left side of the machine. It is wired direct through fuse F3 to the machine’s chassis battery. The auxiliary remote battery will charge whenever the chassis battery is charged and a fuse is in the fuse holder.

NOTE: When the machine is to be placed into long term storage it is best to remove the auxiliary battery from the charger.

External 115 volt chargers are available under part# 5731/80211.

External 12 volt chargers are available under part # 5731/80212.

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SM35002 - SECTION ONE

GENERAL INFORMATION

STARTING THE ENGINE 1

Complete the daily walk-around inspection.

2

Check around the machine to ensure that the area is clear.

3

Make sure the drive control is in the neutral position.

4

Move the engine throttle to the IDLE position.

5

Make sure the vibrator system switches are OFF.

6

The parking brake is engaged whenever the engine is off.

7

Turn the key switch to the ON position but do not start.

8

The following warning lamps on the instrument panel should be on: (replace or repair as needed) a) Alternator warning lamp. b) Engine oil pressure warning lamp. c) You should also be able to hear the electric fuel pump working.

9

Turn the key switch in the preheat position. Hold the key until the preheat light on the panel goes out.

NOTE: Do not use starting fluid. Use of starting fluid can damage the engine. The engine pre-heater is designed as a cold weather starting aid.

10 Turn the key to the START position. Release the key as soon as the engine begins to run. If the engine starts to run then stops, do not actuate the starter again until the engine is at a full stand still.

11 Do not operate the starter motor for more than 30 seconds at one time. After 30 seconds of cranking, the starter motor should be allowed to cool for 3 minutes before re-engaging.

12 Do not run the engine at low engine speeds for long periods of time. Prolonged low engine speeds tend to cause more acids and deposits in the engine oil.

13 Prior to starting the engine with the remote control it is best to start and run the engine in the manual mode to allow it to warm up to operating temperature.

14 To start the engine with the remote controller toggle the radio switch on the instrument panel to radio mode. Stand approximately 20 feet away from the machine and restart the machine with the remote. Doing this allows the remote unit to lock onto a good radio signal.

PARKING BRAKE The parking brake is a hydraulically released spring applied unit built into the rear drum motors which disengages when the machine starts.

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SM35002 - SECTION ONE

GENERAL INFORMATION

MACHINE OPERATION Read the Safety section of this manual and become aware of all operational dangers. Conduct the proper walk-around inspection and make sure your machine is in good working condition.

1

Move the engine throttle control to the high idle position. ENGINE HIGH IDLE IS THE NORMAL OPERATING SPEED.

2

The Parking Brake will release when the engine is started. The machine position will be held by the propulsion system’s closed center control valves.

3

Slowly move the drive control lever forward or backward for desired travel direction and speed. To gain more control in the lower speed ranges make sure the two speed button is OFF. Return the drive control to the neutral position to stop travel.

4

Make the first and last passes on fresh fill materials with the vibratory system OFF.

5

Switch the vibratory system ON only when the machine is in a traveling mode. There are two vibratory modes. One for forward travel, and one for reverse travel. Vibratory operations should be adjusted to travel direction. The machine does not allow vibratory operation in high speed travel mode.

6

Do not operate the vibratory system when the machine is stationary. Switch off the vibratory system before coming to a complete stop.

7

Do not continue vibratory compaction after the optimum compaction has been achieved. Continued vibratory operation has an adverse affect on compaction results.

8

To ensure the best results, test the compaction job using a recognized measuring method.

PARKING 1

Drive the machine to level ground. If the machine must be parked on a slope, point the front of the machine uphill and ensure that the machine is blocked with a fixed object.

2

Place the drive control in the neutral position.

3

Shut off the engine to set the spring actuated parking brake.

TURNING OFF THE ENGINE NOTE: Before turning off the engine make sure the machine is properly parked.

1

Reduce the engine speed to low idle and let the engine idle for approximately 2 minutes.

2

If the machine is being run with the remote controller push in the red button on the controller to turn off the engine.

NOTE: It is necessary that the key switch on the machine’s instrument panel be shut off.

3

Turn off the key switch on the instrument panel. If the key switch is not turned off the hourmeter will continue to run.

4

Remove the key from the switch.

1 - 24

SM35002 - 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 ................................................................... daily Check the air cleaner intake stack ..................................................

Fill the fuel tank ...............................................................................

Service the air cleaner ....................................................................

Service the hydraulic oil filter ..........................................................

Check the engine coolant level .......................................................

Every 10 hours or daily Clean or replace decals that cannot be read ........................... daily Perform “Walk-around Inspection� ..................................................

Check the condition of the engine belt............................................

Check engine oil level .....................................................................

Check hydraulic oil reservoir level ...................................................

Every 100 hours of operation Check the rubber buffers on the drum platform ..............................

Clean or replace air filter element. ..................................................

Every 150 hours Change the engine oil .....................................................................

Replace the engine oil filter.............................................................

Inspect the engine cooling system ..................................................

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SM35002 - SECTION ONE

GENERAL INFORMATION

Every 500 hours of operation Check the engine belt tension.........................................................

Check the battery and its fluid level ................................................

Check the drum vibration frequency ...............................................

Replace engine fuel filters ..............................................................

Clean the fuel tank and filler screen ...............................................

Adjust engine valve clearance ....... see Vibromax or Kubota dealer Every 1000 hours of operation or annually Replace the engine fuel filters and clean fuel tank .........................

Change oil in front and rear vibration system .................................

Change the hydraulic oil & filter ......................................................

Clean the hydraulic oil reservoir & fill screen ..................................

Change engine coolant and clean cooler system ...........................

Adjust engine valve clearance ....... see Vibromax or Kubota dealer

If the machine is left unattended during maintenance work attach a “DO NOT OPERATE� tag.

1 - 26

SECTION TWO ENGINE

2-1

SM35002 - SECTION TWO

ENGINE

ENGINE OVERHAUL The Kubota Model D1005/-BB-EC engine in your machine is warranted by Kubota. If you experience problems with your engine during the warranty period, contact your local Kubota repair center. This manual is not intended to supersede engine overhaul material provided

by Kubota. Beyond the warranty period, it is highly recommended that you obtain the Kubota Engine Workshop Manual 97897-01643 and Parts Manual 97898-54870 from your local dealer for proper overhaul instructions. The Workshop Manual is available as Vibromax #V40273 and the Parts Manual is available as Vibromax #V40274.

KUBOTA ENGINE WARRANTY LIMITED WARRANTY ON INDUSTRIAL ENGINES AND REPLACEMENT PARTS EFFECTIVE MAY 1, 1988.

Our Warranty To You We warrant to you, the original purchaser, that all parts (except those referred to below) of your new Kubota industrial engine, and replacement part purchased from an Authorized Kubota Industrial Engine or OEM Distributor in the United States will be free from defects in materials or workmanship during the following periods (Refer to (Kubota) Service Policy Book for further details): 1. Industrial engines excluding any oil field engine or application for 2 years or 2000 hours whichever occurs first.

1a. For 3 years or 3000 hours, excluding oil field engines or applications, a Major Component Warranty (M.C.W.) parts only, is offered. See Service Policy Book for details of coverage for M.C.W. 2. Replacement parts for 90 days.

What We Will Do We will, at our option, repair or replace any part covered by this warranty which becomes defective, malfunctions or otherwise fails to conform with this warranty under normal use and service during the term of the warranty at no charge for parts or labor (Parts only for M.C.W.)

What You Must Do To Obtain Warranty Service In order to obtain warranty repairs, you must deliver the product, together with proof of purchase, to an Authorized Kubota Industrial Engine Distributor or Dealer at your expense. The names and addresses of such Authorized Kubota Industrial Engine Distributors are listed in telephone directories or may be obtained by writing or telephoning us (Kubota).

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SM35002 - SECTION TWO

ENGINE

What This Warranty Does Not Cover This warranty does not cover: (See (Kubota)Service Policy Book for further details.)

1. Defects, malfunctions or failures resulting from accidents, abuse, misuse, modifications, alteration, improper servicing or lack of performance of required maintenance service.

2. Normal maintenance services or replacement of maintenance items such as light bulbs, pre-heater plugs, indicator and resistant coils, filter elements, lubricants, oils, spark plugs, coolant or belts.

3. Installation of replacement parts, unless originally installed by an Authorized Kubota Industrial Engine Distributor.

3a. Non-genuine Kubota parts.

4. Nihon CAV injection pumps are covered by separate warranties issued by their manufacturer or distributor.

5. Any engines damaged by use of ether, or any starting aid, or greater than a 50/ 50% solution of antifreeze-water.

6. Injection nozzle wear or any engine damage caused by injection nozzle wear or sticking.

7. Damage caused by water entering the engine due to any cause.

8. Used products.

9. Any damage caused by overheating that is not a direct result of a defect in materials or workmanship.

10. Any engine not application approved.

THIS IS THE ONLY EXPRESS WARRANTY ON OUR PRODUCTS We neither assume nor authorize anyone to assume for us any other express warranty. The Distributor/Dealer has no authority to make any representation or promise on behalf of Kubota Tractor Corporation or to modify the terms or limitations of this warranty in any way.

2-3

SM35002 - SECTION TWO

ENGINE

KUBOTA LIMITATIONS ON RESPONSIBILITY WITH RESPECT TO PRODUCTS PURCHASED AND USED FOR PERSONAL, FAMILY OR HOUSEHOLD USE. Our responsibility is to repair or replace defective parts as stated above; we will not be responsible for any other expenses, losses or inconvenience which you may sustain as a result of the purchase, use, malfunction or defective condition of our products. ANY IMPLIED WARRANTIES INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL BE LIMITED IN DURATION TO THE PERIOD SET FORTH ABOVE. Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights, and you may have other rights which vary from state to state.

KUBOTA LIMITATIONS ON RESPONSIBILITY WITH RESPECT TO PRODUCTS USED FOR RENTAL OR FOR COMMERCIAL, INDUSTRIAL OR AGRICULTURAL PURPOSES. This warranty is in lieu of all other warranties, express or implied, and of any other obligations or liability on our part. WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXCLUDED. Our responsibility for any and all losses and damages resulting from any cause whatsoever, including our negligence, alleged damaged or defective goods, whether such defects are discoverable or latent, shall be limited to the repair or replacement of defective parts as stated above. IN NO EVENT WILL WE BE LIABLE FOR LOSS OF USE, LOSS OF PROFITS, LOSS OF OR DAMAGE TO CROPS, INCONVENIENCE, COMMERCIAL LOSS, OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES WHATSOEVER.

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SM35002 - SECTION TWO

ENGINE

Oil and filter change In a new engine or in a newly rebuilt engine, change the oil and filter after 20 hours of operation. After the run-in period, change the oil and filter every 150 hours of operation.

Change the oil while the engine is warm. Contamination is removed from the lubricating system more effectively when the engine is warm.

1. Open the hood for the engine compartment.

2. Remove the filler cap from the top of the valve cover (#1).

3. Place a collecting container with a capacity of 8 quarts at the right side of the front drum.

4. The drain hose for the engine oil (#4 on previous page) is attached to the right front frame to a drain fitting.

5. Remove the plug from the drain fitting and let the oil drain into a suitable container.

6. Remove and replace the engine “spin on� oil filter cartridge (#3) located on the left side of the machine.

2-5

SM35002 - SECTION TWO

ENGINE

7. Replace drain fitting plug.

8. Fill the engine crank case with the proper amount of the recommended engine oil.

9. Start the engine and check for leakage at the spin on filter and the drain fitting.

10. Shut off engine and wait five minutes to recheck oil level.

AIR FILTER SYSTEM

Dust collector Remove the dust accumulated in the filter housing every 10 hours of operation or daily.

1. Open the hood to the engine compartment. The air filter is located on the rear of the engine.

2. Open the rear compartment hood.

3. Empty the collected dust by pinching open the dust valve (#4) located on the filter housing on the left side of the machine.

4. Close both compartment hoods.

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SM35002 - SECTION TWO

ENGINE

Replacing the filter elements 1. Open the hood to the engine compartment.

2. Open the rear compartment hood.

3. Clean or replace the filter element.

NOTE: Replace the filter element after it has been cleaned 3 times. The date of manufacture is printed on the end of the primary element. Do not reinstall an element that is more than two years old.

4. After a filter has been cleaned and dried, use a light to check for holes, wear, deformed end walls etc. Replace the filter element if damage is noted.

5. Install the filter element and cover.

Cleaning the primary filter element

Washing: Washing is the best method of cleaning the filter element. Use D-1400 cleaning agent from Donaldson. The element must be dry before it is reinstalled. Do not use compressed air for drying the element.

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SM35002 - SECTION TWO

ENGINE

NOTE: Read the instructions for cleaning on the D-1400 package.

Compressed air: Compressed air used for cleaning the primary element must not be at a pressure greater than 30 PSI. Apply the compressed air to the inside of the element at a distance at least one inch from the element. Cleaning with compressed air will not remove carbon or soot.

ENGINE COOLING SYSTEM Inspection Inspect the engine cooling system every 150 hours of operation. Be certain the engine is not running and the system has cooled before cleaning or inspecting.

Check coolant level

Periodically check the fluid level in the coolant system at the fill cap.

Never remove the cap from the coolant system fill tube when the coolant is hot. When removing the cap, turn cap slowly and with caution. Boiling coolant, under pressure may escape as cap is removed.

Check the coolant level and if necessary add coolant. Change the coolant every 24 months or each

2-8

SM35002 - SECTION TWO

ENGINE

2000 hours of operation.

NOTE: Measure the antifreeze concentration. For year round protection of the engine down to -34 F, use a 50% ethylene glycol 50% water coolant mixture.

1. Inspect the hoses and hose clamps for damage. Replace all damaged parts.

2. Inspect the radiator for leaks, damage or sediment entrapment in the radiator fins. Clean or repair as necessary.

Cleaning 1. Drain the cooling system. A 10 quart container will be required to collect the antifreeze 2. Clean the cooling system by flushing with water. If sediment, rust, scale or oil is present, use a strong radiator cleaning agent, following the instructions on the container.

Filling the cooling system 1. Fill the system with a solution of 50% water and 50% ethylene glycol based antifreeze.

2. When the cooling system is being filled, air must be vented from the system. This may require the starting and stopping of the engine several times during the filling procedure to purge the system of air.

3. After the system has been filled, run the engine for several minutes while observing the system for leaks. Stop the engine and allow the system time to cool down, then check coolant level.

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SM35002 - SECTION TWO

ENGINE

ENGINE FUEL SYSTEM

Fill the fuel tank at the end of each working day in order to reduce water condensation in the tank.

The use of diesel fuel additives also reduces condensation.

Drain water and sediment from the tank after each 100 hours of operation. Clean the fuel tank and filler screen every 500 hours of operation.

1. Unlock and remove the filler cap (#1).

NOTE: The fuel tank capacity is 5.8 gallons (22 liter).

2. Remove the drain plug from the bottom of the fuel tank and drain the fuel into a suitable container.

3. Flush the fuel tank with diesel fuel.

4. Reinstall the drain plug.

5. Remove the filter screen, clean it in diesel fuel and reinstall it.

6. Fill the fuel tank with fuel and observe the drain plug for signs of leakage 7. Replace the filler cap. Close and lock the fuel door .

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SM35002 - SECTION TWO

ENGINE

Fuel is easily ignited. It can burn or explode. When filling the tank with fuel or when servicing the fuel system shut off the machine and keep away from open flame, welding, or burning cigarettes.

Venting the fuel system It will be necessary to vent the air from the fuel system when; 1. The fuel system components have been removed and reinstalled.

2. The fuel tank is run empty.

Replacing the fuel filter Replace the fuel filters every 500 hours of operation or after six months or when a loss of engine power is noted.

1

To replace the fuel filter, open the cover to the engine compartment and locate the inline and spin-on filters.

2. Replace both filters.

3. Open the bleed screw at the injector pump and turn ON the electric fuel pump by turning ON the key switch.

2 - 11

SM35002 - SECTION TWO

ENGINE

2 - 12

SECTION THREE

ELECTRICAL CIRCUITS

3-1

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

ELECTRICAL SYSTEM Before servicing parts in the electrical system, disconnect the ground cable (-) from the battery.

Disconnect the cable at the alternator if the engine must be run with the battery cables disconnected.

Disconnect the cable at the alternator if an electric welder is to be used on the machine.

Do not clean the alternator with a steam jet or with cleaning solutions.

Battery Clean the battery every 500 hours of operation.

1. Open the rear hood for battery access.

2. Clean the surface of the battery to prevent discharging of the battery.

NOTE: Dirt, moisture and corrosion on the battery will result in battery discharging. Clean the battery with a battery cleaning product, following the instruction on the cleaning container.

Battery fluid level Check the fluid level in the battery every 500 hours of operation. If the fluid level is low, add distilled water to each cell until the level reaches the bottom edge of the fill port.

Batteries produce explosive gases. Keep sparks, flames and burning cigarettes away from the battery. Protect your eyes when working in the area of the battery.

When removing a battery, always disconnect the ground cable (-) first. When installing a battery, always connect the positive cable (+) first.

Battery acid causes severe burns. Batteries contain sulfuric acid.

Avoid contact with the skin, eyes and clothing. EXTERNAL: Flush with water. INTERNAL: Drink large amounts of water or milk and call a doctor. EYES: Flush with water for 15 minutes, then call a doctor.

3-2

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

Fuses and Relays

The machine’s fuses and relays are located on a small panel which can be accessed from the rear hood.

Fuse F1 Fuse F2 Fuse F3

Engine and instrumentation functions Vibration and propulsion functions Remote control battery charger

Relay D1 Relay K1 Relay K2 Relay K3 Relay K4 Relay K5 Relay K6

Engine preheat Engine monitoring Engine remote start Left forward travel Left reverse travel Right forward travel Right reverse travel

3-3

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

UNDERSTANDING ELECTRICAL SCHEMATICS

3-4

SM35002 - SECTION THREE

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

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

UNDERSTANDING ELECTRICAL SCHEMATICS European electrical schematics differ somewhat from USA machinery schematics in that the European schematic is drawn in the form of a ladder diagram. Ladder diagrams are easy to draw and simple to interpret. In the USA they are often used in industrial applications.

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

Ladder diagrams 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) for example, the K4 relay control circuit on line 11 shows terminal 86 as power to the control coil while 85 is control coil ground. The number shown in parentheses below the line number (in this case, 8) indicates there is more to the relay which is shown on line 8. Line 8 shows the working circuit of the K4 relay and illustrates terminal 30 as power to the relay contacts and 87, power from the relay contacts. Shown between the contacts, in parentheses, is the number (11). This indicates there is more to the relay which is shown on line 11.

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

3-5

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

UNDERSTANDING ELECTRICAL SCHEMATICS

3-6

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

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

Delay relay

E

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

F

Fuse

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

Other items which may help you understand the diagram:

G

Battery, alternator

All drawings are shown without power

H

Indicator (panel indicator light, horn, alarm)

All components are shown in the OFF position

K

Relay

All relay contact #87 are normally open contacts

M

Motor

P

Gauges (hour meter, temperature gauge, etc.)

R

Resistor

S

Switch

V

Diode

X

Connector

Y

Solenoid control valve

All relay contact #87a are normally closed contacts Relay terminal #30 is power to the contacts (when possible) Relay terminal #87 or #87a is power from the contacts (when possible) Power to the control coil of the relay is always terminal #86 Ground for the relay control coil is always terminal #85

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

3-7

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW sprinkler pump, emergency flashers, etc.

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

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

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

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.

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

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

3-8

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

VIBROMAX RELAYS

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

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

The numbering system mentioned earlier will apply.

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

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.

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.

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

Relay terminal #85 is always ground.

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SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

ENGINE ELECTRICAL CIRCUITS

3 - 10

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

ENGINE ELECTRICAL CIRCUITS The W1500 trench roller can be started by using the key switch S1 [line 4] if toggle switch S5 [lines 6 and 19] is in the manual run mode. With toggle switch S5 in the radio position the engine must be started from the remote control unit.

When the key switch S1 is turned to the ON position, power from the battery [switch terminal 30] is provided to switch S1 terminal 15 and on to fuses #F1 and #F2. The hour meter which is connected to fuse F1 will start running, the alternator indicator light H2 will illuminate, and the oil pressure light H3 will illuminate. Power is also available to energize K1 coil [line 11] and switch the K1 relay contacts [line 6]. Holding current for the fuel solenoid will then be provided through terminal 17 of switch S1. By turning the key switch to the start position a current path is established to the start terminal 50a on the key switch and the starter motor.

Turning the key switch to the start position will allow the starter to crank the engine.

Engagement power for the fuel solenoid is provided from the 50a terminal of switch S1.

A key switch position between ON and START provides power to the engine preheater circuit [line 1]. Placing the switch in this position provides current to the preheaters [line 1], to the indicator light H1 on the dash and to the heater timer [line 2].

Preheat time is approximately 5 seconds.

When the machine has been started and the alternator [line 5] is producing output current, the alternator indicator light on the dash will extinguish because the alternator regulator, previously at ground, now provides 12 volts which is equal to the current to the indicator light through fuse F1. With 12 volts on both sides of the indicator light, there is no current flow and the light will not glow.

As engine oil pressure rises pressure switch S3 [line 9] will open and remove the ground contact for oil indicator light H3 which will extinguish the light.

When oil pressure switch S3 opened it also removed the ground connection for the K1 relay control coil [line 11] switching the relay contacts [line 6]. Current to fuel solenoid Y1 and brake solenoid Y2 are now provided through fuse F1 and switch S5 [line 6] as long as safety switch S2 [line 6] remains closed.

When using the remote control unit to the start the machine the process is very much the same. The differences being that power for starting is provided through the K2 relay [line 3] which is controlled by the remote control unit [line 18]. Switch S5 would be toggled to the radio position with power to control the fuel and brake solenoids now being provided by the remote controller.

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SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

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.

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.

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.

Batteries produce explosive gases.

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

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SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

BATTERY DIAGNOSTICS STATE OF CHARGE

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.

VOLTAGE READING

SPECIFIC GRAVITY

% CHARGE

12.66

1.260

100

12.60

1.250

91

12.54

1.240

83

12.48

1.230

75

12.42

1.220

62*

12.36

1.210

58

12.30

1.200

0**

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

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.

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

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

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

Wait 30 seconds for the battery to recover.

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SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

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

Measure the voltage just before removing the load.

magnetic field (C). The power to the rotor is

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

Temp C

21

16

10

4

-1

Temp F

70

60

50

40

30

Min-voltage

9.6

9.5

9.4

9.3

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

UNDERSTANDING ALTERNATORS 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.

The rotor (A), when supplied with a small amount of current, will produce an electro-

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.

The output of the stator will be an AC sine wave and must be rectified to obtain a DC output. The rectification of the stator output is accomplished by a pair of diodes for each stator winding. The DC output is then controlled by the regulator/brush assembly on the alternator. The actual battery charging output of the alternator flows out of the B+ terminal to the positive terminal of the starter solenoid.

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SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

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.

VOLTAGE CHECKS AT ALTERNATOR

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.

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.

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

ENGINE

LAMP

OFF

OFF

OFF

ON

OFF

ON

ON

ON

OFF

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

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

Normal warning lamp operation.

KEY

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.

Abnormal warning lamp operation and probable cause: Key (Off); Engine (OFF); Lamp (ON) short in wiring to excite rotor Key (ON); Engine (OFF); Lamp (OFF) bad alternator diode Key (ON); Engine (ON); Lamp (ON) regulator problem

3 - 15

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW connectors.

SYSTEM LEAKAGE Remove the ground cable from the battery.

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

The lamp should not illuminate with the key in the OFF position. If the lamp does illuminate, this is an indication of a power source going to ground. This will eventually discharge the battery.

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

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

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

3 - 16

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW by not allowing full battery power to the starter motor until the drive pinion is fully engaged into the flywheel.

13.6 and 14.4 volts for a 12volt system.

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

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

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

Preengaged starters are used on most engines. They provide a positive engagement

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)

3 - 17

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

causing engagement of the drive pinion into the flywheel.

Turn the key switch to the start position.

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.

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.

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.

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

3 - 18

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW 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.

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

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.

If the reading was 0.5 or less, the ground is

3 - 19

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

3 - 20

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

MACHINE ELECTRICAL CIRCUITS The W1500 has two variations: Manual Controls or Radio Remote Controls. The machines with the remote option can be operated with manual switches on the machine or by the remote control box.

Radio switch S5 and propulsion switches S8, S9, S10, S11 and relays K3, K4, K5, K6 are not present on the manual machine. Additionally control solenoids Y3, Y4, Y5, Y6 will not be on the manual machine since all propulsion functions except the two speed feature are manually controlled by lever operated directional control valves. The K2 relay is also not needed on the manually operated machine. Vibration and two speed functions and controls are the same on both models.

Switch S5 [line 19] receives power from fuse F2. When radio switch S5 is toggled to radio all machine functions are controlled by the remote control unit. When radio switch S5 is in the manual mode, travel control switches S8, S9, S10, and S11 receive power directly from fuse F2 as do the contacts of relays K3, K4, K5, and K6. The travel control switches are connected to the control coils of the travel relays. Actuation of a travel switch energizes the relay coil for that circuit and closes the relay contacts.

Closing of the relay contacts energizes the travel solenoid.

Two speed switch S6 [line 16] receives power from fuse F2 through radio switch S5 [line 19]. When the button of the two speed switch is depressed current is supplied to two speed solenoid Y7 [line 23] through switch terminal S1. At the same time power for the vibration control circuit is interrupted at terminal S of two speed switch S6. The vibration function is not available for use during the high speed travel mode.

The vibration switch S7 [line 17] receives power from fuse F2 through radio switch S5 and the normally closed contacts of high speed switch S6. Vibration switch S7 is a three position toggle switch with the center position being vibration “off�. This is accomplished when no power is available to solenoid Y10 [line 26]. Without power to solenoid Y10 all vibration pump flow is routed back to tank through the open center control valve.

When vibration switch S7 is toggled to reverse travel vibration or forward travel vibration, solenoid Y10 is energized to direct vibration pump flow to the vibration control valve. Depending on the position of vibration switch S7 power is also supplied to reverse travel vibration solenoid Y8 [line 24] or forward travel vibration solenoid Y9 [line 25}.

Note the diodes placed across each solenoid to prevent coil collapse spikes from damaging the remote control unit.

3 - 21

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

ELECTRICAL LAYOUT

3 - 22

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

3 - 23

3 - 24

3 - 25

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

ELECTRICAL SCHEMATICS ITEM D1 F1 F2 F3 G1 G2 H1 H2 H3 H4 K1 K2 K3 K4 K5 K6 M1 M2 RH 1-3 S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y10 V1 - V2 V3 - V4

LINE 2 7 19 21 4 5 2 5 9 10 6 & 11 3 & 18 12 13 14 15 3 8 1 4 6 9 10 6 & 19 16 17 12 13 14 15 6 7 19 20 21 22 23 24 25 26 11 17

DESCRIPTION Engine Preheat Control Timer Fuse F1, Engine and Instrumentation Fuse F2, Machine Controls and Functions Fuse F3, Remote Battery Charger Battery Alternator Engine Preheat Indicator Light Alternator Warning Light Engine Oil Pressure Warning Light Engine Coolant Temperature Warning Light Engine Shut Down Relay Remote Start Relay Left Forward Travel Relay Left Reverse Travel Relay Right Forward Travel Relay Right Reverse Travel Relay Engine Starter Electric Fuel Pump Engine Preheat Plugs Main Key Switch Safety Bar Switch Engine Oil Pressure Switch Engine Coolant Temperature Switch Manual or Radio Remote Switch High Speed Travel Switch Vibration Control Switch Left Side Forward Travel Switch Left Side Reverse Travel Switch Right Side Forward Travel Switch Right Side Reverse Travel Switch Engine Fuel Solenoid Brake Solenoid Left Side Forward Travel Solenoid Left Side Reverse Travel Solenoid Right Side Forward Travel Solenoid Right Side Reverse Travel Solenoid High Speed Travel Solenoid Reverse Travel Vibration Solenoid Forward Travel Vibration Solenoid Vibration On/Off Solenoid Diodes Diodes

3 - 26

3 - 27

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

3 - 29

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

WIRE HARNESS 5731/82110 ENGINE AND MACHINE HARNESS

3 - 30

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

WIRE CHART 5731/82110 ENGINE AND MACHINE HARNESS No.

Color

From

To

battery G1/+

plug X1 port 4

engine starter M1/50a

plug X1 port 3

engine preheater RH 1-3

plug X1 port 1

fuel solenoid Y1/z

plug X1 port 3

engine starter M1/30

alternator G2/30

alternator G2/1G

plug X1 port 6

1

red

3

black

9

black/blue

10

white

11

red

12

black/red

16

blue

alternator G2/L

plug X1 port 5

17

black

fuel solenoid Y1/h

safety bar switch S2

18

green

engine oil pressure switch S3

plug X1 port 8

19

brown

brake solenoid Y2/2

plug X1 port 2

20

black/yellow

brake solenoid Y2/1

safety bar switch S2

21

black

safety bar switch S2

plug X1 port 7

23

red/white

engine temperature switch S4

plug X1 port 9

30

brown

ground terminal

plug X1 port 2

31

black/red

electric fuel pump M2

plug X1 port 10

37

blue/yellow

high speed solenoid Y7/1

plug X2A port 1

38

brown

high speed solenoid Y7/2

ground terminal

40

gray/red

reverse travel vibration solenoid Y8/1

plug X2A port 2

41

brown

reverse travel vibration solenoid Y8/2

ground terminal

43

gray/white

forward travel vibration solenoid Y9/1

plug X2A port 3

44

brown

forward travel vibration solenoid Y9/2

ground terminal

48

gray

vibration on/off solenoid Y10/1

plug X2A port 4

49

brown

vibration on/off solenoid Y10/2

ground terminal

3 - 31

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

WIRE HARNESS 5731/82505 REMOTE RECEIVER HARNESS

3 - 32

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

WIRE CHART 5731/82505 REMOTE RECEIVER HARNESS No.

Color

From

To

32

red

plug X2 port 4

plug X3 port 1

33

brown

plug X3 port 2

plug X3 ground terminal

34

black

plug X2 port 5

plug X3 port 13

35

black

plug X2 port 7

plug X3 port 12

36

blue/yellow

plug X2 port 1

plug X3 port 14

39

gray/red

plug X2 port 2

plug X3 port 10

42

gray/white

plug X2 port 3

plug X3 port 11

48

gray

plug X2 port 6

plug X3 port 16

50

blue/yellow

plug X4 port 1

plug X3 port 6

51

blue/yellow

left forward travel solenoid Y3/1

plug X4 port 1

52

brown

left forward travel solenoid Y3/2

plug X3 ground terminal

53

blue/yellow

plug X4 port 2

plug X3 port 7

54

blue/yellow

left reverse travel solenoid Y4/1

plug X4 port 2

55

brown

left reverse travel solenoid Y4/2

plug X3 ground terminal

56

blue/yellow

plug X4 port 3

plug X3 port 8

57

blue/yellow

right forward travel solenoid Y5/1

plug X4 port 3

58

brown

right forward travel solenoid Y5/2

plug X3 ground terminal

59

blue/yellow

plug X4 port 4

plug X3 port 9

60

blue/yellow

right reverse travel solenoid Y6/1

plug X4 port 4

61

brown

right reverse travel solenoid Y6/2

plug X3 ground terminal

62

black/red

plug X2 port 8

plug X4 port 5

63

black/red

plug X5

plug X3 port 3

70

brown

machine ground

plug X3 ground terminal

3 - 33

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

WIRE HARNESS 5731/82121 INSTRUMENT PANEL HARNESS (without remote)

3 - 34

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

WIRE CHART 5731/82121 INSTRUMENT PANEL HARNESS (without remote) No.

Color

From

To

1

red

key switch S1 terminal 30

plug X1 port 4

2

red

key switch S1 terminal 15

fuse F1/1

3

black

key switch S1 terminal 50

plug X1 port 3

4

black/blue

key switch S1 terminal 50

engine preheat control D1 port 5

5

black/blue

key switch S1 terminal 17

preheat indicator light H1/+

6

black/blue

preheat indicator light H1/-

engine preheat control D1 port 6

7

black/blue

key switch S1 terminal 17

engine preheat control D1 port 4

8

black/blue

key switch S1 terminal 17

key switch S1 terminal 19

9

black/blue

key switch S1 terminal 19

plug X1 port 1

11

black/red

relay K1/87

engine preheat control D1 port 4

12

black/red

fuse F1/2

plug X1 port 6

13

black/red

fuse F1/2

relay K1/86

14

black/red

fuse F1/2

alternator indicator H2/+

15

black/red

alternator indicator H2/+

oil pressure indicator H3/+

16

black/red

alternator indicator H2/-

plug X1 port 5

18

green

oil pressure indicator H3/-

plug X1 port 8

19

black/red

oil pressure indicator H3/+

temperature indicator H4/+

20

black/red

relay K1/87a

relay K1/86

21

black/red

relay K1/30

plug X1 port 7

22

green

oil pressure indicator H3/-

diode V2

23

red/white

temperature indicator H4/-

plug X1 port 9

24

red/white

temperature indicator H4/-

diode V1

25

green/red

relay K1/85

diode V2

26

green/red

relay K1/85

diode V1

28

black/red

temperature indicator H4/+

hourmeter P1/+

29

brown

hourmeter P1/-

ground

30

brown

engine preheat control D1 port 3

plug X1 port 2

31

black/red

fuse F1/2

plug X1 port 10

35

black/red

fuse F2/2

high speed travel switch S6/+

36

black/red

high speed travel switch S6/+

plug X2 port 8

37

black/red

radio remote switch S5 terminal 6

plug X2 port 4

38

blue/yellow

high speed travel switch S6/S1

plug X2 port 1

39

black/red

high speed travel switch S6/S

vibration switch S7 port 2

40

gray/red

vibration switch S7 port 1

plug X2 port 2

41

gray/white

vibration switch S7 port 3

plug X2 port 3

46

blue/yellow

plug X2 port 1

plug X2A port 1

3 - 35

SM35002 - SECTION THREE No.

Color

ELECTRICAL OVERVIEW

From

To

47

black

plug X2 port 2

plug X2A port 2

48

gray/white

plug X2 port 3

plug X2A port 3

49

gray

diode V3

plug X2 port 6

50

gray

plug X2 port 6

plug X2 port 4

51

gray/red

vibration switch S7 port 1

diode V4

52

gray

diode V3

diode V4

53

gray/white

vibration switch S7 port 3

diode V3

3 - 36

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

WIRE HARNESS 5731/82105 INSTRUMENT PANEL HARNESS (with remote)

3 - 37

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

WIRE CHART 5731/82105 INSTRUMENT PANEL HARNESS (with remote) No.

Color

From

To

1

red

key switch S1 terminal 30

plug X1 port 4

2

red

key switch S1 terminal 15

fuse F1/1

3

black

key switch S1 terminal 50

plug X1 port 3

4

black/blue

key switch S1 terminal 50

engine preheat control D1 port 5

5

black/blue

key switch S1 terminal 17

preheat indicator light H1/+

6

black/blue

preheat indicator light H1/-

engine preheat control D1 port 6

7

black/blue

key switch S1 terminal 17

engine preheat control D1 port 4

8

black/blue

key switch S1 terminal 17

key switch S1 terminal 19

9

black/blue

key switch S1 terminal 19

plug X1 port 1

11

black/red

relay K1/87

engine preheat control D1 port 4

12

black/red

fuse F1/2

plug X1 port 6

13

black/red

fuse F1/2

relay K1/86

14

black/red

fuse F1/2

hourmeter P1/+

15

black/red

hourmeter P1/+

alternator indicator H2/+

16

blue

alternator indicator H2/-

plug X1 port 5

18

green

oil pressure indicator H3/-

plug X1 port 8

19

black/red

alternator indicator H2/+

temperature indicator H4/+

20

black/red

radio remote switch S5 terminal 1

relay K1/86

21

black/red

relay K1/30

plug X1 port 7

22

green

oil pressure indicator H3/-

diode V2

23

red/white

temperature indicator H4/-

plug X1 port 9

24

red/white

temperature indicator H4/-

diode V1

25

green/red

relay K1/85

diode V2

26

green/red

relay K1/85

diode V1

27

black/red

fuse F3/2

remote charger plug X5

28

black/red

temperature indicator H4/+

oil pressure indicator H3/+

29

brown

relay K2/85

relay K3/85

30

brown

engine preheat control D1 port 3

plug X1 port 2

31

black/red

fuse F1/2

plug X1 port 10

32

black/red

radio remote switch S5 terminal 2

relay K1/87a

33

back/red

radio remote switch S5 terminal 3

plug X2 port 5

34

black/red

fuse F2/2

radio remote switch S5 terminal 5

35

black/red

radio remote switch S5 terminal 4

high speed travel switch S6/+

36

black/red

high speed travel switch S6/+

plug X2 port 8

37

black/red

radio remote switch S5 terminal 6

plug X2 port 4

38

blue/yellow

high speed travel switch S6/S1

plug X2 port 1

3 - 38

SM35002 - SECTION THREE No.

Color

ELECTRICAL OVERVIEW

From

To

39

black/red

high speed travel switch S6/S

vibration switch S7 port 2

40

gray/red

vibration switch S7 port 1

plug X2 port 2

41

gray/white

vibration switch S7 port 3

plug X2 port 3

42

black

relay K2/86

plug X2 port 7

43

brown

engine preheat control D1 port 3

relay K2/85

44

black

key switch S1 terminal 30

relay K2/30

45

black

relay K2/87

key switch S1 terminal 50

46

blue/yellow

plug X2 port 1

plug X2A port 1

47

black

plug X2 port 2

plug X2A port 2

48

gray/white

plug X2 port 3

plug X2A port 3

49

gray

diode V3

plug X2 port 6

50

gray

plug X2 port 6

plug X2A port 4

51

gray/red

vibration switch S7 port 1

diode V4

52

gray

diode V3

diode V4

53

gray/white

vibration switch S7 port 3

diode V3

54

black

key switch S1 terminal 30

fuse F3/1

55

brown

relay K3/85

relay K4/85

56

brown

relay K4/85

relay K5/85

57

brown

relay K5/85

relay K6/85

58

brown

relay K6/85

hourmeter P1/-

3 - 39

SM35002 - SECTION THREE

ELECTRICAL OVERVIEW

WIRE HARNESS 5731/82175 JOYSTICK HARNESS (machine with remote)

No.

Color

From

To

60

blue/yellow

relay K3/87

plug X4 port 1

61

blue/yellow

relay K4/87

plug X4 port 2

62

blue/yellow

relay K5/87

plug X4 port 3

63

blue/yellow

relay K6/87

plug X4 port 4

64

black/red

joystick switch S8/1

plug X4 port 5

65

black/red

joystick switch S10/1

plug X4 port 5

66

blue/yellow

joystick switch S8/3

relay K3/86

67

blue/yellow

joystick switch S9/3

relay K4/86

68

blue/yellow

joystick switch S10/3

relay K5/86

69

blue/yellow

joystick switch S11/3

relay K6/86

70

black/red

joystick switch S9/1

relay K3/30

71

black/red

relay K3/30

relay K4/30

72

black/red

relay K4/30

relay K5/30

73

black/red

relay K5/30

relay K6/30

74

black/red

joystick switch S8/1

joystick switch S9/1

75

black/red

joystick switch S10/1

joystick switch S11/1

3 - 40

SECTION FOUR

HYDRAULIC SYSTEMS

4-1

SM35002 - SECTION FOUR

HYDRAULIC OVERVIEW

IDENTIFYING HYDRAULIC COMPONENTS

P1 P2 P3 M1 M2 M3 M4 VB1 VB5 VW2 VW3 VW4 VW5 VD1 VD2 VD3 VD4 VR2 VR3 VR4 F1 F2 B NS

vibration pump right side propulsion pump left side propulsion pump right rear drive motor with brake right front drive motor left rear drive motor with brake left front drive motor vibration and high speed controls brake control valve left side propulsion control valve right side propulsion control valve high speed travel control valve vibration control valve vibration system relief valve left side propulsion system relief valve right side propulsion system relief valve propulsion dynamic braking valve left side high speed propulsion check valve right side high speed propulsion check valve propulsion shuttle valve suction strainer return flow filter hydraulic reservoir hydraulic oil level gauge

4-2

SM35002 - SECTION FOUR

HYDRAULIC OVERVIEW

SUCTION LINES

4-3

SM35002 - SECTION FOUR

HYDRAULIC OVERVIEW

PROPULSION SYSTEM DRAWINGS

4-4

4-5

SM35002 - SECTION FOUR

HYDRAULIC OVERVIEW

PROPULSION SYSTEM FUNCTION The propulsion, or drive system, consists of two engine driven gear pumps, one for each side of the machine, and four Poclain piston motors. Each side of the machine is controlled by a spool valve. The spool valves are normally manually operated but can be replaced for solenoid operation when ordered with the factory installed remote control option.

Activating the propulsion control valves VW2 or VW3 directs flow to the left or right side drive motors. Because the front and rear drive motors are in series both motors will drive and the oil will return to the directional control valve and back to tank through valves VD4 and VB5.

Valves VR4 and VD4 are designed into the system to prevent the machine’s drive motors from over speeding on a downhill operation. When pilot pressure is available through shuttle valve VR4 the dynamic brake valve VD4 is open to allow free flow back to tank through the VB5 brake valve.

If the machine starts to over speed traveling on an incline the pressure between the pump and directional control valve will drop. This loss of pressure will cause loss of pilot pressure at the shuttle valve and the dynamic brake valve. The dynamic brake valve will respond by restricting the propulsion system’s return flow.

The four drive motors are set up for left and right side operation. The two motors on each side of the machine are connected in a series flow path. Additionally the motors on the rear of the machine are equipped with spring applied hydraulically released disc brakes. Both left and right side drive systems are protected by its own system relief valve [VD2 or VD3] set at 2986 psi (210 bar).

Flow from the propulsion pumps enters the propulsion valves and is directed through the open centered spool into the dynamic brake valve VD4. The dynamic braking valve senses the pressure in the drive system and opens to allow pump flow to return to tank through the 213 psi (15 bar) relief valve of park brake valve VB5. Note that brake valve VB5 is closed when the machine is operating.

4-7

SM35002 - SECTION FOUR

HYDRAULIC OVERVIEW

VIBRATION SYSTEM DRAWINGS

4-8

SM35002 - SECTION FOUR

HYDRAULIC OVERVIEW

VIBRATION SYSTEM DRAWINGS

4-9

SM35002 - SECTION FOUR

HYDRAULIC OVERVIEW

HIGH SPEED TRAVEL DRAWINGS

4 - 10

SM35002 - SECTION FOUR

HYDRAULIC OVERVIEW

HIGH SPEED TRAVEL SYSTEM

4 - 11

VIBRATION SYSTEM FUNCTION

SM35002 - SECTION FOUR

HYDRAULIC OVERVIEW

VIBRATION SYSTEM FUNCTION The vibration system consists of the fixed displacement vibration pump [P1], the fixed displacement vibration motor [M5], a system relief valve [VD1], and control valves [VW4 & VW5]. Note that valve VW4 has both vibration on/off and high speed travel functions.

Oil flows from pump P1 into the vibration control valve block port P1. When all solenoids are off, oil will flow through the open center of high speed valve VW4 and return through the hydraulic filter back to the reservoir.

HIGH SPEED TRAVEL FUNCTION The high speed travel is obtained by diverting the flow from the vibration system pump into the propulsion system. This will occur when solenoid Y7 on the high speed travel valve is energized. Two check valves are installed in the high speed system to prevent back flow from the propulsion system into the vibration system.

The machine is electrically wired to prevent activation of the vibration solenoids whenever the machine is in the high speed travel mode.

When the forward or reverse vibration switch is toggled on solenoid Y10 of the high speed travel valve is energized blocking the flow back to the hydraulic reservoir.

Additionally solenoids Y8 (reverse travel vibration) or Y9 (forward travel vibration) will be energized to direct flow into the vibration motor. The return flow from the vibration motor returns through the VW5 vibration valve back to the reservoir.

The vibration system is protected by the VD1 relief valve set at 2560 psi (180 bar).

4 - 13

BRAKE SYSTEM DRAWINGS

4 - 14

BRAKE SYSTEM DRAWING

4 - 15

SM35002 - SECTION FOUR

HYDRAULIC OVERVIEW

DRAIN LINE DRAWINGS

4 - 16

SM35002 - SECTION FOUR

HYDRAULIC OVERVIEW

DRAIN LINES DRAWING

4 - 17

SM35002 - SECTION FOUR

HYDRAULIC OVERVIEW

HYDRAULIC TEST PORTS

Pressure testing on this machine requires the use of either a VT8002 gauge set or a VT8004 adaptor for a standard gauge.

4 - 18

SM35002 - SECTION FOUR

HYDRAULIC OVERVIEW

MP1

Working pressure, vibration, 180 bar maximum (located under on vibration valve)

MP2

Working pressure, left travel, 210 bar maximum (located under operator controls)

MP3

Working pressure, right travel, 210 bar maximum (located under operator controls)

MP4

Working pressure, 40 bar maximum (located under operator control panel)

MP5

Working pressure, 30 bar maximum (located inside rear hood, left side)

P1 P2 P3 M1 M2 M3 M4 VB1 VB5 VW2 VW3 VW4 VW5 VD1 VD2 VD3 VD4 VR2 VR3 VR4 F1 F2 B NS

vibration pump right side propulsion pump left side propulsion pump right rear drive motor with brake right front drive motor left rear drive motor with brake left front drive motor vibration and high speed controls brake control valve left side propulsion control valve right side propulsion control valve high speed travel control valve vibration control valve vibration system relief valve left side propulsion system relief valve right side propulsion system relief valve propulsion dynamic braking valve left side high speed propulsion check valve right side high speed propulsion check valve propulsion shuttle valve suction strainer return flow filter hydraulic reservoir hydraulic oil level gauge

4 - 19

HYDRAULIC SCHEMATIC

SECTION FIVE

CHASSIS

5-1

SM35002 - SECTION FIVE

CHASSIS

LOWER FRAME

5-2

SM35002 - SECTION FIVE

CHASSIS

UPPER FRAME

5-3

SM35002 - SECTION FIVE

CHASSIS

VIBRATION SHAFT

5-4

5-5

SM35002 - SECTION FIVE

CHASSIS

VIBRATION SYSTEM Park the machine on a level surface when checking the oil level or draining the oil from the vibration system.

Oil change Change the oil in the vibration system every 1000 hours of operation.

1. Park the machine on a level surface. The plugs for filling and checking the vibratory system are on the right side of the machine.

2. Place a gallon container below the drain plug (#2).

3. Remove the plug and drain the oil from the housing.

4. Replace the drain plug and refill the housing (plug #4) with the proper type and quantity of oil [.53 qt. (0.5 liter) 15W-40]. Fill the unit until oil starts to run out of the level plug (#3) Do NOT over fill.

5. Reinstall the plugs into the housing and check for leaks.

5-6

INDEX

A air filter system ........................................................................................................................ 2 - 6 alternator voltage checks .................................................................................................... 3 - 15 alternators explained ........................................................................................................... 3 - 14

B batteries explained ............................................................................................................... 3 - 12 battery ...................................................................................................................................... 3 - 2 battery charger ...................................................................................................................... 1 - 22 battery diagnostics ............................................................................................................... 3 - 13 bolt torque chart .................................................................................................................... 1 - 11 brake system ......................................................................................................................... 4 - 14

C California Proposition 65 ....................................................................................................... 1 - 2 charge system diagnostics ................................................................................................. 3 - 15 cleaning parts ........................................................................................................................ 1 - 10 component identification ....................................................................................................... 1 - 5 controls .................................................................................................................................. 1 - 18 controls, with remote ............................................................................................................ 1 - 20

D diesel fuel specification ....................................................................................................... 1 - 16 drain lines .............................................................................................................................. 4 - 16

E electrical circuits, machine control ..................................................................................... 3 - 21 electrical layout, with remote .............................................................................................. 3 - 22 electrical schematics ............................................................................................................ 3 - 26 electrical schematics explained ........................................................................................... 3 - 5 electrical system ..................................................................................................................... 3 - 2 electrical wire harnesses ..................................................................................................... 3 - 30 engine cooling system ........................................................................................................... 2 - 8 engine electrical circuits ...................................................................................................... 3 - 11 engine fuel system ............................................................................................................... 2 - 10 engine model number ............................................................................................................ 1 - 3 engine oil change ................................................................................................................... 2 - 5

1

INDEX engine oil specification ........................................................................................................ 1 - 17 engine overhaul ...................................................................................................................... 2 - 2

F fluid specifications ................................................................................................................ 1 - 14 fuses ......................................................................................................................................... 3 - 3

H high speed travel .................................................................................................................. 4 - 13 hydraulic schematic ............................................................................................................. 4 - 20 hydraulic test ports ............................................................................................................... 4 - 18

M machine description ............................................................................................................... 1 - 3 machine identification ............................................................................................................ 1 - 2 machine operation ................................................................................................................ 1 - 24 maintenance schedule ........................................................................................................ 1 - 25 metric conversions ............................................................................................................... 1 - 13

P parking brake ........................................................................................................................ 1 - 23 parking the machine ............................................................................................................ 1 - 24 propulsion system explained ................................................................................................ 4 - 7

R relays ........................................................................................................................................ 3 - 3 relays, understanding ............................................................................................................ 3 - 8 relays, Vibromax types .......................................................................................................... 3 - 9 remote unit ............................................................................................................................ 1 - 21

S safety, during maintenance .................................................................................................. 1 - 9 safety, electrical rules ............................................................................................................ 1 - 8 safety, machine operation ..................................................................................................... 1 - 7

2

INDEX safety, personal ...................................................................................................................... 1 - 6 serial numbers ........................................................................................................................ 1 - 4 spark arrester .......................................................................................................................... 1 - 6 specifications ........................................................................................................................ 1 - 14 starter diagnostics ................................................................................................................ 3 - 18 starter motor test .................................................................................................................. 3 - 19 starters explained ................................................................................................................. 3 - 17 starting the engine ................................................................................................................ 1 - 23 suction lines ............................................................................................................................ 4 - 3

T torque data ............................................................................................................................ 1 - 11

U understanding electrical drawings ....................................................................................... 3 - 5

V vibration frequency ................................................................................................................. 1 - 3 vibration system ...................................................................................................................... 5 - 6 vibration system explained ......................................................................................4 - 12, 4 - 13

3

INDEX

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