EN SD116 TF - VOE21A1004254H

M O R E C A R E . B U I L T I N .

S d 1 1 6

S E R V I C E M A N U A L

V O L V O C O N S T R U C T I O N E Q U I P M E N T

W c c a B h c a a a n e c t s c t e h e m e r i s s y h r c a a a o r n n l i d d s e s p s o k o n s a t h o c t f s w o t e e n n , r r r t t h e a t a p o i n r t n e r m d o h l d e l e i n n u S a i g c t d a l . t a i v t s e e a n h o d a n a f r l d m C a e a l d . i f o o t r n c h i o e a m r t o p r e c o l a u n a u t e s d s d e ,

P r o p o s C i A t i L o F n I 6 O 5 R WN A a I r n i n g

b a D r e i i r e t h k s e n l d o e w e f e n n g c t n s t i , o e a t h e n x d e h S a o t u t h a s e e t r o t r f a n e p C d a r s o l i d o f o m u c r n e t i o i v a e t f o i h t a c s r m a u c o n . s e s c t i a t n u c e n e t ,r s

P r o p o s C i A t i L o F n I 6 O 5 R WN A a I r n i n g

SD-116 TF SERIES Table of Contents...................... Contents.................................. ........................ ............ A1 Features Features of This Manual............................. Manual................................... ...... B1 Safety Information ........................ .................................... .................... ........ C1 Illustrated Hose Schematic Option Without Without Traction Traction Control Control ............. ............. D1 Option With Traction Traction Control................... D2

A1

HYDRAULIC Propulsion / Braking Schematics Schematics ........................ ..................................... .......................... ............. E1 Overview Standard Standard Parallel Parallel on D & F................ F................ E2 Standard Standard on DX, Optional Optional on D & F .. E3 Neutral - Brakes Applied Standard Standard Parallel Parallel on D & F................ F................ E4 Standard Standard on DX, Optional Optional ................ ................ E5 Forward - Brakes Released Standard Standard Parallel Parallel on D & F..... ........... ........... E6 Standard Standard on DX, Optional Optional on D & F .. E7 Reverse - Brakes Released Standard Standard Parallel Parallel on D & F..... ........... E8 Standard Standard on DX, Optional Optional on D & F .. E9 Forward - Brakes Released (Tire Spin) Standard on DX, Optional on D & F..E10 Forward - Brakes Released (Drum Spin) Standard on DX, Optional on D & F..E11 Reverse - Brakes Released (Tire Spin) Standard on DX, Optional on D & F..E12

Component Teardown & Rebuild Propulsion Propulsion Pump................... Pump................................ .......................... ............... .. E13 Axle ...................... .......... ....................... ....................... ....................... ...................... ........... E14 Axle Motor ...................... .......... ....................... ...................... ...................... ............. .. E15 Loop Flush Flush Valve Valve ......................... ..................................... ..................... ......... E16

T A B L E O F C O N T E N T S

EFF. W/ ALL S/N

SD-116 TF SERIES

A2

Vibration Schematics Schematics ........................ ..................................... ......................... .............. F1 Overview................. Overview............................. ......................... .....................F2 ........F2 Neutral, Neutral, No Vibration Vibration ........................ ...............................F3 .......F3 Clockwise, Clockwise, High Amplitude Amplitude ......................F4 ......................F4 Counterclockwise Counterclockwise,, Low Amplitude........... F5 Component Teardown & Rebuild Vibration Vibration Pump ......................... ...................................... ............... ..F6 F6 Vibration Vibration Motor ........................ ..................................... ................ ...F7 F7 Steering Schematics Schematics ........................ ..................................... ......................... ............ G1 Overview................ Overview............................ ......................... ..................... ........ G2 Neutral.................................... Neutral....................... .......................... ................ ... G3 Steer Steer Right.............................. Right.......................................... ................ .... G4 Steer LeftG5 Component Teardown & Rebuild Steering Steering Pump .......................... ....................................... ............... G6 Steering Steering Valve........................ alve..................................... ................. .... G7 Steering Cylinder (S/Ns 169494,169572 169494,169572)) ......................... ........................... .. G8 Steering Steering Cylinder(All Cylinder(All other S/Ns)............ G9


EFF. W/ ALL S/N

SD-116 TF SERIES

A3

ELECTRICAL Schematics.................................................. H1 Battery .................................................... H1 Ignition .................................................... H3 Start ........................................................ H5 Brake/Shutdown - Brakes Applied .......... H7 Brake/Shutdown - Brakes Released ....... H9 Brake/Shutdown - Brakes Released/ Operator Out of Seat....................... H11 Brake/Shutdown - Brakes Test/ Operator In Seat ............................. H13 Anti-Spin Control/No Travel .................. H15 Anti-Spin Control/Travel ....................... H17 Anti-Spin Control/Drum Spin ................. H19 Anti-Spin Control/Wheel Spin............. ... H21 High/Low Speed Low Speed/Anti-Spin Activated ....... H23 High/Low Speed High Speed/Anti-Spin Inactive......... H25 Automatic Vibration/Impact Meter Vibration Off .................................... H27 Automatic Vibration/Impact Meter Manual, Low Amplitude................... H29 Automatic Vibration/Impact Meter Manual, High Amplitude.................. H31 Automatic Vibration/Impact Meter Automatic, Low Amplitude .............. H33 Automatic Vibration/Impact Meter Automatic, High Amplitude .............. H35

Automatic/Variable/Impact Meter ...................... H37 Grid Heater ....................................................... H39 Gauges ............................................................. H41 Instrument Cluster ............................................ H43 Fuses ................................................................ H45 MACHINE Component Teardown & Rebuild ROPS/FOPS Replacement.................................. J1 Swivel Bearing Replacement............................... J2 Drum and Drum Drive .......................................... J3 Eccentric Assembly ............................................. J4 TROUBLESHOOTING Hydraulic..............................................................K1 Electrical ..............................................................K2 Vibration Control System .....................................K3 Traction Enhancement system ............................K4 REFERENCE CHARTS AND SCHEMATICS Hydraulic Symbol Quick Reference Chart................ L1 Electrical Schematic Wire Color Code Reference Chart ................................................L2 Hydraulic Schematic ................................................L3 Electrical Schematic.................................................L5


EFF. W/ ALL S/N

SD-116 TF SERIES

Before performing any maintenance or service procedures on your SD-116 TF SERIES, refer to the Safety section of the SD-116 TF SERIES operation and maintenance manual and the AEM Safety Manual for Safety Instructions.

C1

S A F E T Y I N F O R M A T I O N

032503AA

EFF. W/ ALL S/N

SD-116 TF SERIES OPTION WITHOUT TRACTION CONTROL Suction Filter

Check Valve

Hydraulic Tank

Steering Valve

Propulsion Pump Vibration Pump

Steering Pump

Right Steering Cylinder

D1 Charge Filter

Left Steering Cylinder

Oil Cooler Thermal Bypass Valve

Brake Valve

Axle

Suction Filter

Axle Motor

Drum Drive Motor

Vibration Motor

I L L U S T R A T E D H O S E S C H E M A T I C EFF. W/ ALL S/N

SD-116 TF SERIES OPTION WITH TRACTION CONTROL Suction Filter

Hydraulic Tank

Check Valve

Steering Valve

Propulsion Pump Vibration Pump

Steering Pump

Right Steering Cylinder

D2

Left Steering Cylinder

Oil Cooler Charge Filter Traction Control Valve

Brake Valve Axle

Suction Filter

Axle Motor

Thermal Bypass Valve

Drum Drive Motor

Vibration Motor

I L L U S T R A T E D H O S E S C H E M A T I C EFF. W/ ALL S/N

SD-116 TF SERIES Table of Contents Overview Standard Parallel on D & F........................E2 Standard on DX, Optional on D & F ..........E3

Neutral - Brakes Applied Hydraulic Tank

Standard Parallel on D & F........................E4

Oil Cooler

Standard on DX, Optional on D & F ..........E5

Forward - Brakes Released

Brake Valve

Loop Flush Valve

Propulsion Pump

Standard Parallel on D & F........................E6 Standard on DX, Optional on D & F ..........E7

Reverse - Brakes Released Standard Parallel on D & F........................E8

Axle

Standard on DX, Optional on D & F ..........E9

E1

Thermal Bypass Valve Axle Drive Motor

Forward - Brakes Released (Tire Spin) Standard on DX, Optional on D & F ........E10

Forward - Brakes Released (Drum Spin) Standard on DX, Optional on D & F ........E11

Reverse - Brakes Released (Tire Spin) Standard on DX, Optional on D & F ........E12

Settings and Specifications - Propulsion* Engine RPM (Hi/Low) Flow at Input Speed System Relief Pressure (psi/bar) Charge Relief Pressure (psi)

Drum Drive Motor

116D 116F 2457/950

X

X

219.3 l/m 57.9 g/m

X

X

6090/420

X

X

350

X

X

* For specific application settings, contact your authorized service personnel.

Traction Control Valve Charge Filter

P R O P U L S I O N / B R A K I N G

EFF. W/ ALL S/N

SD-116 TF SERIES PROPULSION

HYDRAULIC TANK SUCTION STRAINER

DUMP / BRAKE / 2 SPEED MANIFOLD

OIL

LOOP FLUSH VALVE

140 F CRACKING 165 F OPEN

M1

AXLE MOTOR

A

25 psi

BYPASS

B M2

E2

L2

CHARGE FILTER

PROPULSION PUMP

M6

M3

D

E M1 A

X

DRUM MOTOR

BR

M5 M4

G

A

BRAKE B

X

M2 L1

S

OVERVIEW STANDARD PARALLEL ONON D &DF& F STANDARD PARALLEL




OIL COOLER

LOOP FLUSH VALVE


THERMAL BYPASS

AXLE MOTOR

M1

A

25 psi B M2

PROPULSION PUMP

E3

L2

CHARGE FILTER

M6

M3

D

E M1 A

X

DRUM MOTOR

BR

M5 M4 G

A

B BRAKE

B

X

M2 L1

S

OVERVIEW STANDARD ON DX OPTIONAL ON D & F

T




OIL

LOOP FLUSH VALVE

COOLER 140 F CRACKING 165 F OPEN

M1

AXLE MOTOR

A

25 psi

BYPASS

THERMAL

B M2

L2

CHARGE FILTER

PROPULSION PUMP

M6

M3

D

E M1

E4

A

X

DRUM MOTOR

BR

M5 M4

G A

B B

BRAKE X

T

M2 L1

S

dashed lines indicate low pressure

NEUTRAL - BRAKES APPLIED STANDARD PARALLEL ON D & F




OIL COOLER

LOOP FLUSH VALVE


THERMAL BYPASS

M1

AXLE MOTOR

A

25 psi B M2

M6

M3

D

L2

TRACTION ENHANCEMENT VALVE

CHARGE FILTER

PROPULSION PUMP

E M1

E5

A

X

DRUM MOTOR

BR

M5 M4 G A

B

B

BRAKE X

T

M2 L1

S

NEUTRAL - BRAKES APPLIED dashed lines indicate low pressure

STANDARD ON DX OPTIONAL ON D & F

SD-116 TF SERIES PROPULSION DUMP / BRAKE / 2 SPEED MANIFOLD

OIL COOLER

LOOP FLUSH VALVE


THERMAL BYPASS

M1

AXLE MOTOR

A

25 psi

B M2

L2

CHARGE FILTER

PROPULSION PUMP

M6

M3

D

E M1

E6

DRUM MOTOR

X

A

BR

M5 M4

G

B BRAKE B

X

T

M2 L1

S


FORWARD - BRAKES RELEASED STANDARD PARALLEL ON D & F




OIL COOLER

LOOP FLUSH VALVE


THERMAL BYPASS

M1

AXLE MOTOR

A

25 psi

B M2

L2

CHARGE FILTER

PROPULSION PUMP

M6

M3

D

E M1

E7

A

X

DRUM MOTOR

BR

M5 M4

G A

B B

BRAKE X

T

M2 L1

S

FORWARD - BRAKES RELEASED dashed lines indicate low pressure





OIL COOLER

LOOP FLUSH VALVE


THERMAL BYPASS

M1

AXLE MOTOR

A

25 psi

B M2

L2

CHARGE FILTER

PROPULSION PUMP

M6

M3

D

E M1

E8

A

X

DRUM MOTOR

BR

M5 M4

G A

B B

BRAKE X

T

M2 L1

S


REVERSE - BRAKES RELEASED STANDARD PARALLEL ON D & F




OIL COOLER

LOOP FLUSH VALVE


THERMAL BYPASS

M1

AXLE MOTOR

A

25 psi B M2

L2

CHARGE FILTER

PROPULSION PUMP

M6

M3

D

E M1

E9

A

X

DRUM MOTOR

BR

M5 M4

A

B BRAKE

B

X

T

M2 L1

S

REVERSE - BRAKES RELEASED dashed lines indicate low pressure





OIL COOLER

LOOP FLUSH VALVE


THERMAL BYPASS

M1

AXLE MOTOR

A

25 psi B M2

L2

CHARGE FILTER

PROPULSION PUMP

M6

M3

D

E M1

E10

A

X

DRUM MOTOR

BR

M5 M4

A

B

B

BRAKE X

T

M2 L1

S


TIRE SPIN - STANDARD ON DX OPTIONAL ON D & F




OIL COOLER

LOOP FLUSH VALVE


THERMAL BYPASS

M1

AXLE MOTOR

A

25 psi B M2

L2

CHARGE FILTER

PROPULSION PUMP

M6

M3

D

E M1

E11

A

X

DRUM MOTOR

BR

M5 M4 G A

B

B

BRAKE X

T

M2 L1

S


DRUM SPIN - STANDARD ON DX OPTIONAL ON D & F




OIL COOLER

LOOP FLUSH VALVE


THERMAL BYPASS

M1

AXLE MOTOR

A

25 psi B M2

L2

CHARGE FILTER

PROPULSION PUMP

M6

M3

D

E M1

E12

X

A

DRUM MOTOR

BR

M5 M4 G A

B

B

BRAKE X

M2 L1

S

REVERSE - BRAKES RELEASED dashed lines indicate low pressure

TIRE SPIN - STANDARD ON DX OPTIONAL ON D & F

SD-116 SD-116 TF SERIES PROPULSION PUMP TABLE OF CONTENTS...........................................E13.1 LIP SEAL AND SHAFT................................... SHAFT............................................E13. .........E13.2 2 Disassembly Disassembly ............................ .......................................... ...........................E .............E13.2 13.2 Inspection Inspection ......................... ....................................... ............................ ....................E13.2 ......E13.2 Assembly............................... Assembly............................................. .............................E ...............E13.3 13.3 MULTI-FUNCTION VALVE CARTRIDGES..............E13.4 Disassembly Disassembly ............................ .......................................... ...........................E .............E13.4 13.4 Inspection Inspection ......................... ....................................... ............................ ....................E13.4 ......E13.4 Assembly............................... Assembly............................................. .............................E ...............E13.4 13.4 CHARGE RELIEF VALVE........................................E13.5 Disassembly Disassembly ............................ .......................................... ...........................E .............E13.5 13.5 Inspection Inspection ......................... ....................................... ............................ ....................E13.5 ......E13.5 Assembly............................... Assembly............................................. .............................E ...............E13.5 13.5 E13.1 CHARGE PUMP ........................... ......................................... ...........................E .............E13.6 13.6 Disassembly Disassembly ............................ .......................................... ...........................E .............E13.6 13.6 Inspection Inspection ......................... ....................................... ............................ ....................E13.6 ......E13.6 Assembly............................... Assembly............................................. .............................E ...............E13.7 13.7 REMOTE CHARGE PRESSURE FILTRATION.......E13.8 Disassembly Disassembly ............................ .......................................... ...........................E .............E13.8 13.8 Inspection Inspection ......................... ....................................... ............................ ....................E13.8 ......E13.8 Assembly............................... Assembly............................................. .............................E ...............E13.8 13.8 MANUAL DISPLACEMENT DISPLACEMENT CONTROL CONTROL ..................E13.9 ..................E13.9 Disassembly Disassembly ............................ .......................................... ...........................E .............E13.9 13.9 Assembly............................... Assembly............................................. .............................E ...............E13.9 13.9

Propulsion Pump

TABLE OF CONTENTS

NOTICE:

SD-116 SD-116 TF SERIES PROPULSION PUMP

Prior to performing repairs on this component, contact a service representative concerning issues of warranty.

DISASSEMBLY 1. Positio Position n the motor motor with the the shaft shaft end end facing facing up. 2. Remove screws (1, Figure Figure 1-1) securing securing the retainer retainer plate plate (2). 3. Remove the retaine retainerr plate plate (2) and seal seal carrier carrier (3) from from the housing (4). 4. Remove Remove the the O-ring O-ring (5) (5) from from the seal carrier carrier (3). (3). 5. Press Press out the the lip seal seal (6) from from the the seal carr carrier ier (3). (3). 6. If necessary necessary,, remove remove the shaft (9) and and bearing bearing assembly (8) from the housing (4).

E13.2

7. Remove Remove the retai retainin ning g ring (7) (7) that that secures secures the beari bearing ng assembly (8) on the shaft (9). 8. Remove Remove the bear bearing ing assemb assembly ly (8) from from the shaft shaft (9) (9) and discard the shaft (9).

INSPECTION 1. Inspect the the seal seal carrier carrier (3), (3), new lip seal seal (6) and O-ring O-ring (5) for any damage or nicks. 2. Inspect the the sealing sealing area area on the shaft shaft (9) for rust, rust, wear, wear, or contamination. Polish the sealing area on the shaft (9) as necessary. 3. Inspect Inspect the the bearin bearing g assembly assembly (8) (8) for dama damage. ge. Use Use a new bearing assembly (8) as required.

Figure 1-1

LIP SEAL AND SHAFT

ASSEMBLY


1. If necessary necessary,, install install the the original original bearing bearing assembly assembly (8, (8, Figure 1-1) or a new bearing assembly (8) on a new shaft (9). 2. Secure Secure the beari bearing ng assemb assembly ly (8) on the the shaft shaft (9) with with the retaining ring (7). 3. Install the shaft shaft (9) (9) and and bearing bearing assembly (8) into the housing (4). 4. Lightly lubricate lubricate the outside outside diameter diameter of of the new new lip seal (6) (6) with Loctite High Performance Sealant #59231. 5. Press Press the new new lip seal seal (6) into into the the seal carr carrier ier (3). (3). 6. Install Install a new new O-ring O-ring (5) (5) on the outside outside diameter diameter of the seal seal carrier (3).

E13.3

CAUTION: To prevent damage to the lip seal (6), wrap the spline or key end of the shaft (9) with thin plastic. 7. Lubricate Lubricate the O-ring (5) and and the inside diameter diameter of the lip lip seal (6) with clean c lean petroleum jelly. 8. Install the seal seal carrier carrier (3) (3) into into the housing (4) bore. bore. 9. Install the cover cover (2) into the the housing housing (4) (4) and secure it with the screws (1). 10. Torque the screws (1) to 16 N·m (12 lb-ft.).

Figure 1-1

LIP SEAL AND SHAFT

DISASSEMBLY


1. Remove the multi-function multi-function valve cartridges cartridges (1, Figure Figure 1-2) from the end cap (2). 2. Remove and discard discard the O-rings O-rings (3) from the the multi-func multi-function tion valve cartridges (1).

INSPECTION 1. Inspect the multi-function multi-function valve cartridge cartridge for for damage damage to parts.

ASSEMBLY CAUTION: If the pressure limiter housing is disassembled for cleaning, the pressure setting must be readjusted after reassembly. 1. Lightly lubricate lubricate the new O-rings O-rings (3) with with clean clean petroleu petroleum m jelly.

E13.4

2. Install Install new new O-rings O-rings (3) onto the multi-fu multi-function nction valve cartridges (1). 3. Install the multi-fun multi-function ction valve cartridges cartridges (1) (1) in the end end cap (2). 4. Torque the multi-fun multi-function ction valve valve cartridges cartridges (1) to 89 N·m (66 lb-ft.).

Figure 1-2

MULTI-FUNCTION VALVE CARTRIDGES

DISASSEMBLY

SD-116 TF SERIES PROPULSION PUMP

NOTE: To maintain original adjustment, mark the plug (7, Figure 1-3), the locknut (8), and the housing (2). 1. Loosen the locknut (8, Figure 1-3) and remove the plug (7) by unscrewing the plug (7) from the housing (2). 2. Remove and discard the O-ring (6) from the plug (7). 3. Remove the spring (5) and charge relief valve (4) from the plug (7).

INSPECTION 1. Inspect the charge relief valve (4) and mating seat in the end cap for damage or foreign material.

ASSEMBLY

E13.5

CAUTION: Do not interchange parts with another valve. 1. Install the charge relief valve (4) and spring (5) onto the plug (7). 2. Install a new O-ring (6) onto plug (7). 3. Install the plug (7) with its locknut (8) aligning the marks made at disassembly and torque the locknut (8) to 52 N·m (38 lb-ft.). 4. Check and adjust the charge pressure as required.

Figure 1-3

CHARGE RELIEF VALVE

DISASSEMBLY


1. Remove the screws (1, Figure 1-4) flange cover (2) and Oring (3). Discard the O-ring (3). 2. Remove the screws (4), washers (5), and flange adapter (6) from the end cap (17). CAUTION: Do not allow the force of the cylinder block spring and swashplate leveler springs to separate the flange adapter from the charge pump housing. 3. Remove the screws (7), retaining plate (8) and O-ring (9). Discard the O-ring (9). 4. Remove the charge pump cover (10), bushing (11), and coupling (12). Note the orientation of the gerotor assembly (15). 5. Remove the charge pump shaft (13) and key (14) from the end cap (17).

E13.6

6. Remove the charge pump gerotor assembly (15) and alignment pin (16).

INSPECTION 1. Surfaces need to be clean and free of any foreign material or paint prior to assembly. 2. Inspect for abnormal wear or damage.

Figure 1-4

CHARGE PUMP

ASSEMBLY


NOTE: Be sure to install the charge pump in the proper orientation. 1. Apply a small amount of petroleum jelly to the charge pump gerotor assembly (15, Figure 1-4), both inside diameter and outside diameter. 2. Install the charge pump gerotor assembly (15) and alignment pin (16). 3. Install the charge pump shaft (13) and key (14) into the end cap (17). The internally splined end of the shaft must engage the main pump shaft. 4. Install the coupling (12), bushing (11), and charge pump cover (10).

E13.7

CAUTION: In order to avoid loss of charge pressure, always install the charge pump cover (10, Figure 1-4) with the drain hole located on the same side of the end cap (17) as the charge inlet port. 5. Install the retaining plate (8) and secure the retaining plate (8) with screws (7). 6. Torque the screws (7) to 13.5 N·m (10 lb-ft.). 7. Install a new O-ring (9) around the charge pump cover (10). 8. Install the flange adapter (6), washers (5), and screws (4) onto the end cap (17). 9. Torque the screws (4) to 298 N·m (220 lb-ft.). 10. Install a new O-ring (3), flange cover (2), and screws (1) onto the flange adapter (6).

Figure 1-4

CHARGE PUMP

DISASSEMBLY


1. Loosen the swivel locknut (19, Figure 1-5). 2. Remove the filter manifold (17) from the end cap (21). 3. Remove and discard the O-ring (20) from the filter manifold (17).

INSPECTION 1. Inspect the filter manifold (17) and tube (18) for blockage or foreign material.

ASSEMBLY 1. Install a new O-ring (20) onto the filter manifold (17). 2. Rotate the filter manifold (17) so the threads engage with the threads in the end cap (21), continue to rotate clockwise 6 or 7 turns.

E13.8

3. Place filter manifold (17) in the desired position. CAUTION: Failure to install the filter manifold to a sufficient depth in the housing will result in insufficient engagement of the tube in the housing. This may allow oil to bypass the filter and enter the charge system. 4. Torque the swivel locknut (19) to 122 N·m (90 lb-ft.). 5. Install a new filter canister per manufacturer’s instructions.

Figure 1-5

REMOTE CHARGE PRESSURE FILTRATION

DISASSEMBLY


1. Clean external surfaces prior to removal. 2. Remove the screws (1, Figure 1-6) that secure the manual displacement control (2) to the housing (8). 3. Remove the manual displacement control (2) with neutral start switch (9), the orifice check valve (3), the spring (4), the spring retainer (5), and the gasket (6) from the housing (8).

CAUTION:

Protect exposed surfaces and cavities from damage and foreign material.

ASSEMBLY 1. Install a new gasket (6) on the housing (8). 2. Install the orifice check valve (3), the spring (4), and the spring retainer (5) into the manual displacement control (2).

E13.9

3. All at once, install the manual displacement control (2) with neutral start switch (9) and engage the pin on the control linkage into the mating hole in the link attached to the swashplate. 4. Check for proper engagement of the control linkage pin by moving the control handle (7) off center creating center torque. If there is a lack of centering torque, repeat step 3. 5. Align the new gasket (6) with the housing (8) and install the screws (2). 6. Torque the screws (2) to 16 N·m (12 lb-ft.). 7. Readjust the neutral start switch (9) per manufacturer’s instructions. NOTICE: The neutral start switch (9, Figure 1-6) “neutral” must be readjusted after reassembling the manual displacement control module.

Figure 1-6

MANUAL DISPLACEMENT CONTROL

TABLE OF CONTENTS. ..........................................E14.1 BRAKES ..................................................................E14.2 Disassembly.......................................................E14.2 Assembly............................................................E14.4 PLANETARY REDUCTION AND AXLE SHAFT .....E14.7 Disassembly.......................................................E14.7 Assembly............................................................E14.9 DIFFERENTIAL .....................................................E14.11 Removal ...........................................................E14.11 Disassembly.....................................................E14.12 Assembly..........................................................E14.13 Installation ........................................................E14.13 REDUCTION GEAR AND PINION ........................E14.17

E14.1

SD-116 TF SERIES AXLE

Axle

Disassembly.....................................................E14.17 Assembly..........................................................E14.19

TABLE OF CONTENTS

DISASSEMBLY


1. Remove the lower plug from the axle arm and drain the oil. 2. Attach a suitable lifting device to the axle arm to be removed. 3. Loosen and remove the screws (29, Figure 1-1) and nuts (17) securing the axle arm to the axle cylinder. 4. Remove the arm from the cylinder, together with the brakes and axle shaft. Using the sling for support, stand the arm on end with the open end facing up. 5. Loosen the screws (93) on the cylinder in an alternate manner and remove them. 6. Move the cylinder outward while supporting the Belleville washers (82). 7. Remove the Belleville washers (82), noting the orientation of the washers.

E14.2

8. Remove the cylinder from the center housing, complete with piston (84). 9. Remove and discard the O-rings (18) from the cylinder. 10. Slowly introduce low-pressure compressed air through the connection member for the negative brake, in order to remove the piston (84). CAUTION: Hold the piston (84, Figure 1-1) back, as it may be suddenly ejected and damaged. 11. Remove and discard the O-rings (85 and 86) from the piston (84). 12. Remove the checking and guiding screws (79) from the pressure plate (87).

Figure 1-1

BRAKES

NOTE: Loosen the screws proportionally.

SD-116 TF SERIES AXLE (79,

Figure

1-1)

in

sequence

and

13. Remove the pressure plate (79) from the axle arm. NOTICE: Note the orientation of the components. The flow regulator wall and oil drain holes must face the oil drain plug. 14. Remove the springs (78) from the axle arm. NOTE: Check the springs for warping or other deformation. Any deformation of the springs requires spring replacement. 15. Remove the brake discs (76 and 77), noting the orientation. NOTE: If the discs are not to be replaced, avoid changing their position. 16. Remove the pinion (89) and O-ring (92) from the axle arm. Discard the O-ring (92).

E14.3

17. Unscrew and extract the brake disc clearance adjustment crown wheel (88).

Figure 1-1

BRAKES

ASSEMBLY


1. Lubricate the threaded portion of the crown wheel (88, Figure 1-1) and screw it into the axle arm as far as it will go. 2. Lightly lubricate a new O-ring (92) and install it onto the pinion (89). 3. Lubricate and install the pinion (89) into the slot provided on the axle arm, inserting the pinion teeth into the crown wheel (88) teeth. 4. Lightly lubricate the first steel brake disc (76), then install it into the axle arm. 5. Lubricate the first friction disc (77), then install it into the axle arm. 6. Complete the brake disc assembly, alternating steel discs (76) and friction discs (77).

E14.4

NOTICE: The oval holes of the friction discs (77, Figure 1-1) must be aligned. 7. Position the springs (78) into the slots of the arm. 8. Install the pressure plate (87) into the axle arm ensuring that the flow regulator and oil drains are oriented toward the axle arm’s oil drain plug. NOTICE: Check the orientation of the pressure plate (87, Figure 1-1) to ensure the flow regulator and oil drains are oriented toward the axle arm’s oil drain plug. 9. Lock the pressure plate (87) into position with screws (79). NOTICE: Tighten the screws (79, Figure 1-1) in sequence and a little at a time. 10. Tighten the screws (79) to 20 to 30 N.m (16 to 22 lb-ft.). 11. Lightlyghtly lubricate new O-rings (85 and 86) and install the O-rings onto the piston (84).

Figure 1-1

BRAKES

12. Lubricate the piston (84, Figure 1-1) and install the piston into the cylinder, ensuring that the piston relief is facing downward.


NOTE: Use a plastic hammer and lightly hammer all around the edge of the piston (84) in an alternate sequence to install the piston into the cylinder. 13. Lightly lubricate new O-rings (18) and install the O-rings onto the cylinder. Position the cylinder on the studs of the center housing without fastening. 14. Position the Belleville washers (82) into the cylinder. NOTE: Check the Belleville washers (82, Figure 1-1) for proper direction and relative centering. 15. Secure the cylinder in place on the center housing with the

E14.5

screws (93). Torque the screws (93) to 86 to 89 N.m (63 to 66 lb-ft). 16. Install the axle arm onto the cylinder and center housing. NOTE: To assist with axle shaft centering, slightly move the wheel hub. 17. Temporarily secure the axle arm with nuts (17) previously coated with Loctite 242. Tighten the nuts (17) lightly to make the axle arm touch the cylinder and center housing. 18. Check to ensure the axle arms are level. Secure the arm into its final position, using screws (29) adequately coated with Loctite 242. Torque the screws to 182 to 202 N.m (134 to 149 lb-ft.). Tighten the screws using the criss-cross method. 19. Connect an external pump to the union piece “A” of the negative brake and introduce pressure of 15 to 30 bar (218 to 435 psi).

Figure 1-1

BRAKES

20. Remove the screw (91, Figure 1-1) and safety plate (90) from the axle arm. Rotate the adjustment pinion (89) counterclockwise to eliminate all existing clearance between the brake discs. Rotate the pinion (89) up to a torque of 8 to


10 N.m (6 to 7 lb-ft.). 21. Rotate the pinion (89) clockwise 4 turns to determine the required clearance of 1 mm. NOTE: A turn of the adjuster produces a clearance of 0.25 mm (1 mm = 4 turns). 22. Install the safety plate (90) and secure in place with the screw (91). Torque the screw to 10 to 11 N.m (7 to 8 lb-ft.).

E14.6

Figure 1-1

BRAKES

DISASSEMBLY


1. Remove the locking screws (61, Figure 1-2) from the planetary cover. 2. Using two screwdrivers or two levers inserted in the slots provided, pry the planet gear carrier assembly (59) away from the hub (7). NOTE: The axle shaft (54, Figure 1-2) can only be removed after the planet gear carrier assembly (59) has been removed. 3. Rotate the hub (7) until one of the screw holes in the planet gear carrier assembly (59) appears at the top. 4. Attach a suitable lifting device to the screw hole and use the lifting device to remove the planet gear carrier assembly (59) from the hub (7).

E14.7

5. If the ring gear (72) is not being disassembled, mark a position between one of the teeth of the axle shaft (54) and the ring gear (72). 6. Remove the axle shaft (54) from the axle arm. 7. Loosen the screws (53) securing the the ring gear support (69) to the hub (7) and remove the screws (53). Remove the ring gear support (69) from the hub (7). 8. Remove the snap ring (71) from the ring gear (72). 9. Re-install and partially tighten five of the ten screws (53) in an alternate and proportional manner. 10. Using a puller and applying counter pressure to the screws (53), disengage the ring gear (72) from the hub (7). 11. Remove the partially-tightened screws (53) and the ring gear (72) from the hub (7). 12. Remove the O-ring (73) from the hub (7). Discard the O-ring (73).

Figure 1-2

PLANETARY REDUCTION AND AXLE SHAFT

13. Attach a suitable lifting device to the hub (7, Figure 1-2), then partially tighten a screw (53) and with the help of a hammer, shift the hub (7) and the external bearing (74).


14. Remove the bearing cone (74) and the hub (7) from the axle arm. Remove the hub (7), complete with the seal (74) and internal bearing (74). 15. Using a puller, remove the centering ring (49) and the seal (48), noting the orientation of the centering ring (49) and seal (48). 16. Remove the bolts (67) and locking plates (66) securing the rear cover to the planet gear carrier (59), then remove the rear cover from the planet gear carrier (59). 17. Remove the planet gear assemblies from the planet gear carrier.

E14.8

18. To disassemble the planet gear assembly, remove the snap ring (55) from the planet pin (57), then remove the friction washer (56), planet gear (65), needle bearing (64), and friction washer (56). If necessary, remove the O-ring (58) and snap ring (55) from the opposite end of the planet pin (57). Discard the O-ring (58) and snap rings (55). Repeat for the remaining planet gear assemblies. NOTE: Note the orientation of the planetary gears. 19. If necessary, use a puller to remove the friction washer (62) from the planet gear carrier. 20. Remove the seal (75) from the hub (7) and discard the seal (75). 21. Remove the internal bearing cone (74) from the hub (7). 22. Remove the internal and external bearing cups (74) from the hub (7) using a pin-driver. Hammer in an alternate sequence to prevent deformation of the bearing cups.

Figure 1-2


ASSEMBLY


1. Position the wheel hub (7, Figure 1-2) under a press. Lubricate the seat of the external bearing cup (74) and press the bearing cup into the hub (7). 2. Install the bearing cone (74) into the hub (7). 3. Apply an appropriate sealant to the outer surface of the seal (75). 4. Position the seal (75) into the hub (7), checking for correct orientation. 5. Press the seal (75) into its seat in the hub (7). Turn the hub (7) upside down, lubricate the seat of the internal bearing cup (74) and press the bearing cup (74) into the hub (74). 6. If the fricton washer (62) has been removed, apply a sealant for removable seals to the outer surface of the friction washer (15) and, using a suitable driver, tap it into the planet gear carrier (59).

E14.9

7. To assemble the planet gear assembly, lightly lubricate a new O-ring (58) and install the O-ring and a new snap ring (55) onto the end of the planet pin (57). Lighly lubricate the planet pin (57) and install the friction washer (56), needle bearing (64), planet gear (65), and friction washer (56). Install a new snap ring (55) on the end of the planet pin (57). Repeat for the remaining planet gear assemblies. CAUTION: The jointed portion of the internal ring of the needle bearings (64, Figure 1-2) must face the bottom of the planet pin (57). 8. Install the rear cover onto the planet gear carrier (5) and secure it in place with the locking plates (66) and bolts (67). 9. Lubricate and install the centering ring (49) and snap ring (48) into the axle arm, paying particular attention to the orientation of the rings.

Figure 1-2

10. Lubricate the inside diameter of the seal (75) and the outside of the axle arm hub.


11. Install the hub (7, Figure 1-2) onto the axle arm hub.


12. Install the external bearing cone (74) into the hub (7). NOTE: Move the bearing cone (74, Figure 1-2) to the limit stop by hammering lightly all around the edge. 13. Install the ring gear (72) into the hub (7) and drive it into place using a suitably-sized driver. 14. Install a new snap ring (71) into the ring gear (72). 15. Lubricate the outer edge of the ring gear support (69), then install the ring gear support (69) into the ring gear (72). 16. Coat the screws (53) with Loctite 270 and install them into the ring gear support (69). 17. Tighten the screws (53) in two stages, using the criss-cross method. Torque the screws (53) to an initial torque of 120

E14.10

N.m (89 lb-ft.), then to a final torque of 219 to 242 N.m (162 to 178 lb-ft.). 18. Lubricate the seal (48), centering ring (49), and the toothed portions and sealing surface of the axle shaft (54). 19. Install the axle shaft (54) into the axle arm, making sure that it is properly inserted into the braking discs and the differential unit. 20. Lubricate a new O-ring (73) and install it into the hub (7). 21. Install the planet gear carrier assembly (59) onto the hub (7). NOTICE: Line up the locating release points. 22. Secure the planet gear carrier (59) to the hub (7) with screws (61). Torque the screws to 40 N.m (30 lb-ft.).

Figure 1-2


REMOVAL


1. Remove the axle arms and the reduction unit from the differential housing. 2. Remove the stud screws (23, Figure 1-3) from the intermediate cover and remove the intermediate cover from the side of the differential opposite the beveled gear (46). 3. Remove and discard the O-ring (18) from the intermediate cover. 4. Remove the bolt (35) and locking plate (34), then remove the ring nut (33) from the intermediate cover. 5. Using a suitable driver, remove the bearing cup (41) from the intermediate cover. 6. Remove the stud screws (24) from the intermediate cover and remove the intermediate cover from the side of the differential housing nearest the beveled gear (46).

E14.11

7. Remove and discard the O-ring (18) from the intermediate cover. 8. Remove the bolt (35) and locking plate (34), then remove the ring nut (33) from the intermediate cover. 9. Using a suitable driver, remove the bearing cup (41) from the intermediate cover. 10. Position a stop block made from a soft metal (aluminium, etc.) between the differential housing and the toothed portion of the beveled gear (46). 11. With the beveled gear (46) resting on the stop block, remove the screws (40) and spring washers (39) securing the differential carrier (37) to the beveled gear (46). 12. Using a suitable driver, push the differential carrier (37) away from the beveled gear (46) to disengage the differential carrier (37) from the beveled gear (46).

Figure 1-3

DIFFERENTIAL

13. Remove the differential carrier (37, Figure 1-3) from the beveled gear (46) and the differential housing.


14. Remove the beveled gear (46) from the differential housing.

DISASSEMBLY No-Spin Differential Unit 1. Using a suitable puller, remove the bearing cones (41) from each end of the differential carrier (37). 2. Remove the screws (36) joining the differential unit half box (37) to the main body (37). 3. Using a plastic hammer, separate the half box (37) from the main body (37), noting the coupling marks. 4. Remove the no-spin unit (38) from the differential unit main body (37). Unscrew the wing nut of the stay and disassemble the no-spin unit (38) in order to remove the spacer (42) that prevents the axial sliding of the axle shafts. E14.12

Figure 1-3

DIFFERENTIAL

ASSEMBLY


No-Spin Differential Unit 1. Assemble the no-spin unit (38, Figure 1-3), inserting the spacer (42) and using the stay. 2. Install the no-spin unit (38) into the differential unit main body (37). 3. Install the differential unit half-box (37) onto the main body (37), ensuring that the coupling marks align. 4. Coat the screws (36) with Loctite 270 and install them into the differential unit half-box (37). Tighten the screws (36) using the criss-cross method and torque them to 86 to 89 N.m (63 to 66 lb-ft.). 5. Remove the stay from the differential carrier (37).

INSTALLATION E14.13 1. Position the differential carrier (37) under a press and, using an appropriately-sized driver, install the first bearing cone (41). 2. Turn the unit upside down and position the differential carrier (37) under a press. Using an appropriately-sized driver, install the second bearing cone (41). 3. Using a suitable press, install a bearing cone (41) into each of the intermediate covers. 4. Install the beveled gear (46) into the differential housing. 5. Install the differential carrier (37) into the differential housing. 6. Install the beveled gear (46) onto the differential carrier (37), and fasten it to the flange. Ensure that the holes of the differential carrier flange (37) match those of the beveled gear (46).

Figure 1-3

7. Install the spring washers (39) onto the screws (40).

DIFFERENTIAL

8. Coat the screws (40, Figure 1-3) with Loctite 270 and install the them hand tight into the beveled gear (46).


9. Position the stop block between the differential housing and the toothed portion of the beveled gear (46). While holding the beveled gear (46) resting on the stop block, tighten the screws (40), using the criss-cross method, to a torque of 135 to 138 N.m (100 to 102 lb-ft.). 10. Lubricate and install a new O-ring (30) onto the intermedate cover, then install the intermediate cover on the side of the differential housing nearest to the beveled gear (46). 11. Install the stud screws (24) and torque them to 129 to 143 N.m (95 to 105 lb-ft.). 12. Ensure that the differential carrier (37) is tightly engaged in the intermediate cover. Lubricate and install a new O-ring (30) onto the remaining intermedate cover, then install the intermediate cover on the side of the differential housing opposite the beveled gear (46). E14.14 13. Install the stud screws (23) and torque them to 129 to 143 N.m (95 to 105 lb-ft.). 14. Remove the bolt (35) and locking plate (34) from one of the intermediate covers. Using a suitable wrench, remove the ring nut (33) from the intermediate cover and remove any residue of thread locking substances. 15. Apply Loctite 242 to the ring nut (33), then re-install the ring nut (33) into the intermediate cover. 16. Repeat steps 14 and 15 for the intermediate cover on the opposite end of the differential housing. 17. Remove the spring ring (21) and cap (22) from the rear of the differential housing to allow checking of the clearance between the pinion (46) and the beveled gear (46) to take place.

Figure 1-3

DIFFERENTIAL

18. Coat the mounting surface of the differential housing with Loctite 510 and install the reduction gear assembly and pinion assembly (46, Figure 1-3).


19. Coat the bolts (5 and 7) with Loctite 242 and install the bolts (5 and 7) into the reduction gear assembly. Tighten the bolts (5 and 7), using the criss-cross method, to a torque of 129 to 143 N.m (95 to 105 lb-ft.). 20. Screw the ring nut (33) on the side of the differential housing nearest the beveled gear (46) until the clearance between the pinion (46) and beveled gear (46) equals zero, then unscrew the ring nut (33) by approximately 1/4 turn. 21. Allow the pinion (46) to turn a few times in both directions to allow the bearings to set. Pre-load the bearings through the ring nut on the side of the differential housing opposite the beveled gear (46) to increase pinion torque up to a value of

E14.15

140 to 210 N.cm (12 to 18 lb-in.), checked using a torque meter. CAUTION: If bearings are old, check static torque. If new, check continuous torque. 22. Introduce a dial indicator through the rear cap (22) hole. 23. Position the dial indicator on the center of one of the beveled gear teeth (46), pre-set it to 1 mm and reset it to zero. 24. Manually move the beveled gear (46) in both directions to check the existing clearance between the pinion (46) and the beveled gear (46). 25. Mark the position of the ring nuts (33) in relation to the intermediate covers. 26. Using a suitable wrench, adjust the clearance between the pinion (46) and the beveled gear (46) crown by loosening one ring nut (33) and tightening the opposite ring nut (33) proportionally. Normal clearance is 0.18 to 0.23 mm (0.007 to 0.906 in).

Figure 1-3

DIFFERENTIAL

NOTE: The difference between the MINIMUM and MAXIMUM clearance for the entire circumference of the beveled gear (46, Figure 1-3) should not exceed 0.09 mm (0.004 in).


27. Install the locking plates (34, Figure 1-3) on the ring nuts (33) and secure them with the screws (35). Torque the screws to 10 to 11 N.m (7 to 8 lb-ft.). 28. Using a suitable driver, install the cap (22) into the rear of the differential housing and position it in its seat with the snap ring (21). 29. Using a driver and a plastic hammer, install the driving gear (2) into the reduction gear housing. Apply Loctite 510 to the mounting surface of the reduction gear housing and install the cover. 30. Secure the cover in place with the spring washers (8) and the screws (1 and 9). Torque the screws (1 and 9) to 82 to 91

E14.16

N.m (60 to 67 lb-ft.). 31. Install the vent (4) into the reduction gear housing and tighten the vent to a torque of 35 to 50 N .m (26 to 37 lb-ft.). 32. Complete the assembly of the axle by installing the axle arms.

Figure 1-3

DIFFERENTIAL

DISASSEMBLY


1. Remove the axle arms from the differential unit. 2. Loosen and remove the screws (1 and 9, Figure 1-4) and spring washers (8) securing the cover to the reduction gear housing. Remove the plugs (10 and 11) for oil fill and oil drain, then remove the vent (4). NOTE: While removing the cover, leave two of the screws (9, Figure 14) in position for safety. 3. Using a plastic hammer, loosen the cover, then remove the two remaining screws (9) and remove the cover. NOTE: If operations on the differential unit need to be performed, remove the complete reduction gear unit from the differential unit (remove screws [5 and 7, Figure 1-4]).

E14.17

4. Place a stop block of soft metal (aluminium, etc.) between the reduction gear housing and the gear (6) of the pinion. 5. Loosen and remove the pinion locking nut (30). 6. Remove the pinion gear (6) and the driving gear (2), complete with bearing (3). Use a lever to remove the driving gear (14). 7. Use a suitable puller to remove the bearing (3) from the driving gear (2). 8. Loosen all screws (5 and 7) and remove the upper screws (7) securing the reduction gear housing to the differential unit. Leave the two lower screws (5) in position for safety. 9. Connect the reduction gear housing to a suitable lifting device and remove the screws (5) previously left in place for safety. 10. Using a plastic hammer, tap the reduction gear housing to remove it from the differential unit.

Figure 1-4

REDUCTION GEAR AND PINION

11. Position the reduction gear housing under a press and, using a driver, remove the pinion (46, Figure 1-4), complete with the shim (32), bearing cone (31), shim (43) and spacer (44). The bearing cone (31) on the inside of the reduction gear housing should come off the pinion (46) as the pinion is pressed out of the reduction gear housing.


12. Remove the spacer (44) and shim (43) from the pinion (46). 13. Position the pinion (46) under a press and remove the bearing cone (31) and shim (32) from the pinion (46). 14. With the help of a suitable driver, remove the bearing cups (31) and seal (45) from the reduction gear housing. Note the orientation of the seal (45).

E14.18

Figure 1-4


ASSEMBLY


1. Mark the cup and face plate of one of the the bearings (31, Figure 1-4), then allow the bearing to set by rotating it in both directions while applying a vertical thrust. With a digital depth gauge, check the overall thickness of the bearing (e.g.: 42.35 mm) and set the gauge to zero again. 2. Lay two 20 mm gauged blocks on the face of the reduction gear housing. With the depth gauge set to zero, measure the space between the blocks and the striking surface of the bearing (31). The measurement obtained (e.g.: 0.81 mm) is the theoretical thickness of the shim “St” (32) to be inserted under the bearing cup (31). 3. On the bar-hold of the pinion (46), check the value “X” (in brackets) relative to the deviation from the theoretical centre distance. NOTE: “Y,” the number not in brackets, is the number of the pinion/ E14.19 beveled gear coupling. This number will correspond to a number stamped on the inside of the beveled gear (46, Figure 1-4). 4. To calculate the final thickness “S”, add the negative value of “X” to “St” or, alternatively, subtract the positive v alue of “X”. For example: Deviation X=(±0.13 mm): S=St+X=0.81+0.13=0.94 mm Deviation X=(+0.12 mm): S=St ± X=0.81 ± 0.12=0.69 mm NOTICE: Round off to as close to 0.05 mm as possible. 5. Using a driver, mount the seal (45) in the reduction gear housing. Carefully check the orientation of the seal (45). Lubricate the outer surface of the seal (45). 6. Place the reduction gear housing under a press and install the bearing cup (31) that was not countermarked in step 1.

Figure 1-4


SD-116 TF SERIES AXLE 7. Turn the reduction gear housing upside down and insert shim “S,” then install the countermarked bearing cup (31, Figure 14) into the reduction gear housing. 8. Install special tool T12 (see below) onto tool T11 (see below), then install the bearing cones (31) onto tool T11 so that they are opposed to each other and separated by the spacer (44). 9. Position a depth comparator in one of the four radial holes of tool T11. Preset the comparator to 3 to 4 mm, then set it to zero. Tool T11

Tool T12

E14.20

Figure 1-4


SD-116 TF SERIES AXLE 10. Remove the bearing cones (31, Figure 1-4) from tool T11 and fit them in the bearing cups (31) installed in reduction gear housing. Ensure that the countermarked bearing cone is fitted into the countermarked bearing cup already installed in the centering hub of the reduction gear housing. 11. Install tool T11 into the gear reduction housing and tighten it manually to obtain a safe rolling torque. While tightening the tool, perform a few rotations to set the bearings. 12. Introduce the previously reset depth comparator, in one of the four radial holes and measure. The deviation from zero indicates the nominal value “H” relative to the shims that are to be inserted.

E14.21

13. The deviation found is to be added to a fixed value of 0.13 divided by 0.15 mm in order to obtain the correct size for shim “S1” (43), which is to be inserted between the bearing (31) and the spacer (44). This will produce the specified bearing pre-load. NOTICE: Perform accurate measurements. A variation of 0.001 mm causes a variation in the torque by 20 to 40 N m (15 to 30 lb-ft.). .

14. Install the shim (32) onto the pinion (46), then press the countermarked bearing cone (31) onto the pinion (46). NOTICE: Lubricate the pinion (46, Figure 1-4) with oil. 15. Install the pinion (46), the shim (43), the spacer (44) and the remaining bearing cone (31) into the reduction gear housing and assemble the components with a press. 16. Install the reduction gear housing (11) onto the differential housing without the differential unit. Secure in place temporarily with the two lower screws (5).

Figure 1-4


SD-116 TF SERIES AXLE 17. Install the bearing (3, Figure 1-4) into the reduction gear housing. 18. Install the gear (6) onto the pinion (46). Coat the nut (30) with Loctite 242 and hand-tighten it onto the end of the pinion (46). 19. Between the reduction gear housing and the gear (6) of the pinion, place the stop block used for disassembly, then tighten the nut (30) to a minimum tightening torque of 500 N.m (369 lb-ft.). 20. Allow the pinion to rotate a few times in both directions to enable bearings to set. 21. Using a torque meter, check the torque of the pinion (46). The proper torque should be 140 to 150 N .cm (198 to 212 oz-in.). NOTICE: If the torque exceeds the maximum value, then the shim “S1” E14.22 (43, Figure 1-4) placed between bearing (31) and the spacer (44) needs to be increased. 22. If the torque does not reach the set value, increase the tightening torque setting of the nut (30), in different stages, until a maximum value of 700 N.m (516 lb-ft.) is obtained. NOTICE: If the torque does not reach the minimum value, then the shim “S1” (43, Figure 1-4) needs to be reduced. NOTICE: In order to be able to calculate the increase or reduction of shim “S1”, it is necessary to bear in mind that a 0.01 mm variation in the size of the shim (43, Figure 1-4) results in the torque of the pinion (46) varying by 20 to 40 N cm (28 to 57 oz-in.). .

23. Remove the reduction gear unit from the differential housing. Install the differential unit into the differential housing, then install the reduction gear unit and the axle arms onto the differential unit.

Figure 1-4


SD-116 TF SERIES AXLE MOTOR TABLE OF CONTENTS...........................................E15.1 LIP SEAL AND SHAFT............................................E15.2 Disassembly.......................................................E15.2 Inspection ...........................................................E15.2 Assembly............................................................E15.3 LOOP FLUSHING VALVE .......................................E15.4 Disassembly.......................................................E15.4 Inspection ...........................................................E15.4 Assembly............................................................E15.4 CONTROL SUPPLY ORIFICE AND ORIFICE CHECK VALVE ........................................E15.5 Disassembly.......................................................E15.5 Inspection ...........................................................E15.5 E15.1 Assembly............................................................E15.5 ORIFICE CHECK VALVE AND ELECTRIC 2-POSITION CONTROL VALVE...........E15.6 Disassembly.......................................................E15.6 Assembly............................................................E15.7

Axle Drive Motor

TABLE OF CONTENTS

SD-116 TF SERIES AXLE MOTOR

NOTICE: Prior to performing repairs on this component, contact a service representative concerning issues of warranty.

DISASSEMBLY 1. Position the motor with the shaft end facing up. 2. Remove the screws (1, Figure 1-1) securing the retainer plate (2). 3. Remove the retainer plate (2) and the seal carrier (3) from the housing (4). 4. Remove and discard the O-ring (5) from the seal carrier (3). 5. Press out and discard the lip seal (6) from the seal carrier (3). 6. If necessary, remove the shaft (9) and the bearing assembly (8) from the housing (4).

E15.2

WARNING: Safety glasses must be worn when removing the retaining ring (7). 7. Remove and discard the retaining ring (7) that secures the bearing assembly (8) on the shaft (9). 8. Remove the bearing assembly (8) from the shaft (9).

INSPECTION 1. Inspect the seal carrier (3) for any damage or nicks. 2. Inspect the sealing area on the shaft (9) for rust, wear, or contamination. Polish the sealing area on the shaft (9) as necessary. 3. Inspect the bearing assembly (8) for damage. Use a new bearing assembly (8) as required.

Figure 1-1

LIP SEAL AND SHAFT

ASSEMBLY


1. If necessary, install the original bearing assembly (8, Figure 1-1) or a new bearing assembly (8) on the shaft (9) WARNING: Safety glasses must be worn when installing the retaining ring (7). 2. Secure the bearing assembly (8) on the shaft (9) with a new retaining ring (7). 3. Install the shaft (9) and the bearing assembly (8) into the housing (4). 4. Lightly lubricate the outside diameter of the new lip seal (6) with Loctite High Performance Sealant #59231. 5. Press the new lip seal (6) into the seal carrier (3). 6. Install a new O-ring (5) on the outside diameter of the seal carrier (3).

E15.3

CAUTION: To prevent damage to the lip seal (6, Figure 1-1), wrap the spline or key end of the shaft (9) with thin plastic. 7. Lubricate the new O-ring (5) and the inside diameter of the new lip seal (6) with clean petroleum jelly. 8. Install the seal carrier (3) and retainer plate (2) into the housing (4) bore and secure with the screws (1). 9. Torque the screws (1) to 9.5 N·m (7 lb-ft.).

Figure 1-1

LIP SEAL AND SHAFT

DISASSEMBLY


1. Remove the plugs (1, Figure 1-2) from both sides of the valve orifice. 2. Remove and discard the O-rings (4) from each plug (1). 3. Remove the springs (2), the spring guides (3), and the flushing valve shuttle spool (5) from the valve orifice in the housing (6). 4. Note the orientation of the spring guides (3). Remove the springs (2) and the spring guides (3) from the flushing valve shuttle spool (5).

INSPECTION 1. Inspect the parts for damage or foreign material.

ASSEMBLY

E15.4

1. Install the flushing valve shuttle spool (5) into the valve orifice of housing (6). 2. Install the spring guides (3) with the shoulders facing out and the springs (2) on each side of the flushing valve shuttle spool (5). 3. Install the new O-rings (4) on each plug (1). 4. Install the plugs (1) into both sides of the valve orifice and torque the plugs (1) to 41 N·m (30 lb-ft.).

Figure 1-2

LOOP FLUSHING VALVE

SD-116 TF SERIES AXLE MOTOR DISASSEMBLY 1. Remove the control supply orifice (26, Figure 1-3) from the housing (6). 2. Remove and discard the O-rings (13 and 15) and the backup rings (14) from the control supply orifice (26). 3. Remove the orifice check valve (12) from the housing (16). 4. Remove and discard the O-rings (13 and 15) and the backup rings (14 and 16) from the orifice check valve (12).

INSPECTION 1. Inspect the filter screen (17) and the control supply orifice (26). Make sure they are not plugged or contain foreign material. 2. Inspect the orifice check valve (12) and make sure it is not plugged.

E15.5

3. Inspect that the orifice check valve seat is secure in the orifice check valve (12) and that the check ball is free. NOTICE: Do not interchange control supply orifice (26, Figure 1-3) with orifice check valve (12).

ASSEMBLY 1. Install the new backup rings (14) and the new O-rings (13 and 15) on the control supply orifice (26). 2. Install the control supply orifice (26) into the housing (6). 3. Torque the control supply orifice (26) to 37 N·m (27 lb-ft.). 4. Install the new backup rings (14 and 16) and the new Orings (13 and 15) on the orifice check valve (12). 5. Install the orifice check valve (12) into the housing (6). 6. Torque the orifice check valve (12) to 37 N·m (27 lb-ft.).

Figure 1-3

CONTROL SUPPLY ORIFICE AND ORIFICE CHECK VALVE


NOTE: Remove the orifice check valve (20, Figure 1-4), before removing the electric 2-position control.

DISASSEMBLY 1. Loosen and remove the seal nut (18, Figue 1-4) from the orifice check valve (20). 2. Remove the orifice check valve (20) from the housing (6). 3. Remove and discard the O-ring (19) from the orifice check valve (20). 4. Disconnect the electrical connection (23). 5. Remove the nut (24) and the solenoid (25) from the solenoid valve (22). 6. Remove the solenoid valve (22) from the housing (6). 7. Remove and discard the O-rings (21) from the solenoid valve (22).

E15.6

Figure 1-4

ORIFICE CHECK VALVE AND ELECTRIC 2-POSITION CONTROL VALVE


NOTE: Install the orifice check valve (18, 19, and 20, Figure 1-4) AFTER installing the electric 2-posi tion control.

ASSEMBLY 1. Install the new O-rings (21, Figure 1-4) on the solenoid valve (22). CAUTION: Do not over torque the solenoid valve. Over torquing may result in the valve spool sticking. 2. Install the solenoid valve (22) and torque the solenoid valve (22) to 47 N·m (35 lb-ft.). 3. Install the solenoid (25) and the nut (24) on the solenoid valve (22). 4. Torque the nut (24) to 5 N·m (44 in-ft.). 5. Install the orifice check valve (20) into the housing (6).

E15.7

6. Torque the orifice check valve (20) to 15 N·m (11 lb-ft.). 7. Install a new O-ring (19) and the seal nut (18) onto the orifice check valve (20). 8. Torque the seal nut (18) to 34 N·m (25 lb-ft.).

Figure 1-4

ORIFICE CHECK VALVE AND ELECTRIC 2-POSITION CONTROL VALVE

SD-116 TF SERIES LOOP FLUSH VALVE TABLE OF CONTENTS...........................................E16.1 LOOP FLUSHING VALVE .......................................E16.2 Disassembly.......................................................E16.2 Inspection ...........................................................E16.2 Assembly............................................................E16.2 CHARGE RELIEF VALVE........................................E16.3 Disassembly.......................................................E16.3 Inspection ...........................................................E16.3 Assembly............................................................E16.3

Loop Flush Valve

E16.1

TABLE OF CONTENTS

NOTICE:

SD-116 TF SERIES LOOP FLUSH VALVE


DISASSEMBLY 1. Remove the plugs (1, Figure 1-1) from both sides of the valve housing (6). 2. Remove and discard the O-rings (2) from each plug (1). 3. Remove the springs (3), spring guides (4), and flushing valve shuttle spool (5) from the valve housing (6). NOTE: Note the orientation of the spring guides (3, Figure 1-1).

INSPECTION 1. Inspect the parts for damage or foreign material.

E16.2 ASSEMBLY

1. Install the shuttle spool (5) into the valve housing (6). 2. Install the spring guides (4) with the shoulders facing out and springs (3) on each side of the shuttle spool (5). 3. Install new O-rings (2) on each plug (1). 4. Install plugs (1) into both sides of the valve housing (6) and torque the plugs (1) to 41 N·m (30 lb-ft.).

Figure 1-1

LOOP FLUSHING VALVE

DISASSEMBLY

SD-116 TF SERIES LOOP FLUSH VALVE

NOTE: To maintain original adjustment, mark the plug (10, Figure 1-2), locknut (7), and the housing (6). 1. Loosen the locknut (7, Figure 1-2) and remove the plug (10) by unscrewing the plug (10) from the housing (6). 2. Remove and discard the O-ring (8) from the plug (10). 3. Remove the spring (11) and charge relief valve (9) from the plug (10).

INSPECTION 1. Inspect the charge relief valve (9) and mating seat in the valve housing for damage or foreign material.

ASSEMBLY

E16.3

NOTICE Do not interchange parts with another valve. 1. Install the charge relief valve (9) and spring (11) onto the plug (10). 2. Install a new O-ring (8) onto plug (10). 3. Install the plug (10) with its locknut (7) aligning the marks made at disassembly and torque the locknut (7) to 52 N·m (38 lb-ft.). 4. Check and adjust the charge pressure as required.

Figure 1-2

CHARGE RELIEF VALVE

SD-116 TF SERIES Table of Contents Overview ...........................................F2 Neutral - No Vibration ..........F3 Clockwise - High AmplitudeF4 Counterclockwise Low Amplitude................. F5

Settings and Specifications - Vibration* Engine RPM (Hi/Low) Flow at Input Speed

116D 116F

2457/950

X

X

90.5 l/m 23.9 g/m

X

X

5000/345

X

X

285

X

X

System Relief Pressure (psi/bar) Charge Relief Pressure (psi)


Hydraulic Tank Oil Cooler

Vibration Motor

F1 Suction Filter

V I B R A T I O N

Thermal Bypass Valve Vibration Pump

EFF. W/ ALL S/N

SD-116 TF SERIES VIBRATION


SUCTION FILTER

OIL COOLER 140 F CRACKING 165 F OPEN

THERMAL BYPASS VALVE 25 PSI

VIBRATION PUMP

M3

D

F2

A

M4

VIBRATION MOTOR M1

M1 M5 B

A M2

M2

B

L1

S

OVERVIEW

L2



SUCTION FILTER

L

E

G

E

N

D

OIL COOLER BYPASS



VIBRATION PUMP

M3

D

F3

VIBRATION MOTOR

A

M4

M1

M1 M5 B

A

M2

M2

B

L1

S

NEUTRAL - NO VIBRATION

L2



L

SUCTION FILTER

E

G

E

N

D

OIL COOLER 140 F CRACKING



VIBRATION PUMP

M3

D

F4

A

M4

VIBRATION MOTOR M1

M1 M5 B

A M2

M2

L2

B

L1

S

CLOCKWISE - HIGH AMPLITUDE



SUCTION FILTER

L

E

G

E

N

D

OIL COOLER 165 F OPEN



VIBRATION PUMP

M3

D

F5

A

M4

VIBRATION MOTOR M1

M1 M5 B

A

M2

M2

B

L1

S

COUNTERCLOCKWISE LOW AMPLITUDE

L2

SD-116 TF SERIES VIBRATION PUMP TABLE OF CONTENTS.............................................F6.1

F6.1

LIP SEAL ...................................................................F6.2 Disassembly .........................................................F6.2 Inspection .............................................................F6.2 Assembly..............................................................F6.2 BYPASS VALVE.........................................................F6.3 Disassembly .........................................................F6.3 Inspection .............................................................F6.3 Assembly..............................................................F6.3 CHARGE CHECK AND HIGH PRESSURE RELIEF VALVE ...........................F6.4 Disassembly .........................................................F6.4 Inspection .............................................................F6.4 Assembly..............................................................F6.4 CHARGE RELIEF VALVE..........................................F6.5 Disassembly .........................................................F6.5 Inspection .............................................................F6.5 Assembly..............................................................F6.5 FILTER ADAPTER.....................................................F6.6 Disassembly .........................................................F6.6 Assembly..............................................................F6.6 ELECTRICAL DISPLACEMENT CONTROL (SD-116DX/F Only) .................................F6.7 Disassembly .........................................................F6.7 Inspection .............................................................F6.7 Assembly..............................................................F6.8

FORWARD - NEUTRAL - REVERSE CONTROL (SD-116D Only) .......................................F6.9 Disassembly .........................................................F6.9 Inspection .............................................................F6.9 Assembly............................................................F6.10

Vibration Pump

TABLE OF CONTENTS

SD-116 TF SERIES VIBRATION PUMP NOTICE: Prior to performing repairs on this component, contact a service representative concerning issues of warranty.

DISASSEMBLY 1. Remove the retaining ring (1, Figure 1-1) from the housing (2). 2. Carefully remove the lip seal (3) from the housing (2) bore. A slide type hammer may be used to remove the lip seal (3).

INSPECTION 1. Inspect the sealing area on the shaft (4) for rust, wear, or contamination. Polish the sealing area on the shaft (4) as necessary.

ASSEMBLY

F6.2

1. Lightly lubricate the outside diameter of the new lip seal (3) with Loctite High Performance Sealant #59231. CAUTION: To prevent damage to the lip seal (3, Figure 1-1), wrap the spline or key end of the shaft (4) with thin plastic. 2. Slide the new lip seal (3) over the shaft (4) and press it into the housing (2) bore. 3. Install the retaining ring (1).

Figure 1-1

LIP SEAL

SD-116 TF SERIES VIBRATION PUMP DISASSEMBLY 1. Remove the bypass valve (5, Figure 1-12) from the housing (2). 2. Remove and discard the O-ring (6) and backup ring (7) from the bypass valve (5).

INSPECTION 1. Inspect the bypass valve (5) and mating seat for damage or foreign material. Use new parts as required.

ASSEMBLY 1. Install a new backup ring (7) and O-ring (6) onto the bypass valve (5). 2. Lubricate the new O-ring (6) with clean hydraulic fluid and install the bypass valve (5) into the housing (2). 3. Torque the bypass valve (5) to 9.5 to 13.6 N·m (7 to 10 lb-ft.).

F6.3

Figure 1-2

BYPASS VALVE

SD-116 TF SERIES VIBRATION PUMP DISASSEMBLY 1. Remove the charge check and high pressure relief valve plug (8, Figure 1-3). 2. Remove and discard the O-ring (9) from the charge check and high pressure relief valve plug (8). 3. Remove the spring (10) and poppet or valve cartridge (11) from the housing (2).

INSPECTION 1. Inspect the poppet or valve cartridge (11) and mating seat in the housing (2) for damage or foreign material. If the seat in the housing (2) is damaged, a new vibration pump must be used and the original must be returned to the manufacturer for warranty repair or replacement. NOTE: Always replace ball type check valves with the poppet type.

F6.4

ASSEMBLY 1. Install a new O-ring (9) on the charge check and high pressure relief valve plug (8). 2. Install a new poppet or valve cartridge (11), new spring (10), and charge check and high pressure relief valve plug (8) into the housing (2). 3. Torque the charge check and high pressure relief valve plug (8) to 41 to 95 N·m (30 to 70 lb-ft.). CAUTION: The high pressure relief valves are factory set and should not be tampered with except for replacing the entire poppet or valve cartridge. Disassembly may change the setting and cause system malfunctions or premature failure.

Figure 1-3

CHARGE CHECK AND HIGH PRESSURE RELIEF VALVE

SD-116 TF SERIES VIBRATION PUMP DISASSEMBLY 1. Remove the charge relief valve plug (12, Figure 1-4). 2. Remove and discard the O-ring (13) from the charge relief valve plug (12). 3. Remove and discard the shims (14) from the charge relief valve plug (12). 4. Remove the spring (15) and poppet (16) from the housing (2).

INSPECTION 1. Inspect the poppet and mating seat in the end cap for damage or foreign material. Use new parts as required.

ASSEMBLY 1. Install a new O-ring (13) on the charge relief valve plug (12).

F6.5

2. Install new shims (14) in the inside diameter of the charge relief valve plug (12). 3. Install a new poppet (16), new spring (15), and charge relief valve plug (12) with shims (14) into the housing (2). 4. Torque the charge relief valve plug (12) to 41 to 95 N·m (30 to 70 lb-ft.).

Figure 1-4

CHARGE RELIEF VALVE

SD-116 TF SERIES VIBRATION PUMP DISASSEMBLY 1. Remove the screws (1, Figure 1-5) from the housing (19). 2. Remove the filter adapter (2) and gasket (3) from the housing (19).

ASSEMBLY 1. Install a new gasket (3) and filter adapter (2) onto the housing (19). 2. Install the screws (1) to secure the filter adapter (2) onto the housing (19). 3. Torque the screws (1) to 22 to 28 N·m (16 to 21 lb-ft.).

F6.6

Figure 1-5

FILTER ADAPTER

SD-116 TF SERIES VIBRATION PUMP NOTICE: The removal of any portion of the electrical displacement control mechanism may result in the loss of neutral, which will require readjustment.

(SD-116DX/F Only)

DISASSEMBLY 1. Remove the screws (4 and 5, Figure 1-6). 2. Carefully lift the electrical displacement control (6) off the housing (19). 3. Remove the O-rings (11 and 12) from the control (6). 4. Remove the screws (14) from the servo piston covers (15 and 17) on each side of the housing (19). 5. Remove the servo piston covers (15 and 17). 6. Remove and discard the gaskets (16).

INSPECTION

F6.7

1. Clean all parts in a suitable solvent and allow to air dry. 2. Clean all sealing surfaces. 3. Inspect all machined surface for burrs and sharp edges. Remove any burrs or sharp edges as required.

Figure 1-6

ELECTRICAL DISPLACEMENT CONTROL

SD-116 TF SERIES VIBRATION PUMP ASSEMBLY

(SD-116DX/F Only)

1. Install a new gasket (16, Figure 1-6) for each servo piston cover (15 and 17). 2. Install the servo piston covers (15 and 17) and secure each with screws (14). 3. Torque the screws (14) to 8 to 11 N·m (11 to 15 lb-ft.). 4. Install new O-rings (11 and 12) on the control (6). 5. Carefully install the spool of the electrical displacement control (6) on the housing (19). 6. Install the screws (4 and 5), torque the screws to 13 to 14 N·m (10 to 11 lb-ft.). 7. Perform pump neutral adjustment.

F6.8

NOTICE: After installing the servo piston cover (15, Figure 1-6), the pump neutral adjustment MUST be performed before the machine is put back into service. Performance of the pump neutral adjustment may adjust the position of the displacement limiter.

Figure 1-6

ELECTRICAL DISPLACEMENT CONTROL

SD-116 TF SERIES VIBRATION PUMP (SD-116D Only)

DISASSEMBLY 1. Remove the screws (4, Figure 1-7). 2. Remove the control (6) from the gasket (7). 3. Remove the screws (5) from the gasket (7). 4. Remove the gasket (7) from the housing (19). Discard the gasket. 5. Remove and discard the O-rings (8 and 9) from the gasket (7). 6. Remove the screws (14) from each side of the housing (19). 7. Remove the servo piston covers (15 and 17). 8. Remove and discard the gaskets (16).

INSPECTION 1. Clean all parts in a suitable solvent and allow to air dry. 2. Clean all sealing surfaces.

F6.9

3. Inspect all machined surfaces for burrs and sharp edges. Remove any burrs or sharp edges as required.

Figure 1-7

FORWARD - NEUTRAL REVERSE CONTROL

SD-116 TF SERIES VIBRATION PUMP ASSEMBLY

(SD-116D Only)

1. Install a new gasket (16, Figure 1-7) for each servo piston cover (15 and 17). 2. Install the servo piston covers (15 and 17) and secure each with screws (14). 3. Torque the screws (14) to 8 to 11 N·m (11 to 15 lb-ft.). 4. Install new O-rings (8 and 9) onto a new gasket (7). 5. Install the gasket (7) onto the housing (19) 6. Install the screws (5) onto the gasket (7). 7. Torque the screws (5) to 8 to 11 N-m (11 to 15 lb-ft.). 8. Install the control (6) onto the gasket (7). 9. Install the screws (4), torque the screws to 13 to 14 N·m (10 to 11 lb-ft.). 10. Perform pump neutral adjustment.

F6.10

NOTICE: After installing the servo piston cover (15, Figure 1-7), the pump neutral adjustment MUST be performed before the machine is put back into service.

Figure 1-7

FORWARD - NEUTRAL REVERSE CONTROL

SD-116 TF SERIES VIBRATION MOTOR TABLE OF CONTENTS.............................................F7.1 SHAFT SEAL.............................................................F7.2 Disassembly.........................................................F7.2 Inspection .............................................................F7.2 Assembly..............................................................F7.3 Vibration Motor

F7.1

TABLE OF CONTENTS

SD-116 TF SERIES VIBRATION MOTOR NOTICE: Prior to performing repairs on this component, contact a service representative concerning issues of warranty.

DISASSEMBLY 1. Remove the retaining ring (6, Figure 1-1) located on the shaft end of the motor (8). 2. Remove the support washer (10) and lip seal (7) from the motor housing (8). 3. Remove the second retaining ring (6) from the motor housing 4. Remove the O-rings and ball bearing from the motor housing. Discard the O-rings. 5. If necessary, remove the shaft from inside the motor housing.

F7.2

6. Turn the vibration motor over with the motor shaft end facing down. Locate and loosen the screws that connect the end cap gasket (9) to the motor housing (8). 7. Remove the end cap (9) from the motor housing (8). 8. Remove the end gasket (2) from the end cap (9) and discard. 9. Remove the needle bearing (1) from the end cap motor.

INSPECTION 1. Inspect parts for damage or wear, use new parts as required.

Figure 1-1

SHAFT SEAL

SD-116 TF SERIES VIBRATION MOTOR ASSEMBLY 1. Place a new needle bearing (1, Figure 1-1) and a new gasket (2) on the motor end cap (9). 2. Place the motor end cap (9) on the motor shaft (8). Make sure that the screw hole are line up perfectly on both the end cap (9) and the motor shaft (8). 3. Using the screws provided, fasten the end cap motor (9) to the motor shaft (8). 4. Lubicate the new O-rings (4) with petroleum jelly and in them along with the ball bearing (5) on the motor shaft . 5. Place the first retaining ring (6) on the motor shaft. 6. Lightly lubricate the outside of the diameter of the new lip seal (7) with Loctite High Performance Sealant #59231. 7. Install the new lip seal (7) into the shaft end of the motor housing (8).

F7.3

8. Install the support washer (10) and retaining ring (6).

Figure 1-1

SHAFT SEAL

SD-116 TF SERIES Table of Contents Overview...............................G2 Neutral ..................................G3 Steer Right........................... G4 Steer Left ..............................G5

Settings and Specifications - Steering*

116D

116 F

2457/950

X

X

24.2 l/m 6.4 g/m

X

X

2610/180

X

X

Engine RPM (Hi/Low) Flow at Input Speed System Relief Pressure (psi/bar)


Steering Cylinders

G1 Return Filter

S T E E R I N G

Hydraulic Tank Steering Valve Steering Pump

EFF. W/ ALL S/N

SD-116 TF SERIES STEERING STEERING CYLINDERS HYDRAULIC TANK SUCTION STRAINER

RETURN F ILTER V

G2

STEERING PUMP V

STEERING VALVE

OVERVIEW

SD-116 TF SERIES STEERING STEERING CYLINDERS HYDRAULIC TANK

RETURN FILTER V

SD-70/77 TF SERIES

G3

L

E

G

E

N

STEERING PUMP V

dashed lines indicate low pressure STEERING VALVE

NEUTRAL

D

SD-116 TF SERIES STEERING HYDRAULIC TANK

STEERING CYLINDERS

SUCTION STRAINER

RETURN F ILTER

V

G4 L

E

G

E

N

STEERING PUMP V


STEER RIGHT

D

SD-116 TF SERIES STEERING HYDRAULIC TANK STEERING

SUCTION STRAINER

CYLINDERS

RETURN F ILTER

V

G5 L

E

G

E

N

STEERING PUMP V


STEER LEFT

D

SD-116 TF SERIES STEERING PUMP TABLE OF CONTENTS............................................ G6.1 SEAL KIT .................................................................. G6.2 Disassembly ........................................................ G6.2 Inspection ............................................................ G6.3 Assembly............................................................. G6.3

G6.1

Steering Pump

TABLE OF CONTENTS

NOTICE:

SD-116 TF SERIES STEERING PUMP


DISASSEMBLY 1. Place the pump in a vise from the flange side. Be careful not to damage the pump housing (1, Figure 1-1) or flange (2). 2. Loosen and remove the screws (3) from the pump housing (1) and flange (2). 3. Place the pump on a table with the shaft end facing up. 4. Remove the flange (2) and dowel pins (4) from the pump housing (1). 5. Clean up any oil left on the work surface after removing the flange (2). 6. Carefully remove and discard the anti-extrusion ring (5) then the seal (6) from the flange (2).

G6.2

WARNING Safety glasses must be worn when removing the retaining ring (7, Figure 1-1). 7. Place the flange (2) down on the work surface with a shop towel beneath the flange. Remove the retaining ring (7) and shaft seal (8) from the flange (2). 8. Remove the cover (9) and dowel pins (10) from the pump housing (1). 9. Clean up any oil left on the work surface after removing the cover (9). 10. Carefully remove and discard the anti-extrusion ring (5) then the seal (6) from the cover (9). 11. Carefully remove and discard the O-ring seal (11) from both ends of the pump housing (1).

Figure 1-1

SEAL KIT

INSPECTION

SD-116 TF SERIES STEERING PUMP

1. Carefully clean and dry all machined surfaces thoroughly. 2. Inspect all machined surfaces for burrs and sharp edges. Remove burrs and sharp edges as required.

ASSEMBLY 1. Lightly lubricate the new O-ring seals (11, Figure 1-1) and seals (6) with petroleum jelly. 2. Install the new O-ring seals (11) on both ends of the pump housing (1). 3. Install a new seal (6) in the cover (9). 4. Secure the seal (6) in the cover (9) by installing a new antiextrusion ring (5) to the outside diameter of the seal (6). 5. Install the dowel pins (10) and cover (9) onto the pump housing (1).

G6.3

WARNING Safety glasses must be worn when installing the retaining ring (7). 6. Press a new shaft seal (8) into the flange (2) and secure shaft seal (8) with the retaining ring (7). 7. Install a new seal (6) in the flange (2). 8. Secure the seal (6) in the flange (2) by installing a new antiextrusion ring (5) to the outside diameter of the seal (6). 9. Install the dowel pins (4) in the pump housing (1).

Figure 1-1

SEAL KIT

SD-116 TF SERIES STEERING PUMP CAUTION: Be careful not to damage the shaft seal (8) on the splined shaft when installing the flange (2, Figure 1-1). 10. Carefully install the flange (2, Figure 1-1) over the shaft and down onto the pump housing (1). 11. Place the pump in a vise from the flange side. Be careful not to damage the pump housing (1) or flange (2). 12. Install the screws (3) to secure the cover (9) and the pump housing (1) to the flange (2). 13. Torque the screws (3) to 50 to 55 N·m (36.9 to 40.5 lb-ft.). Follow the pattern shown in Figure 1-1.

G6.4

Figure 1-1

SEAL KIT

SD-116 TF SERIES STEERING VALVE TABLE OF CONTENTS............................................ G7.1 STEERING VALVE ................................................... G7.2 Disassembly ........................................................ G7.2 Inspection ............................................................ G7.4 Assembly............................................................. G7.4

Steering Valve

G7.1

TABLE OF CONTENTS

SD-116 TF SERIES STEERING VALVE NOTICE: Prior to performing repairs on this component, contact a service representative concerning issues of warranty.

DISASSEMBLY 1. Clean the exterior of the steering valve thoroughly. 2. Fasten the edges of the port face sides in a vise. Use protective material on the vise jaws to prevent damage to the housing (10, Figure 1-1). 3. Loosen and remove the screws (1), special screw (2) and washers (3) from the housing (10). 4. Remove the end cap (4). 5. Carefully remove the gerotor assembly (5) from the spacer plate (6).

G7.2

6. Remove and discard the seals (7) from the gerotor assembly (5). 7. Remove the spacer plate (6) and the drive (9), from the housing (10). 8. Remove and discard the seal (11) from the housing (10). 9. Remove the housing (10) from the vise. 10. Remove the check valve (8) from the housing (10). 11. Remove the threaded bushing (12) over the ball (13) from the housing (10). 12. Carefully remove the ball (13) from the valve port by tipping the housing (10).

Figure 1-1

STEERING VALVE

SD-116 TF SERIES STEERING VALVE 14. Press the spool (14, Figure 1-1) inward and the sleeve (15), bearing races (16 and 17), needle bearing (18), and ring (19) will be pushed out of the housing (10) together. Take care to keep the pin (20) in the sleeve (15) and spool (14) horizontal. 15. Remove the ring (19), bearing races (16 and 17), and the needle thrust bearing (18) from the spool (14) and sleeve (15) assembly. NOTE: The outer bearing race (16, Figure 1-1) can sometimes “stick” in the housing (10), therefore check that the outer bearing race (16) has come out. 16. Push the pin (20) from the spool (14) and sleeve (15) assembly.

G7.3

17. Carefully press the spool (14) out from the control end of the sleeve (15), then carefully remove the centering springs (21) from the spool (14) using only your hands. 18. Remove the dust seal (22) and the O-ring (23) from the housing (10). Be careful not to damage the housing (10). 19. Remove the pressure relief valve assembly from the housing (10). NOTE: The pressure relief valve assembly consists of a plug (25, Figure 1-1), seal washer (26), set screw (27), spring (28), and a piston (29). 20. Loosen and remove the plug (25) and seal washer (26) from the housing (10). 21. Remove the set screw (27) from the pressure relief valve port. 22. Shake out the spring (28) and piston (29) from the housing (10).

Figure 1-1

STEERING VALVE

SD-116 TF SERIES STEERING VALVE INSPECTION 1. Inspect all mating surfaces for burrs and sharp edges. Replace parts as required. Do not use grit paper or file or grind these parts. 2. Clean all metal parts in a cleaning solvent. Blow dry all metal parts. Do not wipe dry with cloth or paper towel.

ASSEMBLY 1. Install the two flat centering springs (21, Figure 1-1) in the centering springs slots of the spool (14). 2. Place the curved centering springs (21) between the flat centering springs (21) that are already installed in the spool (14). 3. Align the centering springs (21) within the spring slots of the spool (14).

G7.4

4. Install the spool (14) and sleeve (15) carefully so that the spring slots line up at the same end. Make sure the three slots in the end of the spool (14) align with the three holes in the sleeve (15) opposite to the end with the centering springs slots. 5. Press the centering springs (21) together and push the centering springs (21) into place in the sleeve (15). 6. Align the centering springs (21) and center them in the spool (14) and sleeve (15) assembly. 7. Install the ring (19) over the spool (14) and on the sleeve (15). Make sure the ring (19) can rotate smoothly over the centering springs (21). 8. Insert the pin (20) through the spool (14) and sleeve (15) assembly until the pin is flush on both sides of the sleeve (15).

Figure 1-1

STEERING VALVE

SD-116 TF SERIES STEERING VALVE NOTE: The inside chamfer on the inner bearing race (17, Figure 1-1) must face the splined end of the spool (14). 9. Install the inner bearing race (17, Figure 1-1), needle bearing (18), and the outer bearing race (16) on the splined end of the spool (14). 10. Place the housing (10) on the work surface with the bore in a horizontal position. Guide the outer part of the assembly tool into the bore for the spool (14) and sleeve (15) assembly. 11. Lightly lubricate the new O-ring (23) with clean hydraulic oil and place the O-ring (23) on the inner part of the assembly tool. 12. Hold the outer part of the assembly tool in the bottom of the housing (10) and guide the inner part of the assembly tool into the bottom of the housing (10).

G7.5

13. Press and turn the O-ring (23) into position in the housing (10). 14. Remove the inner and outer parts of the assembly tool out of the housing (10) bore, leaving the guide from the inner part in the bore. 15. Install the spool (14) and sleeve (15) assembly splined end in the gerotor end of the housing (10). Make sure the parts do not tilt out of position. 16. Push the spool (14) and sleeve (15) assembly gently into place with slight rotating action, keeping the pin (20) nearly horizontal. 17. The spool (14) and sleeve (15) assembly will push out the assembly tool guide. The O-ring (23) is now in position. 18. Test for free rotation by turning the spool (14) and sleeve (15) assembly with fingertip force at the splined end.

Figure 1-1

STEERING VALVE

SD-116 TF SERIES STEERING VALVE 19. Place the housing (10, Figure 1-1) on a clean, lint free cloth with the bore in a vertical position. 20. Install the check valve (8) in the housing (10), refer to Figure 1-1. 21. Install the check ball (13) in the check valve port of the housing (10). 22. Install the threaded bushing (12) in the check valve port of the housing (10). The top of the threaded bushing (12) must lie just below the surface of the housing (10). 23. Lightly lubricate the new seal (11) with clean hydraulic oil and install the seal (11) in the housing (10). 24. Align the bolt holes in the spacer plate (6) with the bolt holes in the housing (10) and install the spacer plate (6) on the housing (10).

G7.6

25. Install the drive (9), making sure the drive (9) is engaged with the pin (20). Use the mounting fork tool to hold the drive (9) in position. 26. Lightly lubricate the seals (7) with clean hydraulic oil and install the seals (7) on both sides of the gerotor assembly (5). NOTE: The gerotor assembly (5, Figure 1-1) and the drive (9) must fit together so that a tooth base in the gerotor assembly (5) is positioned in relation to the slot of the drive (9), refer to Figure 15. 27. Align the splines of the gerotor assembly (5) with those of the drive (9) and install the gerotor assembly (5) on the spacer plate (6). 28. Align the bolt holes in the gerotor assembly (5) with the bolt holes in the spacer plate (6) without disengaging the gerotor assembly (5) from the drive (9).

Figure 1-1

STEERING VALVE

SD-116 TF SERIES STEERING VALVE 29. Install end cap (4, Figure 1-1) on the gerotor assembly (5), aligning the bolt holes. 30. Remove the mounting fork tool from the drive (9). 31. Install the special screw (2) and washer (3) in the check valve port bolt hole in the end cap (3). 32. Install the screws (1) and washers (3) in the end cap (4). 33. Cross tighten the screws (1) and special screw (2) and torque the screws (1) and special sc rew (2) to 30 ± 6 N·m (22 ± 4.4 lb-ft). 34. Install the pressure relief valve assembly in the housing (10). NOTE: The pressure relief valve assembly consists of a plug (25, Figure 1-1), seal washer (26), set screw (27), spring (28), and a piston (29).

G7.7

35. Install the piston (29) and spring (28) into the pressure relief valve port. 36. Install the set screw (27) in the pressure relief valve port and adjust the set screw (27) to 95 to 100 bar (1380 to 1450 psi). 37. Install the seal washer (26) and plug (25) into the pressure relief valve port. 38. Torque the plug (25) to 50 ± 10 N·m (36 ± 7 lb-ft.). 39. Press the dust seal (22) into housing (10).

Figure 1-1

STEERING VALVE

SD-116 TF SERIES STEERING CYLINDER (S/Ns 169494, 169572)

TABLE OF CONTENTS............................................ G8.1 SEAL KIT .................................................................. G8.2 Disassembly........................................................ G8.2 Inspection ............................................................ G8.3 Assembly............................................................. G8.4 Steering Cylinders

G8.1

TABLE OF CONTENTS

SD-116 TF SERIES STEERING CYLINDER NOTICE: Prior to performing repairs on this component, contact a service representative concerning issues of warranty.

(S/Ns 169494, 169572)

DISASSEMBLY 1. Clean the outside of the cylinder. If the hoses were removed with the cylinder, remove the hoses from the cylinder. 2. Fasten the tube (1, Figure 1-1) in an acceptable repair stand or other holding equipment., Be careful not to damage the tube (1). 3. Extend the piston rod (2) until the piston (3) bottoms out on the head (4). 4. Loosen and remove the set screw (5) and nylon plug (16) from the headcap (6).

G8.2

5. Insert a spanner wrench into the holes provided. Remove the headcap (6) from the tube (1) by turning the headcap (6) counterclockwise. If the headcap (6) is sruck or moves erratically, tap the headcap (6) with a brass or plastic mallet while turning it. 6. Wrap the headcap (6) with a soft cloth to prevent the inside diameter of the headcap (6) from touching the piston rod (2). 7. Gently tap the piston (3) against the head (4) to drive the piston rod (2) assembly from the tube (1). 8. Place the piston rod (2) assembly on a suitable work surface that will not damage the piston rod (2).

Figure 1-1

SEAL KIT

SD-116 TF SERIES STEERING CYLINDER 9. Loosen and remove the locknut (7, Figure 1-1) from the piston rod (2).

(S/Ns 169494, 169572)

10. Remove the piston (3), head (4), and headcap (6) from the piston rod (2). 11. Remove and discard the O-ring (8) from the piston rod (2). 12. Remove and discard the wiper (9), lip seal (10), and wear rings (11) from the inside diameter of the head (4). 13. Remove and discard the O-ring (12) and backup ring (13) from the outside diameter of the head (4). 14. Remove and discard the wear ring (14) and glyd-ring (15) from the piston (3).

INSPECTION 1. Clean all parts in cleaning solvent. Use only lint free cloths for cleaning and drying.

G8.3

2. If the piston rod (2), piston (3), head (4), or the tube (1) are damaged in any way, a new cylinder assembly must be used.

Figure 1-1

SEAL KIT

SD-116 TF SERIES STEERING CYLINDER ASSEMBLY

(S/Ns 169494, 169572)

1. Install a new lip seal (10, Figure 1-1) in the middle groove in the inside diameter of the head (4). 2. Install a new wiper (9) in the front groove in the inside diameter of the head (4). 3. Install new wear rings (11) in the back groove in the inside diameter of the head (4). 4. Install a new backup ring (13) in the groove on the outside diameter of the head (4) closest to the headcap (6). 5. Install a new O-ring (12) in the groove on the outside diameter of the head (4) next to the backup ring (13). 6. Install a new glyd-ring (15) and wear ring (14) in the grooves on the outside diameter of the piston (3). 7. Lubricate the inside and outside diameters of both the piston (3) and head (4) with clean hydraulic oil.

G8.4

8. Place the piston rod (2) on a clean work surface. 9. Wrap the headcap (6) with a soft cloth to prevent the inside diameter of the headcap (6) from touching the piston rod (2). 10. Install the headcap (6) onto the piston rod (2). 11. Install the head (4) followed by the piston (3) onto the piston rod (2) noting the proper orientation of each component. 12. Secure the piston (3) onto the piston rod (2) with the lock nut (7). 13. Torque the lock nut (7) to 610 to 664 N·m (450 to 490 lb-ft.).

Figure 1-1

SEAL KIT

SD-116 TF SERIES STEERING CYLINDER 14. Install the piston rod (2, Figure 1-1) assembly into the tube (1) until the headcap (6) engages the threads of the tube (1). Turn the headcap (6) counterclockwise until the first thread just passes the engagement point, then turn the headcap (6) clockwise until it is hand-tight or fully seated.

(S/Ns 169494, 169572)

15. Use a spanner wrench to tighten the headcap (6) 1/8 to 1/4 turn past fully seated. 16. Install the nylon plug (16) and set screw (5) into the headcap (6).

G8.5

Figure 1-1

SEAL KIT

SD-116 TF SERIES STEERING CYLINDER (All Other S/Ns)

TABLE OF CONTENTS............................................ G9.1 SEAL KIT .................................................................. G9.2 Disassembly........................................................ G9.2 Inspection ............................................................ G9.3 Assembly............................................................. G9.3 Steering Cylinders

G9.1

TABLE OF CONTENTS

NOTICE:


Prior to performing repairs on this component, contact a service representative concerning warranty issues.

DISASSEMBLY 1. Clean the outside of the cylinder. If the hoses were removed with the cylinder, remove the hoses from the cylinder. 2. Fasten the tube (1, Figure 1-1) in an acceptable repair stand or other holding equipment. Be careful not to damage the tube (1). 3. Extend the cylinder rod (4) until the piston (3) bottoms out on the head (2). 4. Gently tap the piston (3) against the head (2) to drive the cylinder rod (4) from the tube (1). 5. Place the cylinder rod (4) assembly on a suitable work surface to prevent damage.

G9.2

6. Loosen and remove the locknut (25) from the cylinder rod (4). 7. Remove the piston (3) and head (2) from the cylinder rod (4). 8. Remove and discard the rod seal (11) and the rod wiper seal (13) from the inside diameter of the head. 9. Remove and discard the O-ring (10) and backup washer (40) from the outside diameter of the head (2). 10. Remove and discard the seal (14) and wear ring (15) from the piston (3).

Figure 1-1

SEAL KIT

INSPECTION


1. Clean all parts in cleaning solvent. Use only lint-free cloths for cleaning and drying. 2. If the cylinder rod (4, Figure 1-1), piston (3), head (2), or tube (1) is damaged in any way, a new cylinder assembly must be used.

ASSEMBLY 1. Install a new O-ring (11) and a new rod wiper seal (13) in the inside diameter of the head (2). 2. Install a new backup washer (40) in the groove on the outside diameter of the head (2). 3. Install a new O-ring (10) in the groove on the outside diameter of the head (2) next to the backup washer (40). 4. Install a new seal (14) and a new wear ring (15) in the groove on the outside diameter of the piston (3).

G9.3

5. Lubricate the inside and outside diameters of both the piston (3) and head (2) with clean hydraulic oil. 6. Place the cylinder rod (4) on a clean work surface. 7. Install the head (2), followed by the piston (3), onto the cylinder rod (4), noting the proper orientation of each component. 8. Secure the piston (3) onto the cylinder rod (4) with the locknut (25). 9. Torque the locknut (25) to 407 N·m (300 lb-ft.). 10. Install the cylinder rod (4) in the tube (1).

Figure 1-1

SEAL KIT

SD-116 TF SERIES Table of Contents Battery....................................H2

Grid Heater Relays

Starter Alternator

H1

Grid Heaters Ignition Switch

Fuses

E L E C T R I C A L

-

-

Starter Relay Power Relay Fuel Solenoid Relay Batteries Master Switch

BATTERY

EFF. W/ ALL S/N

SD-116 TF SERIES ELECTRICAL

POWER RELAY 87A

30

87 86

FUEL SOLENOID RELAY

STARTER RELAY

85

87A

30

IGNITION SWITCH

87A

30

87

87

86

86

85

85

RD

GRID HEATER

OFF IGNITION

RD

START RD

RD

IGN

RD

F1 FUSE 15 A

GRID HEATER RELAYS 1 . 0

PR

GRID HEATER

GRN

1.0

H2

RD

1 . 0

2.0

BATTERIES

RD RD

+

RD

5.0

5.0

TO OPTIONAL FRONT LIGHT RELAY

.8

RD RD

.8

CAP B+

W

STATOR

STARTER SOLENOID STARTER MOTOR

MASTER SWITCH (OPTIONAL)

TO OPTIONAL REAR LIGHT RELAY.

O O O O OO OOO OO O O O O O O

O O r O O o O O t a l u g e R

D+ FUSE LINK

ALTERNATOR

BATTERY

SD-116 TF SERIES Table of Contents Ignition ......................................H4

Park Brake Test Switch 1625 27.1 1425 23.8

1225 20.4

1450 1350 22.5

1250 20.8

24.2

1550 25.8

1825 30.4

1650 2750

Air Filter Restriction Switch Throttle Solenoid Emergency Stop Switch Power Port

Backup Alarm Switch (Behind Hood)

E L E C T R I C A L

Seat Timer Diode (In Harness) Backup Alarm

2025 33.8

VPM HZ

Park Brake Switch

H3

Fuses

Throttle Switch

Power Relay

Hi/Low Speed Switch

Seat Timer Ignition Switch

Throttle Solenoid Timer

Seat Switch (Under Seat) Horn Park Brake Pressure Switch

Vibration Speed Sensor Hydraulic Oil Temperature Switch Rear Speed Sensor

IGNITION

EFF. W/ ALL S/N

34 - BN

RD/BE

CLOSES AT 180 F

11 - GY/OE

FUSES TO INSTRUMENT CLUSTER SEE GAUGES


TO HORN SWITCH

HORN

1

SPARE

F12 15A

10 - BK/OE

F11 10A

TO CAB OPTIONS

11 - GY/OE

11 - GY/OE

BACK UP ALARM

AIR FILTER RESTRICTION SWITCH

36 - LGN TO I TERM. ON GAUGES

F10 10A

2

HYDRAULIC OIL HIGH TEMP. SWITCH

F9 10A

F2 10A A

F4 15A

F6 5A 30

87A F7 10A 87 10 - RD/WE 86

16 - DBE/RD

TO ANTI SPIN CONTROL OPTION

17 - GY/GN

B

BACK UP ALARM SWITCH

TO LIGHT OPTIONS

13 - DBE/YW

F5 5A

POWER RELAY

12 - LGN/WE

12 - LGN/WE

F3 10A

HIGH / LOW SPEED SWITCH

12 - LGN/WE 18 - RD/BK

3 BK

F8 30A

2

1

POWER PORT 85

H4

HIGH

LOW

32 - WE 6 - LBE

PARK BRAKE SWITCH 27 - DPE/WE

IGNITION SWITCH

6 - LBE

OFF

9 ON 3

7

1A

2A

2

1B

2B

5

P

1

4

B A C

16 - DBE/RD

PARK BRAKE PRESSURE SWITCH

6

IGNITION START

VIBRATION SPEED SENSOR

21 - BN/BK

OFF

WE SGL RD BK

EMERGENCY STOP 27 - DPE/WE

IGN 6 - LBE

REAR SPEED SENSOR 23 - RD/DGN

THROTTLE SWITCH 2

7 - OE/GN 5 PR

3 HIGH 1

2

27 - DPE/WE

6 4 LOW 5

16 - DBE/RD

4 DRIVE

27 - DPE/WE

TO AUTO / MANUAL VIBRATION SELECT SWITCH OPTION

27 - DPE/WE

25 - RD/BK

+ F1 15A

COM

A 27 - DPE/WE

32 - WE

BK

A B C

A

B

22 - GY/RD

SEAT SWITCH

C

N/C

29 - LGN/BK INIT

SEAT TIMER DIODE

SEAT TIMER

HOLD

RD WE BK

THROTTLE SOLENOID

TO FUEL SOLENOID

N/O

B

THROTTLE SOLENOID TIMER

WE SGL RD BK

3 TEST 1 6

GRN

3 - OE/RD

B A C

16 - DBE/RD

BRAKE TEST SWITCH

IGNITION

SD-116 TF SERIES Table of Contents Start ...........................................H6

Neutral Start Switch Diode (In Harness) Fuel Solenoid Grid Heater Control Module Air Filter Restriction Switch Emergency Stop Switch Starter Solenoid

Air Filter Restriction Indicator (On Instrument Cluster)

162 5 27.1

145 0

142 5 23.8

135 0 22.5

122 5 20.4

125 0 20.8

182 5 30.4

24.2 155 0 25.8

165 0 275 0

202 5 33.8

VPM HZ

H5 Park Brake Switch

Throttle Switch Fuses Neutral Start Switch

Hydraulic Oil Temperature Indicator

E L E C T R I C A L

Ignition Switch Power Relay Starter Relay Fuel Solenoid Relay

START

EFF. W/ ALL S/N


34 - BN

FUSES

HOLD

TO INSTRUMENT CLUSTER F12 15A SEE GAUGES

HYD. OIL TEMP .

F11 10A

BK

RD BK WE

A C B

F9 10A

TO AUDIBLE ALARM OPTION CIRCUIT

F10 1/A F2 10A

FUEL SOLENOID PULL

GRID HEATER CONTROL MODULE

71 - PK

AIR FILTER RESTRICTION

F3 10A F4 15A F5 5A

POWER RELAY

F6 5A 30

F7 10A 87 10 - RD/WE 86

30 - LGN/BE

85

6 - LBE


IGNITION SWITCH

H6

TO AUDIBLE ALARM CIRCUIT TO EITHER OPTION CIRCUIT

F8 30A

6 - LBE

OFF IGNITION

1A

2A

1B

2B

7 2 9 - YW/BE 5

EMERGENCY STOP

OE

GRID RELAY OUT

PE

GRID RELAY OUT

GN

START IN

BN

N/A

9 ON 3 1

FUEL SOLENOID RELAY 26 - OE/WE

85

6 4

OFF

86 87 30

6 - LBE

87A

STARTER RELAY 2

7 - OE/GN

3

HIGH

1

30

26 - OE/WE 28 - GY/BK

87A 87

5

C

6 4 LOW

28 - GY/BK

86

THROTTLE SWITCH

B

62 - WE/BE

A

GRN

3 - OE/RD

LIGHT OUT

C D F

IGN

PR

RD

E 71 - PK

NEUTRAL SWITCH DIODE

85 2 - DBE

F1 15A BK

B

IGN

B

PARK BRAKE SWITCH

8 - DGN/OE

START

BE

A

26 - OE/WE

59 - BK/RD

87A

A

NEUTRAL START SWITCH STARTER SOLENOID

START

SD-116 TF SERIES Table of Contents Brake/Shutdown Brakes Applied ................ H8 Emergency Stop Switch

Brake Test Switch

Neutral Start Switch Diode (In Harness) Brake Test Diode (In Harness)

1625 27 1 .

1450

1425 238.

12 25 204.

1825

24 2 . 1350

15 50

22 5 .

258.

12 50 2 0 8 .

30 4 .

1650 27 50

2025 33 8 .

VPM HZ

Park Brake Switch

H7

Seat Switch (Under Seat)

Seat Timer Diode (In Harness) Fuses Seat Timer

E L E C T R I C A L

Brake Latching Relay Pump Return To Normal Solenoid

Brake Release Solenoid

Park Brake Pressure Switch

BRAKE/SHUTDOWN BRAKES APPLIED

EFF. W/ ALL S/N

SD-116 TF SERIES ELECTRICAL 21 - BN/BK P


TEST 27 - DPE/WE

2

1A

2A

2

1B

2B

5

EMERGENCY STOP

19 - LGN/YW

19 - LGN/YW

BRAKE TEST DIODE

5

49 - PK/WE

4

81 - YW/RD

A

86

BK

6

9 ON 3 1

85

3 1

PARK BRAKE SWITCH 7

BRAKE LATCHING RELAY

BRAKE TEST SWITCH

87

B

30 87A

DRIVE 20 - LGN/YW

6 4

20 - YW/BK 20- YW/RD

OFF

BRAKES APPLIED

BRAKE RELEASE SOLENOID

23 - RD/DGN

PUMP RETURN TO NEUTRAL SOLENOID

A

A

B

B

20 - YW/BK

27 - DPE/WE

H8


20 - YW/BK 20 - YW/BK

C B A

27 - DPE/WE

27 - DPE/WE

COM

A A

B

22 - GY/RD

SEAT SWITCH OPERATOR OUT OF SEAT

C

29 - LGN/BK

SEAT TIMER DIODE

N/C N/O

B 27 - DPE/WE

+

INIT

SEAT TIMER

62 - WE/BE

TO FUEL SOLENOID RUN CONDITION

BK

B

A

NEUTRAL START SWITCH

BRAKE / SHUTDOWN BRAKES APPLIED

SD-116 TF SERIES Table of Contents Brake/Shutdown Brakes Released ........... H10 Emergency Stop Switch

Brake Test Switch


1625 27 1 .

1450

1425 238.

12 25 204.

1825

24 2 . 1350

15 50

22 5 .

258.

12 50 2 0 8 .

30 4 .

1650 27 50

2025 33 8 .

VPM HZ

Park Brake Switch

H9


Seat Timer Diode (In Harness) Fuses Seat Timer

E L E C T R I C A L

Brake Latching Relay Pump Return To Normal Solenoid



BRAKE/SHUTDOWN BRAKES RELEASED

EFF. W/ ALL S/N



TEST 27 - DPE/WE

2

1A 1B

2A 2B

EMERGENCY STOP

2

5

19 - LGN/YW

19 - LGN/YW

BRAKE TEST DIODE

5

49 - PK/WE

4

81 - YW/RD

A

86

BK

6

9 ON 3

85

3 1

PARK BRAKE SWITCH 7


BRAKE TEST SWITCH

87

B

20 - LGN/YW

6 4

30

87A

DRIVE

1


OFF

BRAKES RELEASED


23 - RD/DGN


A

A

B

B

20 - YW/BK

27 - DPE/WE

H10


20 - YW/BK 20 - YW/BK

C B A

27 - DPE/WE

27 - DPE/WE

COM

A 27 - DPE/WE

A

B

22 - GY/RD

SEAT SWITCH OPERATOR IN SEAT

C

B 29 - LGN/BK

SEAT TIMER DIODE

+

N/C N/O

INIT

62 - WE/BE

TO FUEL SOLENOID RUN CONDITION

BK

B

A

SEAT TIMER NEUTRAL START SWITCH

BRAKE / SHUTDOWN BRAKES RELEASED

SD-116 TF SERIES Table of Contents Brake/Shutdown Brakes Released/ Operator Out of Seat.... H12 Emergency Stop Switch

Brake Test Switch


16 25 27 .1

14 50

14 25 13 50 22 .5

12 50 2 0 .8

20 .4

18 25

24 .2

23 .8

12 25

30 .4 15 50 25 .8

16 50 2750

20 25 33 .8

VPM HZ

H11

Park Brake Switch


Seat Timer Diode (In Harness) Fuses

E L E C T R I C A L

Seat Timer Brake Latching Relay Pump Return To Normal Solenoid



BRAKE/SHUTDOWN BRAKES RELEASED OPERATOR OUT OF SEAT

EFF. W/ ALL S/N



TEST 27 - DPE/WE

2

1A

2A

2

1B

2B

5

6

9 ON 3

5

49 - PK/WE

19 - LGN/YW

19 - LGN/YW

85

3 1

PARK BRAKE SWITCH 7


BRAKE TEST SWITCH

4

BRAKE TEST DIODE 81 - YW/RD

A

86

BK

87

B

20 - LGN/YW

6 4

30

87A

DRIVE

1


OFF

EMERGENCY STOP BRAKES RELEASED 23 - RD/DGN



A

A

B

B

20 - YW/BK

27 - DPE/WE

H12


20 - YW/BK 20 - YW/BK

C B A

27 - DPE/WE

27 - DPE/WE

COM

A 27 - DPE/WE

A

B

22 - GY/RD

SEAT SWITCH OPERATOR OUT OF SEAT

C

B 29 - LGN/BK

SEAT TIMER DIODE

+

N/C N/O

INIT

SEAT TIMER

62 - WE/BE

TO FUEL SOLENOID SHUTDOWN CONDITION

BK

B

A

NEUTRAL START SWITCH

BRAKE / SHUTDOWN BRAKES RELEASED/ OPERATOR OUT OF SEAT

SD-116 TF SERIES Table of Contents Brake/Shutdown Brake Test/ Operator Operator In Seat .......... ............ H14 Emergency Stop Switch

Brake Test Switch


16 25 27 .1

14 50

1425 13 50 22 .5

12 50 2 0 .8

20 .4 .4

18 25

24 .2

23 .8

1225

30 .4 .4 15 50 25 .8

16 50 2750

20 25 338 .

VPM HZ

H13

Park Brake Switch


Seat Timer Diode (In Harness) Fuses

E L E C T R I C A L

Seat Timer Brake Latching Relay Pump Return To Normal Solenoid



BRAKE/SHUTDOWN BRAKE TEST OPERATOR IN SEAT

EFF. W/ ALL S/N



TEST 27 - DPE/WE

2

1A

2A

2

1B

2B

5

EMERGENCY STOP

19 - LGN/YW

BRAKE TEST DIODE

9 ON 3

5

49 - PK/WE

85

4

81 - YW/RD

A

86

BK

6

87

B

87A

DRIVE

1

4

30

20 - LGN/YW

6


OFF

BRAKES APPLIED 23 - RD/DGN

H14

19 - LGN/YW

3 1

PARK BRAKE SWITCH 7


BRAKE TEST SWITCH



A

A

B

B

20 - YW/BK

27 - DPE/WE


20 - YW/BK 20 - YW/BK

C B A

27 - DPE/WE

27 - DPE/WE

COM

A B 27 - DPE/WE

A

B

22 - GY/RD

SEAT SWITCH OPERATOR IN SEAT

C

N/C N/O

29 - LGN/BK

SEAT TIMER DIODE

+

62 - WE/BE

TO FUEL SOLENOID

INIT RUN CONDITION

BK

B

A

SEAT TIMER NEUTRAL START SWITCH

BRAKE / SHUTDOWN BRAKES TEST/ OPERATOR IN SEAT

SD-116 TF SERIES Table of Contents Anti-Spin Control No Travel ...................... H16

E L E C T R I C A L

Speedometer

1625 27. 1 1425 23. 8

1350 22. 5

1225 1250 20. 4 20. 8 VPM

1450 24. 2

125. 55 0 8

1825 30. 4

1650 2750

2025 33. 8

HZ

Fuses

Hi/Low Speed Switch

H15 Rear Anti-Spin Control Solenoid Front Anti-Spin Control Solenoid Anti-Spin Anti-Spin Control Control Module

Drum Speed Sensor Rear Speed Sensor

ANTI-SPIN CONTROL NO TRAVEL

EFF. W/ ALL S/N

SD-116 TF SERIES ELECTRICAL SPEEDOMETER

S

CONNECTOR AT ANTI SPIN MODULE

G

GY / GN

A1 A2

I

BK

A3 B1

RD / WE LBE / BL

B2 B3

LGN LBE / BK

C1 C2

BK / WE

RD / WE

C3

REAR SPEED SENSOR B A C

DBE / RD

FUSES

D1 D2 D3

WE SGL RD BK

BK / WE

E1

BK

E2 E3 F1

HARNESS 4 PIN CONNECTIONS

FRONT ASC SOLENOID

LBE

WE

F2

XB

F3

F12 15A

REFERENCE TO CONNECTOR PIN

XC

F11 10A F9 10A

H16

GY / GN

GY / GN

X

F10 1/A

A

X

A1

F2 10A

IGN

F3 10A

ANALOG IN 0

VALVE 0

ANALOG IN 1

VALVE 1

X

ANALOG IN 2

DIGITAL OUTPUT

X

ANALOG IN 3

F4 15A F5 5A

D3


F6 5A F7 10A

3 LGN / WE

1

F8 30A

E1

HIGH PK / RD

2

B1 X X

B2

HARNESS 4 PIN CONNECTION

CAN LOW CAN HIGH

D

WE

X

LOW


LBE / BK

SENSOR POWER

BK / WE

REAR ASC SOLENOID

ANTI - SPIN CONTROL MODULE

X

DIGITAL 0

F1

DIGITAL 1

TxD

DIGITAL 2

RxD

PK/RD

MAINTENANCE JUMPER

/ BOOT

GND A3

6200

C

C1 X

LGN

X

C2 DBE / BK

X

BK X

GY / GN

DRUM SPEED SENSOR SGL BK B BN + A - BE C

LBE

2000 B A C

HARNESS 4 PIN CONNECTIONS BK X

C

ANTI-SPIN CONTROL NO TRAVEL

SD-116 TF SERIES Table of Contents Anti-Spin Control Travel............................. H18

E L E C T R I C A L

Speedometer

1625 27. 1 1425 23. 8

1450 1350 22. 5

1225 1250 20. 4 20. 8 VPM

24. 2

125. 55 0 8

1825 30. 4

17 65 50 0 2

2025 33. 8

HZ

Fuses

Hi/Low Speed Switch

H17 Rear Anti-Spin Control Solenoid Front Anti-Spin Control Solenoid Anti-Spin Control Module


ANTI-SPIN CONTROL TRAVEL

EFF. W/ ALL S/N


SPEEDOMETER


S

I

G

GY / GN

A1 A2

BK

A3

RD / WE

B1

LBE / BL

B2 B3

LGN

C1 C2

BK / WE

LBE / BK

C3

REAR SPEED SENSOR

D1 D2

B A C

DBE / RD

FUSES

WE SGL RD BK

BK / WE

E1

BK

E2 E3 F1

X

FRONT ASC SOLENOID

LBE

D3


RD / WE

WE

F2

B

F3

F12 15A


XC

F11 10A

REAR ASC SOLENOID

F9 10A

GY / GN X

F10 1/A

H18

GY / GN

A


X

A1

F2 10A

IGN

F3 10A

ANALOG IN 0

VALVE 0

ANALOG IN 1

VALVE 1

X

ANALOG IN 2

DIGITAL OUTPUT

X

ANALOG IN 3

F4 15A D3


F5 5A F6 5A

F7 10A

3 LGN / WE

HIGH PK / RD

2

1

F8 30A

D

WE

X

LOW

E1

CAN LOW

X

CAN HIGH DIGITAL 0

/ BOOT

DIGITAL 1 DIGITAL 2

TxD RxD

F1


LBE / BK

SENSOR POWER

BK / WE

PK/RD

GND A3

MAINTENANCE JUMPER 6200

B1 X X

B2

C1 X X

C2


LGN DBE / BK

X

C

BK

X

GY / GN

DRUM SPEED SENSOR SGL BK B BN + A - BE C

LBE

2000 B A C


C

ANTI-SPIN CONTROL TRAVEL

SD-116 TF SERIES Table of Contents Anti-Spin Control Drum Spin ..................... H20

E L E C T R I C A L

Speedometer

1625 27. 1 1425 23. 8

1450 1350 22. 5

1225 1250 20. 4 20. 8 VPM

1825 30. 4

24. 2 15 58 0 25.

17 65 50 0 2

2025 33. 8

HZ

Fuses

Hi/Low Speed Switch



ANTI-SPIN CONTROL DRUM SPIN

EFF. W/ ALL S/N


SPEEDOMETER


S

A1 A2

I

G

A3 B1 B2 B3 C1 C2

BK / WE

B A C

BK RD / WE LBE / BL LGN LBE / BK

RD / WE

C3

REAR SPEED SENSOR DBE / RD

GY / GN

D1 D2 D3

WE SGL RD BK

E1

FRONT ASC SOLENOID LBE BK / WE

BK

E2 E3 F1


FUSES

XB

F12 15A

F3


F11 10A F9 10A

GY / GN

GY / GN

X

F10 1/A

H20

WE

F2

A

XC

A1

F2 10A

IGN

F3 10A

ANALOG IN 0

F4 15A F5 5A

F7 10A

3 LGN / WE

PK / RD

2

1

F8 30A

X

DIGITAL OUTPUT

X

ANALOG IN 3

WE


DIGITAL 0

F1

DIGITAL 1

TxD

DIGITAL 2

RxD

PK/RD

/ BOOT

GND

C1 X

LGN

X

C2

DBE / BK

A3 X BK

6200

SGL BK B BN + A - BE C

X

CAN LOW

X

MAINTENANCE JUMPER

DRUM SPEED SENSOR

X

B2

CAN HIGH

D X

LOW


VALVE 1

ANALOG IN 2

E1

HIGH

B1

VALVE 0

ANALOG IN 1

D3


F6 5A

LBE / BK

SENSOR POWER

BK / WE

REAR ASC SOLENOID


X

C GY / GN

2000 B A C

X

LBE


C

ANTI-SPIN CONTROL DRUM SPIN

SD-116 TF SERIES Table of Contents Anti-Spin Control Wheel Spin ................... H22

E L E C T R I C A L

Speedometer

1625 27. 1 1425 23. 8

1450 1350 24. 2 22. 5

1225 1250 20. 4 20. 8 VPM

125. 55 0 8

1825 30. 4

17 65 50 0 2

2025 33. 8

HZ

Fuses

Hi/Low Speed Switch



ANTI-SPIN CONTROL WHEEL SPIN

EFF. W/ ALL S/N


SPEEDOMETER


S G

GY / GN

A1 A2

I

BK

A3

RD / WE LBE / BL

B1 B2 B3

B A C

DBE / RD

WE RD BK

D1 D2 D3

SGL

BK / WE

E1

BK

E2 WE

F2 F3

XB

F12 15A


F11 10A F9 10A

GY / GN

GY / GN

X

F10 1/A

H22

FRONT ASC SOLENOID

LBE

E3 F1


RD / WE

C3

REAR SPEED SENSOR

FUSES

LGN LBE / BK

C1 C2

BK / WE

A

X

X

F2 10A

IGN B1

ANALOG IN 0

F4 15A F5 5A F6 5A

3 LGN / WE

PK / RD

2

1

F8 30A

VALVE 1

X

ANALOG IN 2

DIGITAL OUTPUT

X

ANALOG IN 3

E1

HIGH

X X

B2


CAN LOW CAN HIGH

D

WE

X

LOW

X

DIGITAL 0

/ BOOT

F1

DIGITAL 1

TxD RxD

DIGITAL 2


VALVE 0

ANALOG IN 1

D3


F7 10A

LBE / BK

SENSOR POWER

BK / WE

REAR ASC SOLENOID


A1

F3 10A

C

PK/RD

GND A3

MAINTENANCE JUMPER 6200

C

C1 X

LGN

X

C2

DBE / BK

X

BK X

GY / GN

DRUM SPEED SENSOR SGL BK B + BN A - BE C

LBE

2000 B A C


C

ANTI-SPIN CONTROL WHEEL SPIN

SD-116 TF SERIES Table of Contents High/Low Speed Low Speed/ Anti-Spin Activated ...... H24

16 25 271.

14 50

1425 238 .

1350 225 .

1225 204 .

1250 208 .

242.

1825 304.

1550 258 .

16 50 27 50

20 25 338 .

VPM HZ

H23

Hi/Low Speed Switch

High Speed Drum Motor Solenoid

E L E C T R I C A L

High Speed Axle Motor Solenoid

HIGH/LOW SPEED LOW SPEED/ANTI-SPIN ACTIVATED

EFF. W/ ALL S/N

SD-116 TF SERIES ELECTRICAL HIGH SPEED AXLE MOTOR SOLENOID ( ON SD-120 ONLY )

31 - BK/OE

HIGH LOW SPEED SWITCH

A

BK B

HIGH

31 - BK/OE

F3 10A

12 - LGN/WE

H24

LOW

A 31 - BK/OE

79 - PK/RD

BK

B

TO ANTI SPIN CONTROL MODULE

HIGH SPEED DRUM MOTOR SOLENOID

HIGH / LOW SPEED LOW SPEED/ANTI-SPIN ACTIVATED

SD-116 TF SERIES Table of Contents High/Low Speed High Speed/ Anti-Spin Inactive......... H26

16 25 271.

14 50

1425 238 .

1350 225 .

1225 204 .

1250 208 .

242.

1825 304.

1550 258 .

16 50 27 50

20 25 338 .

VPM HZ

H25

Hi/Low Speed Switch

High Speed Drum Motor Solenoid

E L E C T R I C A L

High Speed Axle Motor Solenoid

HIGH/LOW SPEED HIGH SPEED/ANTI-SPIN INACTIVE

EFF. W/ ALL S/N

SD-116 TF SERIES ELECTRICAL HIGH SPEED AXLE MOTOR SOLENOID ( ON SD-120 ONLY )

31 - BK/OE

A

HIGH LOW SPEED SWITCH

BK B

HIGH

31 - BK/OE

F3 10A

12 - LGN/WE

H26

LOW

A 31 - BK/OE

79 - PK/RD

BK

B

TO ANTI SPIN CONTROL MODULE

HIGH SPEED DRUM MOTOR SOLENOID

HIGH / LOW SPEED HIGH SPEED/ANTI-SPIN INACTIVE

SD-116 TF SERIES Table of Contents Automatic Vibration/Impact Meter Vibration Off ................. H28

Impact Meter

Vibration On/Off Switch VPM Meter Speedometer

1625 27. 1

1425 23. 8

1350 22. 5

1225 20. 4

1250 2 0 .8

1450 24. 2

1825 30. 4

1550 25. 8

1650 2750

2025 33. 8

VPM HZ

Automatic/Manual Vibration Switch

H27

Fuses

High/Low Amplitude Switch

Low Vibration Solenoid High Vibration Solenoid Automatic Vibration & Impact Meter Control Module

E L E C T R I C A L

Vibration Speed Sensor

Rear Speed Sensor

AUTOMATIC VIBRATION/ IMPACT METER VIBRATION OFF

EFF. W/ ALL S/N

SD-116 TF SERIES ELECTRICAL VIBRATION ON/OFF

AUTO/MANUAL VIBRATION SELECT SWITCH AUTO. F5 5A

1

16- DBE / RD

39- LPE

2

HIGH VIBRATION SOLENOID

HIGH / LOW AMPLITUDE SWITCH 3

40-YW / BN 2

3 MANUAL

1

HIGH

89- YW / WE 1 2

LOW

3 BK

4

38- WE / OE

1 55- DBE / BK

SPEEDOMETER

VPM METER

2

16- DBE / RD

IMPACT METER

3 BK

S

S

I

S

I G

G

I G

Zd1 F10 1/A

4

LOW VIBRATION SOLENOID

ZENER DIODE 500 OHM 5.1 V 5 WATT

36- LGN RESISTOR

H28

500 OHM 3 WATT

43- LBE / RD

YW IGN SENSOR POWER 44 - DGN/YW

B A

45- BK / WE

C

ANALOG IN 0

WE SGL RD

VALVE 0

ANALOG IN 1

VALVE 1

ANALOG IN 2

DIGITAL OUTPUT

ANALOG IN 3

BK

CAN LOW CAN HIGH

BK

DIGITAL 0


/ BOOT 67- LGN

TxD

DIGITAL 1

RxD

DIGITAL 2 GND

68- DBE / BK

45- BK / WE

B A 16- DBE / RD

C

WE RD BK

BK

SGL

MACHINE NOT IN MOTION

BK

AUTO VIBRATION & IMPACT METER CONTROL MODULE

REAR SPEED SENSOR

AUTOMATIC VIBRATION / IMPACT METER - VIBRATION OFF

SD-116 TF SERIES Table of Contents Automatic Vibration/Impact Meter Manual/Low Amplitude..... H30

Impact Meter


1625 27. 1

1425 23. 8

1350 22. 5

1225 20. 4

1250 2 0 .8

1450 24. 2

1825 30. 4

1550 25. 8

1650 2750

2025 33. 8

VPM HZ


H29

Fuses



E L E C T R I C A L


Rear Speed Sensor

AUTOMATIC VIBRATION/ IMPACT METER MANUAL/LOW AMPLITUDE

EFF. W/ ALL S/N

SD-116 TF SERIES ELECTRICAL AUTO/MANUAL VIBRATION SELECT SWITCH

VIBRATION ON /OFF

HIGH / LOW AMPLITUDE SWITCH


AUTO. F5 5A

1

16- DBE / RD

39- LPE

2

3

40-YW / BN 2

3 MANUAL

1

HIGH

89- YW / WE

1 2

LOW

3 BK

4

38- WE / OE

1 55- DBE / BK

SPEEDOMETER

S

S

I

S

I G

G

2

16- DBE / RD

IMPACT METER

VPM METER

3 BK

I G

Zd1 F10 1/A

4



36- LGN RESISTOR 500 OHM

H30

3 WATT

43- LBE / RD


B A

45- BK / WE

C

WE RD

ANALOG IN 0

SGL

VALVE 0

ANALOG IN 1

VALVE 1

ANALOG IN 2

DIGITAL OUTPUT

ANALOG IN 3

BK

CAN LOW CAN HIGH

BK

DIGITAL 0


/ BOOT

DIGITAL 1

TxD

DIGITAL 2

RxD

67- LGN

GND 68- DBE / BK

45- BK / WE

B A 16- DBE / RD

C

WE

BK

SGL

RD BK

MACHINE IN MOTION

BK

REAR SPEED SENSOR


AUTOMATIC VIBRATION / IMPACT METER - MANUAL/LOW AMPLITUDE

SD-116 TF SERIES Table of Contents Automatic Vibration/Impact Meter Manual/High Amplitude.... H32

Impact Meter


1625 27. 1

1425 23. 8

1350 22. 5

1225 20. 4

1250 2 0 .8

1450 24. 2

1825 30. 4

1550 25. 8

1650 2750

2025 33. 8

VPM HZ


H31

Fuses



E L E C T R I C A L


Rear Speed Sensor

AUTOMATIC VIBRATION/ IMPACT METER MANUAL/HIGH AMPLITUDE

EFF. W/ ALL S/N


VIBRATION ON /OFF



AUTO. F5 5A

1

39- LPE

2

16- DBE / RD

3

40-YW / BN 2

3 MANUAL

1

HIGH

89- YW / WE 1 2

LOW

3 BK

4

38- WE / OE

1 55- DBE / BK

SPEEDOMETER

S

S

I

3 BK

S

I G

G

2

16- DBE / RD

VPM METER

I G

Zd1 F10 1/A

4



36- LGN RESISTOR

H32

500 OHM 3 WATT

43- LBE / RD


B A

45- BK / WE

C

WE RD BK

ANALOG IN 0

SGL

VALVE 0

ANALOG IN 1

VALVE 1

ANALOG IN 2

DIGITAL OUTPUT

ANALOG IN 3 CAN LOW CAN HIGH

BK

DIGITAL 0


/ BOOT 67- LGN

TxD

DIGITAL 1

RxD

DIGITAL 2 GND

68- DBE / BK

45- BK / WE

B A 16- DBE / RD

C

WE RD BK

BK

SGL

MACHINE IN MOTION

BK


REAR SPEED SENSOR

AUTOMATIC VIBRATION / IMPACT METER - MANUAL/HIGH AMPLITUDE

SD-116 TF SERIES Table of Contents Automatic Vibration/Impact Meter Automatic/Low Amplitude.... H34

Impact Meter


1625 27. 1

1425 23. 8

1350 22. 5

1225 20. 4

1250 2 0 .8

1450 24. 2

1825 30. 4

1550 25. 8

1650 2750

2025 33. 8

VPM HZ


H33

Fuses



E L E C T R I C A L


Rear Speed Sensor

AUTOMATIC VIBRATION/ IMPACT METER AUTOMATIC/LOW AMPLITUDE

EFF. W/ ALL S/N

SD-116 TF SERIES ELECTRICAL AUTO/MANUAL VIBRATION SELECT SWITCH F5 5A

AUTO. 1

16- DBE / RD

VIBRATION ON /OFF

39- LPE

2

HIGH / LOW AMPLITUDE SWITCH 3

40-YW / BN 2

3 MANUAL

1

HIGH


89- YW / WE

1 2

LOW

3 BK

4

38- WE / OE

1 55- DBE / BK

SPEEDOMETER

S

VPM METER

S

I

S

I G

G

3 BK

I G

Zd1 F10 1/A

36- LGN

H34

2

16- DBE / RD

IMPACT METER

4


ZENER DIODE 500 OHM 5.1 V 5 WATT RESISTOR 500 OHM 3 WATT

43- LBE / RD

YW IGN SENSOR POWER

44 - DGN/YW

B A C

45- BK / WE

ANALOG IN 0

WE SGL RD BK

VALVE 0

ANALOG IN 1

VALVE 1

ANALOG IN 2

DIGITAL OUTPUT

ANALOG IN 3 CAN LOW CAN HIGH

BK

DIGITAL 0


DIGITAL 2

45- BK / WE B A C

16- DBE / RD

WE RD BK

/ BOOT 67- LGN

TxD

DIGITAL 1 GND

RxD 68- DBE / BK BK

SGL

MACHINE IN MOTION


BK

REAR SPEED SENSOR

AUTOMATIC VIBRATION / IMPACT METER - AUTOMATIC/ LOW AMPLITUDE

SD-116 TF SERIES Table of Contents Automatic Vibration/Impact Meter Automatic/High Amplitude... H36

Impact Meter


1625 27. 1

1425 23. 8

1350 22. 5

1225 20. 4

1250 2 0 .8

1450 24. 2

1825 30. 4

1550 25. 8

1650 2750

2025 33. 8

VPM HZ


H35

Fuses



E L E C T R I C A L


Rear Speed Sensor

AUTOMATIC VIBRATION/ IMPACT METER AUTOMATIC/HIGH AMPLITUDE

EFF. W/ ALL S/N


VIBRATION ON /OFF


AUTO. F5 5A

1

39- LPE

2

16- DBE / RD

3

40-YW / BN 2

3 MANUAL

1

HIGH


89- YW / WE 1 2

LOW

3 BK

4

38- WE / OE

1 55- DBE / BK

SPEEDOMETER

S

VPM METER

S

I

IMPACT METER

S

I G

G

2

16- DBE / RD

3 BK


ZENER DIODE

I G

Zd1 F10 1/A

4

500 OHM 5.1 V 5 WATT

36- LGN RESISTOR 500 OHM

H36

3 WATT

43- LBE / RD


B A

45- BK / WE

C

WE RD

ANALOG IN 0

SGL

VALVE 0

ANALOG IN 1

VALVE 1

ANALOG IN 2

DIGITAL OUTPUT

ANALOG IN 3

BK

CAN LOW CAN HIGH

BK

DIGITAL 0


/ BOOT

DIGITAL 1

TxD

DIGITAL 2

RxD

67- LGN

GND 68- DBE / BK

45- BK / WE

B A 16- DBE / RD

C

WE RD BK

BK

SGL

MACHINE IN MOTION

BK

REAR SPEED SENSOR


AUTOMATIC VIBRATION / IMPACT METER - AUTOMATIC/ HIGH AMPLITUDE

SD-116 TF SERIES Table of Contents Automatic/Variable/ Impact Meter ................ H38

Impact Meter


1625 27. 1

1425 23. 8

1350 22. 5

1225 20. 4

1250 2 0 .8

1450 24. 2

1825 30. 4

1550 25. 8

1650 2750

2025 33. 8

VPM HZ


H37

Fuses



E L E C T R I C A L


Rear Speed Sensor

AUTOMATIC/VARIABLE/ IMPACT METER

EFF. W/ ALL S/N

S

S

I

S

I G

G


IMPACT METER

VPM METER

SPEEDOMETER

I G

200 OHM EACH F10 1/A

36- LGN 43- LBE / RD 200 OHM

TO VIB SPEED SENSOR SIGNAL B TERMINAL

AUTO/MANUAL VIBRATION SELECT SWITCH

45 - BK / WE

2

200 OHM

43- LBE / RD


VIBRATION ON /OFF

AUTO. 3

1 2 3 4 5 D D D D D E E E E E E E E E E P P P P P S S S S S

39-LPE

3

40- YW / BN

1

MANUAL

15 14

16

VARIABLE FREQUENCY SWITCH

11

HIGH

54- LBE / BK

55- DBE / BK 2

1

13 12 BK

LOW

48- WE / BK

F5 5A

C

B

A

38 - WE / OE


16 - DBE / RD 16- DBE / RD 54- LBE / BK 41- DPE

1 16- DBE / RD Zd1

H38

REAR SPEED SENSOR


48- WE / BK

2 3 BK

4

RESISTOR 500 OHM 3 WATT

L G S E D K R B W

1 IGN

B A C

SENSOR POWER

K B

VALVE 0

ANALOG IN 1

VALVE 1

ANALOG IN 2

DIGITAL OUTPUT

ANALOG IN 0 90-YW

ANALOG IN 3 44- DGN / YW

CAN LOW

B R W K D E S G L


ANALOG IN 1

VALVE 1

ANALOG IN 2

DIGITAL OUTPUT

/ BOOT

40- YW / BN


CAN HIGH DIGITAL 0

DIGITAL 1

TxD

DIGITAL 1

DIGITAL 2

RxD

DIGITAL 2

GND

AUTO VIB. & IMPACT METER CONTROL MODULE

42- GY / WE

4

CAN LOW

DIGITAL 0

C A B

BK

VALVE 0

ANALOG IN 3

CAN HIGH BK

3

SENSOR POWER

ANALOG IN 0

45- BE / WE

2

IGN

BK

/ BOOT 60- PK / WE

TxD RxD GND

61- LGN / OE

64- RD / BE BK

63- GY

PROGRAM PORT

VARIABLE VIBRATION CONTROL MODULE

44- DGN / YW

PROGRAM PORT

AUTOMATIC/ VARIABLE / IMPACT METER

SD-116 TF SERIES Table of Contents Grid Heater..............................H40

E L E C T R I C A L

Grid Heaters

1625 2 7.1

1450

1425

1 82 5

2 4.2

2 3.8

1350 2 2.5

1225

1250

2 . 04

2 . 08

3 0.4

1 55 0 2 5.8

1650 2750

2025 3 3.8

V PM HZ

Fuel Solenoid

H39

Grid Heater Indicator (On Instrument Cluster) Temperature Sensor Alternator Grid Heater Relays Grid Heater Control Module

Fuses

Fuel Solenoid Relay Grid Heater Control Module Seat Timer

GRID HEATER

EFF. W/ ALL S/N

SD-116 TF SERIES ELECTRICAL SEAT TIMER ENGINE RUN CONDITION COM

+

N/C

N/O 47- WE / BN

INIT

FUEL SOLENOID RELAY HOLD 87A BK

30 87 71- PK

86

A

A

C

C

B

B

RD

FUEL SOLENOID

BK WE PULL

85 50- RD

GRID HEATER CONTROL MODULE

GRID HEATER

52- LGN / RD

BK IGN

H40

BE

A

LIGHT OUT

RD

B

GRID RELAY OUT

OE

C

GRID RELAY OUT

PE

D

START IN

GN

E

N/A

BN

F

RD 37 - BN /RD

RD

GRID HEATER RELAYS 53- LGN WE 51- RD A

D N G YW

BK

B

. P M E T

RD 5.0 RD 37- BN / RD

BK

GRID HEATER INDICATOR

BK

CAP B+

W

A STATOR 92- RD / BK

B

O O O O O

O O O O O O O O O O O O

A 34- BN

TEMPERATURE SENSOR

O O r O O t O O o a l u g e R

BK

D+

ALTERNATOR F9 10A

GRID HEATER

GRID HEATER

SD-116 TF SERIES Table of Contents Gauges ....................................H42

VPM Meter

1625

23.8

1350 22.5

1250 20.8

1450 24.2

1550 25.8

1650 2750

Engine Oil Pressure Sender

Hydraulic Oil Temperature Gauge

27.1

1425

1225 20.4

E L E C T R I C A L

Engine Oil Pressure Gauge

1825 30.4

2025 33.8

VPM HZ

Voltmeter Speedometer Impact Meter

H41 Fuses


Hydraulic Oil Temperature Sender

Rear Speed Sensor GAUGES

EFF. W/ ALL S/N

SD-116 TF SERIES ELECTRICAL FROM WORK LIGHT SWITCH TERM. 3

HYDRAULIC OIL TEMPERATURE

VOLTMETER

73 - 0E

OIL PRESSURE 73 - 0E

SPEEDOMETER 73 - 0E

VPM METER

IMPACT

73 - 0E

73 - 0E 73 - 0E

36 - LGN

36 - LGN

36 - LGN

36 - LGN

36 - LGN

43 - LBE/RD 36 - LGN

44 - DGN/YW

TO AUTOVIB. & IMPACT METER CONTROL MODULE, TERM. B1

82 - YW/GN

H42

45 - BK/WE

F10 10A

TO AUTOVIB. & IMPACT METER CONTROL MODULE, TERM. E1 P B A

83 - DGN/BK

C

WE RD BK

SGL


BK

ENGINE OIL PRESSURE SENDER

TO AUTOVIB. & IMPACT METER CONTROL MODULE, TERM. D3 TO ANTISPIN CONTROL MODULE, E1

T

B A C

WE RD BK

SGL

REAR SPEED SENSOR

BK

HYDRAULIC OIL TEMPERATURE SENDER

GAUGES

SD-116 TF SERIES Table of Contents Instrument Cluster .................H44

Coolant Level Hydraulic Oil Temperature Indicator (In Indicator (In Instrument Cluster) Instrument Cluster) Coolant Temperature Engine Coolant Sender Engine Oil Temperature Gauge Air Filter Pressure Sender Tachometer Restriction Switch

H43

Grid Heater Indicator (In Instrument Cluster) 1625 27. 1 1450

1425 23. 8

1250 20. 8

Alternator Charge Indicator (In Instrument Cluster)

1825 30. 4

24. 2 1350 22. 5

1225 20. 4

1550 25. 8 1650 2750

2025 33. 8

VPM HZ

E L E C T R I C A L

Fuel Level Gauge Air Filter Restriction Indicator (In Instrument Cluster)

Fuses

Low Oil Pressure Indicator (In Instrument Cluster) INSTRUMENT CLUSTER

EFF. W/ ALL S/N

SD-116 TF SERIES ELECTRICAL ALTERNATOR CHARGE INDICATOR

I

ENGINE COOLANT TEMERATURE GAUGE

LOW OIL PRESSURE INDICATOR FUEL LEVEL GAUGE

TACHOMETER I

I

RPM G

T

T G

DIODE AIR FILTER RESTRICTION INDICATOR

G

BACK LIGHT

BACK LIGHT

BACK LIGHT

GRID HEATER INDICATOR

H44

14 - LGN/BK

HYDRAULIC OIL TEMPERATURE INDICATOR

COOLANT LEVEL INDICATOR

73 - OE 78 - GY

FROM LIGHT SWITCH

34 - BN

15 - DBE/WE

77 - TN

30 - LGN/BE

35 - WE/RD

FROM SIGNAL OPTION 37 - BN/RD

FROM B TERM ON GRID HEATER CONTROL MODULE

85 - DGN

FROM FUEL GAUGE SENDER

5 - YW 4 - OE/BE

34 - BN

P

FROM ALTERNATOR D+ TERM LAMP RESISTOR 68 OHM \ 5 WATT F9 10A

ENGINE OIL PRESSURE SENDER

T


FROM ALTERNATOR W TERM

COOLANT TEMPERATURE SENDER

INSTRUMENT CLUSTER

SD-116 TF SERIES Table of Contents Fuses .......................................H46

Voltmeter VPM Meter

Instrument Cluster

Work Lights

E L E C T R I C A L

Beacon Light Air Filter Backup Alarm

Engine Oil Pressure Gauge

Coolant Level Sensorr

Speedometer 1625 27. 1 1450

1425 23. 8

1225 20. 4

1250 20. 8

1350 22. 5

24. 2

1550 25. 8

1825 30. 4

1650 2750

2025 33. 8

VPM HZ

Power Port Seat Switch Park Brake (Under Seat) Switch

H45

Automatic/Manual Vibration Switch Fuel Throttle Solenoid

Impact Meter

Fuses

Horn

Anti-Spin Control Module

Ignition Switch

Hydraulic Oil Temperature Switch

FUSES

EFF. W/ ALL S/N

SD-116 TF SERIES ELECTRICAL FUSE NO

H46

AMPERE RATING

CIRCUIT KEY SWITCH, E-STOP, IGNITION, FUEL & THROTTLE SOLENOID HOLD CIRCUITS, SEAT SWITCH AND PARK BRAKE

F1

15 AMP

F2

10 AMP

HORN, AIR FILTER, HYDRAULIC OIL TEMPERATURE & COOLANT LEVEL CIRCUITS

F3

10 AMP

TWO SPEED CIRCUIT & BACK UP ALARM

F4

15 AMP

WORK LIGHTS, BEACON & TURN SIGNAL / HAZARD LIGHTS

F5

5 AMP

AUTO / MANUAL VIBRATION & IMPACT METER

F6

5 AMP

ANTI-SPIN CONTROL

F7

10 AMP

POWER PORT

F8

30 AMP

THROTTLE SOLENOID PULL-IN CIRCUIT

F9

10 AMP

INSTRUMENT CLUSTER

F10

10 AMP

VOLTMETER, OIL PRESSURE, SPEEDOMETER, VPM & IMPACT METER GAUGES

F11

10 AMP

CAB OPTIONS

F12

10 AMP

STRIKE OFF BLADE OPTION

FUSES

SD-116 TF SERIES / ROPS/FOPS REPLACEMENT TABLE OF CONTENTS............................................. J1.1 ROPS/FOPS.............................................................. J1.2 Tools Required ..................................................... J1.2 Safety ................................................................... J1.2 Removal ............................................................... J1.3 Inspection ............................................................. J1.4 Installation ............................................................ J1.4

ROPS/FOPS

J1.1

032503AA

TABLE OF CONTENTS

SD-116 TF SERIES/ ROPS/FOPS REPLACEMENT TOOLS REQUIRED: • Safety glasses • Torque multiplier

• Loctite number 271

• Sockets and wrenches for these models • Lifting device with straps and chains, and sufficient capacity for lifting weight specified on ID tag located on the ROPS/FOPS

SAFETY Appropriate safety practices should be observed at all times. Refer to the AEM Safety Manual for safety instructions.

J1.2

These safety practices include the use of safety glasses and adherence to common safety procedures, which should include safety practices pertaining to your specific location and situation. WARNING: Lifting equipment should be in perfect condition and have sufficient capacity for lifting the weight specified on the ID tag located on the rollover protective structure (ROPS)/falling object protective structure (FOPS). Take note of the lifting height to ensure that the ROPS/FOPS will clear the unit, and check for overhead power lines or other obstructions. When attaching chains or straps, examine them closely to ensure they are free from defects.

Figure 1-1

ROLLOVER PROTECTIVE STRUCTURE (ROPS)

SD-116 TF SERIES/ ROPS/FOPS REPLACEMENT REMOVAL NOTE To ensure the safe removal and installation of your ROPS/ FOPS, refer to and view the service video which is available from your distributor. WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions. 1. Attach the straps or chains of the suitable lifting device to the ROPS/FOPS (1, Figure 1-1). 2. Once the lifting device is attached, take out the slack so the straps or chains are fully supporting the ROPS/FOPS (1).

J1.3

3. Remove the plastic plugs (10) covering the ROPS attaching hardware. 4. Remove the capscrews (2), hex nuts (4), and flatwashers (3). WARNING: All assisting personnel should stay clear of pinch points and avoid standing under the suspended ROPS/FOPS at all times. 5. Check above the unit for obstructions. Lift the ROPS/FOPS (1) clear of the frame with the suitable lifting device and move to desired location.

Figure 1-1


SD-116 TF SERIES/ ROPS/FOPS REPLACEMENT INSPECTION 1. Check the ROPS/FOPS (1, Figure 1-1) for signs of fatigue or cracks. If cracks are found, the machine should be placed out of service and the ROPS/FOPS and all mounting hardware replaced. 2. Check all mounting hardware for damage and wear. Replace as necessary.

INSTALLATION 1. Attach a suitable lifting device with straps or chains to the ROPS/FOPS. WARNING: All assisting personnel should stay clear of pinch points and avoid standing under the suspended ROPS/FOPS at all times.

J1.4

2. Check overhead for obstructions and lift the ROPS/FOPS (1) slowly over the unit and lower it into position. 3. Apply Loctite #271 to capscrews (2). 4. Install the capscrews (2), hex nuts (4), and flatwashers (3) and secure the ROPS/FOPS. 5. Torque the capscrews (2) to 637 N·m (470 lbs-ft.). 6. Install the plastic plugs (10). 7. Remove the lifting device from the ROPS/FOPS (1).

Figure 1-1


SD-116 TF SERIES / SWIVEL BEARING REPLACEMENT TABLE OF CONTENTS............................................. J2.1 SWIVEL BEARING.................................................... J2.2 Tools Required ..................................................... J2.2 Safety ................................................................... J2.2 Removal and Disassembly................................... J2.4 Cleaning and Inspection....................................... J2.7 Assembly.............................................................. J2.7

J2.1

032503AA

TABLE OF CONTENTS

SD-116 TF SERIES / SWIVEL BEARING REPLACEMENT TOOLS REQUIRED: • Safety glasses

• Basic sockets and wrenches

• Torque wrench

• Loctite number 271

• Feeler gauges

• Petroleum jelly

• Sledge hammer

• Heat resistant gloves

• Non-residue type solvent • Straps or chains • Anti-seize • Lifting device, such as a 3,000 lb. Auto-Crane that is in perfect condition

SAFETY

J2.2

Accidents are caused by failure to follow simple, fundamental safety rules and precautions. Refer to the AEM Safety Manual for safety instructions. Most accidents can be avoided by paying attention, using common sense, and following the instructions. WARNING: Improper maintenance can be hazardous. Study the Operator’s Manual and Service Manual before starting, operating, maintaining, fueling, or servicing the compactor. 032503AA

No unauthorized person should be allowed to operate, service, or maintain this compactor. Read and understand all unit mounted safety labels before starting, maintaining, fueling, or servicing this unit. WARNING: Unexpected machine motion or moving parts can cut or crush.

Figure 1-1

TOOLS REQUIRED AND SAFETY

SD-116 TF SERIES / SWIVEL BEARING REPLACEMENT WARNING: Oil under pressure can cause serious cuts or injury. Exercise extreme caution when working around pressurized hydraulic systems. Do not work on a hydraulic system while the engine is running or pressure is still in the system. Ensure all pressure is relieved from the system before performing maintenance. When handling oil, grease, or other chemical substances, observe the product related safety regulations. Substances such as oil, grease or fuel could be hazardous to health if used incorrectly. Avoid ingestion, skin contact, and breathing fumes.

J2.3

Keep hands and fingers from between small parts. Wear protective gear such as safety glasses, heavy gloves, and safety shoes. Do not perform any work on the equipment that is unauthorized. Avoid whenever possible servicing, cleaning, or examining the compactor with the engine running. Before starting any work, check the de-energized parts for the presence of power. Ground or short circuit them in addition to insulating adjacent live parts and elements.

032503AA

NOTE: Clean the machine, especially connections, of any traces of oil, fuel, or preservatives before carrying out maintenance or repair. Never use aggressive detergents. Use lint free cleaning rags.

Figure 1-1


SD-116 TF SERIES / SWIVEL BEARING REPLACEMENT WARNING: When draining fluids, ensure that adequate sealable containers are available and that every care is taken to prevent spillage. Always ensure waste fluids are disposed of in an environmentally safe manner.

REMOVAL AND DISASSEMBLY WARNING: Crushing hazard. Improper support of the frame could cause death or severe injury. Ensure that adequate supports are used prior to working in or around the articulation joint area.

J2.4

1. Park the machine on a level surface with ample clearance for working. 2. Block the tires of the machine to prevent the machine from moving. Refer to Figure 1-2. 3. Block the drum frame in such a manner that it can be moved back when the articulation joint is unbolted. WARNING: Exercise extreme caution when working around pressurized hydraulic systems. Do not work on a hydraulic system while the engine is running or pressure is still in the system. Ensure all pressure is relieved from the system before disconnecting hydraulic lines and performing maintenance. 4. Tag and disconnect the hydraulic lines to the propulsion, vibration, and blade systems that are routed between the drum frame and rear frame. Cap or plug all lines and openings. 5. Tag and disconnect any electrical harnesses connected between the two frames.

Block Drum Frame

Figure 1-2

JACK AND BLOCK PLACEMENT

SD-116 TF SERIES SWIVEL BEARING REPLACEMENT WARNING: Exercise extreme caution when working around pressurized hydraulic systems. Do not work on a hydraulic system while the engine is running or pressure is still in the system. Ensure all pressure is relieved from the system before disconnecting hydraulic lines and performing maintenance. 6. Remove the drum assembly (1, Figure 1-3) and scraper from the drum frame (2). Refer to the Drum and Drum Drive Teardown and Rebuild Procedure J3. WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions.

J2.5

7. Attach an adequate lifting/supporting device to the drum frame (2). 8. Remove the capscrews (27) and washers (28) from the lock plate (26) on the drum frame and swivel horizontal oscillating pin (5). 9. Remove the lock plate (26). 10. Loosen the stop nut (6) on the drum frame oscillating pin (5). 11. Remove the pin (5), washer (7) and nut (6) from the swivel and drum frame. 12. Remove the hitch pin (16) and remove the lock pin (9). 13. Move the drum frame clear of the swivel. 14. Remove and discard the bearings (4) and dust seals (24 and 25) from the drum frame (2).

Figure 1-3

DRUM FRAME AND SWIVEL BEARINGS

SD-116 TF SERIES SWIVEL BEARING REPLACEMENT 15. Tag and disconnect the hydraulic lines to the steering cylinder (6, Figure 1-4). Cap and plug all lines and openings. 16. Support the rod end of the steer cylinder (6). 17. Remove the roll pin (12, Figure 1-3) and cylinder pivot pin (11) from the steering cylinder rod end.

NOTE: Steer cylinder barrel ends to frame attaching hardware shown in this illustration.

18. Remove the steer cylinder rod end from the swivel (3). 19. Remove and discard the bushings (10) from the top of the frame swivel (3).

Refer to Figure 1-3 for rod end attaching hardware.

20. Repeat steps 15 through 19 for the other steer cylinder.

J2.6

Figure 1-4

REAR FRAME AND STEER CYLINDERS

SD-116 TF SERIES SWIVEL BEARING REPLACEMENT WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions. 21. Attach an adequate lifting device to the swivel (3, Figure 15). 22. Remove the capscrews (27) and washers (28) from the lock plate (26) on vertical swivel oscillating pin (5, Figure 15). 23. Remove the lock plate (26). 24. Remove the stop nut (6) and washer (7) from the pin (5). 25. Remove the pin (5) from the swivel (3) and rear frame. 26. Using the lifting device, remove the swivel (3).

J2.7

27. Remove and discard the bearings (7) and dust seals (9 and 10, Figure 1-4) from the top and bottom of the rear frame swivel mounting sleeve.

CLEANING AND INSPECTION 1. Ensure all parts are cleaned in a type solvent. 2. Inspect all fasteners for damage. 3. Discard all gaskets and seals.

ASSEMBLY AND INSTALLATION 1. Install the drum frame oscillating pin (5, Figure 1-5) in the swivel (3) and secure temporarily with the washer (7) and stop nut (6). Do not torque the pin at this time.

Figure 1-5


SD-116 TF SERIES SWIVEL BEARING REPLACEMENT 2. Apply a coat of grease to the new bearings (7, Figure 1-6). NOTE: Bearings are to be cooled to -18°C (0°F) for 2 to 4 hours before installation. 3. Lower the temperature of the bearings. 4. Install the new bearings (7) into the top and bottom of the rear frame swivel mounting sleeve. 5. Install new dust seals (9 and 10) onto the top and bottom of the rear frame swivel mounting sleeve

NOTE: Steer cylinder barrel ends to frame attaching hardware shown in this illustration. Refer to Figure 1-5 for rod end attaching hardware.

J2.8

Figure 1-6

REAR FRAME AND STEER CYLINDERS

SD-116 TF SERIES SWIVEL BEARING REPLACEMENT WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions. 6. Attach an adequate lifting device to the swivel (3, Figure 17). 7. Apply a light coat of Never-Seize to the large diameter of the vertical swivel oscillating pin (5). 8. Using the adequate lifting device, install the swivel (3) to the rear frame swivel mount, being careful not to damage the drum frame horizontal oscillating pin temporarily installed in the swivel. 9. Install the vertical swivel oscillating pin (5) into the swivel (3) and rear frame mounting sleeve.

J2.9

10. Install the washer (7) and stop nut (6) onto the oscillating pin (5). 11. Torque the pin (5) to 340 N·m (250 lb-ft.). 12. Install the new O-ring (41). 13. Install the lock plate (26). 14. Apply Loctite #271 to the capscrews (27). 15. Install the washers (28) and capscrews (27) into the lock plate (26). 16. Torque the capscrews (27) to 61 N·m (45 lb-ft.). 17. Apply a coat of grease to the new bushings (10). 18. Install the new bushings (10) into the top of the swivel (13).

Figure 1-7


SD-116 TF SERIES SWIVEL BEARING REPLACEMENT 19. Connect the steer cylinder (6, Figure 1-6) rod end to the swivel (3). 20. Install the steer cylinder pivot pin (11, Figure 1-7) and connect the steer cylinder to the frame swivel (3). Install the roll pin (12). 21. Repeat steps 19 and 20 for the other steer cylinder. 22. Uncap, unplug and connect the hydraulic lines to the steer cylinders as tagged during disassembly. 23. Apply a coat of grease to the new bearings (4). NOTE: Bearings are to be cooled to -18°C (0°F) for 2 to 4 hours before installation. 24. Lower the temperature of the bearings (4). 25. Install the bearings (4) into the drum frame (2).

J2.10

26. Install the dust seals (24 and 25) onto the drum frame (2). WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions. 27. Attach an adequate lifting device to the drum frame (2). 28. Using the lifting device, align the drum frame (2) with the swivel (3). Keep the lifting device attached to the drum frame. 29. Remove the temporarily installed oscillating pin (5) from the swivel (3).

swivel

horizontal

30. Apply a light coat of Never-Seize to the large diameter of the pin (5).

Figure 1-7


SD-116 TF SERIES SWIVEL BEARING REPLACEMENT NOTICE: During installation of the horizontal swivel oscillating pin (5. Figure 1-7), and ensure the weight of the drum frame (2) is off of the pin so as not to cause damage to the pin. 31. Install the horizontal swivel oscillating pin (5, Figure 1-7) into the drum frame (2) and swivel (3). 32. Ensure the pin (5) is centered in the drum frame (2). 33. Install the washer (7) and stop nut (6) onto the pin (5). 34. Torque the pin (5) to 340 N·m (250 lbs-ft.). 35. Install the lock plate (26). 36. Apply Loctite #271 to the capscrews (27). 37. Install the washers (28) and capscrews (27) into the lock plate (26). 38. Torque the capscrews (27) to 61 N·m (45 lb-ft.).

J2.11

39. Install the drum assembly (1) and scraper into the drum frame (2). Refer to the Drum and Drum Drive Teardown and Rebuild Procedure J3. 40. Connect the hydraulic lines to the propulsion, vibration, and blade systems. 41. Connect the electrical harness between the two frames. 42. Lubricate the articulation joint and pins, steer cylinder pins, steer cylinder bearings and swivel pins. Refer to the Operation and Maintenance Manual for maintenance instructions. 43. Operate the machine and check for proper operation and leaks. 44. It is recommended that after the first 50 to 100 hours of operation, the articulation joint fasteners be checked for proper torque.

Figure 1-7


SD-116 TF SERIES DRUM AND DRUM DRIVE TABLE OF CONTENTS ............................................. J3.1 DRUM AND DRUM DRIVE........................................ J3.2 Tools Required .............................................. J3.2 Safety............................................................ J3.2 Removal and Disassembly............................ J3.4 Drum Drive Motor Removal and Disassembly ...................................................................... J3.7 Drum Drive Side Disassembly ...................... J3.8

J3.1

Carrier Disassembly...................................... J3.9 Vibration Side Disassembly ....................... J3.10 Cleaning and Inspection ..............................J3.11 Vibration Side Assembly ..............................J3.11 Carrier Assembly......................................... J3.14 Drive Side Assembly and Installation .................................................................... J3.15 Drum Drive Assembly and Installation .................................................................... J3.17 Assembly and Installation ........................... J3.19

DRUM AND DRUM DRIVE

032503AA

TABLE OF CONTENTS

SD-116 TF SERIES DRUM AND DRUM DRIVE TOOLS REQUIRED: • Safety glasses

• Basic sockets and wrenches

• Blue Loctite

• Feeler gauges

• Sledge hammer

• Heat resistant gloves

• Non-residue type solvent • Acetylene torch • Straps or chains

• Loctite primer-T

• Anti-seize

• Petroleum jelly

• Loctite number 271 red and blue

• Torque wrench

• Lifting device, such as a 3,000 lb. Auto-Crane that is in perfect condition

SAFETY

J3.2

Accidents are caused by failure to follow simple, fundamental safety rules and precautions. Refer to the AEM Safety Manual for safety instructions. Most accidents can be avoided by paying attention, using common sense, and following the instructions. WARNING: Improper maintenance can be hazardous. Study the Operator’s Manual and Service Manual before starting, operating, maintaining, fueling, or servicing the compactor.

032503AA

No unauthorized person should be allowed to operate, service, or maintain this compactor. Read and understand all unit mounted safety labels before starting, maintaining, fueling, or servicing this unit. WARNING: Unexpected machine motion or moving parts can cut or crush.

Figure 1-1


SD-116 TF SERIES DRUM AND DRUM DRIVE WARNING: Oil under pressure can cause serious cuts or injury. Exercise extreme caution when working around pressurized hydraulic systems. Do not work on a hydraulic system while the engine is running or pressure is still in the system. Ensure all pressure is relieved from the system before performing maintenance. When handling oil, grease, or other chemical substances, observe the product related safety regulations. Substances such as oil, grease or fuel could be hazardous to health if used incorrectly. Avoid ingestion, skin contact, and breathing fumes.

J3.3

Keep hands and fingers from between small parts. Wear protective gear such as safety glasses, heavy gloves, and safety shoes. Do not perform any work on the equipment that is unauthorized. Avoid whenever possible servicing, cleaning, or examining the compactor with the engine running. Before starting any work, check the de-energized parts for the presence of power. Ground or short circuit them in addition to insulating adjacent live parts and elements.

032503AA

NOTE: Clean the machine, especially connections, of any traces of oil, fuel, or preservatives before carrying out maintenance or repair. Never use aggressive detergents. Use lint free cleaning rags. NOTE: Take extra care when working around or on the hydraulic system to ensure its complete cleanliness.

Figure 1-1


SD-116 TF SERIES DRUM AND DRUM DRIVE WARNING: When draining fluids, ensure that adequate sealable containers are available and that every care is taken to prevent spillage. Always ensure waste fluids are disposed of in an environmentally safe manner.

REMOVAL AND DISASSEMBLY 1. Park the machine on a level surface with ample clearance for working. This should include space to allow for rolling the drum assembly out from the frame of the compactor. 2. Install the articulation lock pin and chock the tires securely to prevent movement when removing the drum assembly. 3. Jack at the center articulation joint to raise the frame, (Figure 1-2).

J3.4

4. To allow for easier removal of the drum mounting hardware, measure from the inner drum shell to the top and bottom of the frame rail; positions A and B. Adjust the jack up or down until the measurements are roughly equal. This will relieve any load on the shock mounts. 5. Repeat the previous procedure on the other side of the drum.

Block Drum Frame

WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions. 6. Attach an adequate lifting/supporting device to the scraper.

Figure 1-2

JACK AND BLOCK PLACEMENT

SD-116 TF SERIES DRUM AND DRUM DRIVE 7. Remove the capscrews (42, Figure 1-3), flatwashers (21), shims (19 and 20), and nuts (23) from the scraper and drum frame (2). 8. Tag and wire the shims (19 and 20) together so that they can be reinstalled at the same locations. 9. Using the lifting device, remove the scraper from the drum frame (2). WARNING: Exercise extreme caution when working around pressurized hydraulic systems. Do not work on a hydraulic system while the engine is running or pressure is still in the system. Ensure all pressure is relieved from the system before disconnecting hydraulic lines and performing maintenance.

J3.5

NOTE’ Steps 11 and 12 are usually done after drum assembly is removed from drum frame. 10. Tag and disconnect the hydraulic lines to the vibration motor (27, Figure 1-6) (left side of the drum). 11. Remove the capscrews (37) and flatwashers (36) securing the vibration motor (27) to the carrier assembly (23). 12. Remove the vibration motor (27) and O-ring (28) from the carrier assembly (23). 13. Tag and disconnect the hydraulic lines and the electrical line to the drum drive motor (1, Figure 1-5). Cap or plug all lines and openings.

Figure 1-3

DRUM, DRUM FRAME AND SCRAPER

SD-116 TF SERIES DRUM AND DRUM DRIVE 14. Remove the capscrews (22, Figure 1-4), flatwashers (21), shims (19 and 20) and hex nuts (23), securing the drum assembly (1) to the drum frame (2). 15. Tag and wire the shims (19 and 20) together so that they can be reinstalled at the same location. 16. Carefully roll the drum assembly (1) out of the drum frame (2) and block into position for further maintenance.

J3.6

Figure 1-4

DRUM, DRUM FRAME AND SCRAPER

SD-116 TF SERIES DRUM AND DRUM DRIVE DRUM DRIVE REMOVAL AND DISASSEMBLY WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions. 1. Use an adequate lifting/supporting device to support drive motor (1, Figure 1-5) and drive plate (2). 2. Remove the nuts (35, Figure 1-6) flatwashers (34) and washers (39) securing the drive plate assembly (33) to the shock mounts (16). 3. Using the lifting device, remove the drive motor (1), drive plate (2) and mounting plate (3) from the drum.

J3.7

4. Remove the capscrews (30, Figure 1-6) and flatwashers (29) securing the shock mounts (16) to the drum (1). 5. Remove the shock mounts(16) from the drum (1). 6. Remove the capscrews (7, Figure 1-5) and flatwashers (4) from the drive plate (2) and drive motor (1). 7. Remove the capscrews (5), flatwashers (4), and hex nuts (6) from the mounting plate (3) and drive motor (1). 8. Separate the drum drive motor (1) from the drive plate (2) and mounting plate (3). 9. If maintenance of the drum drive motor (1) is required, refer to the Drum Drive Motor service information for this model.

Figure 1-5

DRUM DRIVE

SD-116 TF SERIES DRUM AND DRUM DRIVE DRUM DRIVE SIDE DISASSEMBLY 1. Remove the capscrews (12, Figure 1-6) from the cover (11). 2. Remove the cover (11) from the bearing housing drive (2). 3. Remove and discard the O-ring (9). WARNING: Safety glasses must be worn when removing the retaining ring. 4. Remove the retaining ring (19) from the eccentric (5). WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions.

J3.8

5. Attach an adequate lifting/supporting device to the bearing housing drive (2). 6. Remove the bolts (10) and flatwashers (8) securing the bearing housing drive (2) to the drum (1). 7. Using the lifting device, remove the bearing housing drive (2) from the drum (1). 8. Remove and discard the O-ring (20) from the bearing housing drive (2). WARNING: Safety glasses must be worn when removing the retaining rings. 9. Remove the retaining rings (7) and remove the bearings (6) from the bearing housing drive (2).

Figure 1-6

DRUM ASSEMBLY

SD-116 TF SERIES DRUM AND DRUM DRIVE CARRIER DISASSEMBLY WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions. 1. Attach an adequate lifting/supporting device to the shock mounting plate (10, Figure 1-7). 2. Remove the nuts (12). flatwashers (11) and washers (9) securing the shock mount plate (10) to the shock mounts (6). 3. Using the lifting device, remove the shock mount plate (10).

J3.9

WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions. 4. Attach an adequate lifting device to the carrier plate (1). 5. Remove the capscrews (8) and the flatwashers (7) securing the shock mounts (6) to the carrier plate (1). 6. Using the lifting device, remove the carrier plate (1) from the drum. 7. Remove and discard the oil seal (5) from the carrier plate (1).

Figure 1-7

CARRIER ASSEMBLY

SD-116 TF SERIES DRUM AND DRUM DRIVE VIBRATION SIDE DISASSEMBLY 1. Remove the coupling (24, Figure 1-8) and splined shaft (26) from the drum (1). WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions. 2. Attach an adequate lifting/supporting device to the bearing housing spindle (3, Figure 1-8). 3. Remove the bolts (10) and flatwashers (8) from the bearing housing spindle (3). 4. Using the lifting device, remove the bearing housing spindle (3) from the drum (1).

J3.10

5. Remove and discard the O-ring (20) from the bearing housing spindle (3). WARNING: Safety glasses must be worn when removing the retaining rings. 6. Remove the retaining ring (18) from the spindle (3). 7. Remove the bearing (15). 8. Remove the spacer (4) and bearing (15). 9. Remove and discard the V-ring seal (17). 10. Remove the wear sleeve (14). 11. Remove the eccentric (5) from the drum (1). 12. If maintenance of the eccentric assembly is required, refer to the Eccentric Assembly service information for this model.

Figure 1-8

DRUM ASSEMBLY

SD-116 TF SERIES DRUM AND DRUM DRIVE CLEANING AND INSPECTION 1. Clean all metal parts in a nonresidue type solvent. 2. Check all mounting hardware for damage or wear. Replace as necessary. 3. Inspect all threaded holes. 4. Check the carrier plate for cracks, wear, or other damage. Replace as necessary. 5. Check the bearings for wear, spalling, or other damage. 6. Check shocks for cracks, wear or other damage. Replace as necessary. 7. Clean the inside of the drum.

VIBRATION SIDE ASSEMBLY

J3.11

1. Install the wear sleeve (14, Figure 1-8) onto the bearing housing spindle (3). 2. Apply petroleum jelly to the new V-ring seal (17). 3. Install the new V-ring seal (17) onto the bearing housing spindle (3). 4. Heat the bearings (15) to 107° C (225° F) for 15 to 30 minutes before installation. WARNING: Wear protective heat resistant gloves when handling heated parts. Contact with hot bearings will c ause severe burns. NOTE: Bearings are to be cooled to -18°C (0° F) for 2 to 4 hours before installation. 5. Lower the temperature of the new bearings (15). 6. Apply a coat of grease to the new bearings (15). 7. Install the new bearing (15) and the spacer (4) onto the bearing housing spindle (3).

Figure 1-8

DRUM ASSEMBLY

SD-116 TF SERIES DRUM AND DRUM DRIVE WARNING: Safety glasses must be worn when installing the retaining rings. 8. Install a new bearing (15, Figure 1-8) and the retaining ring (18) onto the bearing housing spindle (3). 9. Apply petroleum jelly to the new O-ring (20). 10. Install the new O-ring (20) into the bearing housing spindle (3). WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions.

J3.12

11. Attach an adequate lifting/supporting device to the bearing housing spindle (3 Figure 1-8). 12. Using the lifting device, install the bearing housing spindle (3) into the drum (1). 13. Apply Loctite #271 (red) to the bolts(10). 14. Install the bolts (10) and flatwashers (8) into the bearing housing spindle (3). 15. Torque the bolts (10) to 373 N·m (275 lb-ft.). WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions. 16. Using the lifting device, install the eccentric assembly (5) into the drum from the drive side of the drum and into the bearing housing spindle (3).

Figure 1-8

DRUM ASSEMBLY

SD-116 TF SERIES DRUM AND DRUM DRIVE 17. Support the eccentric assembly (5, Figure 1-8) until the bearing housing drive (2) is installed. 18. Coat the contact areas of both ends of the splined shaft (26) with Dow Corning Moly-Kote grease prior to installation into the coupling (24) and eccentric (5). 19. Install the splined shaft (26) and coupling (24) into the drum (1). 20. Check the eccentric oil. Refer to the Operation and Maintenance Manual for this model.

J3.13

Figure 1-8

DRUM ASSEMBLY

SD-116 TF SERIES DRUM AND DRUM DRIVE CARRIER ASSEMBLY 1. Install new oil seal (5, Figure 1-9) into the carrier plate (1). 2. Apply Loctite #271 to the capscrews (8). 3. Install the shock mounts (6) onto the carrier plate (1). 4. Install the capscrews (8) and flatwashers (7) onto the shock mounts (6) 5. Torque the capscrews (8) to 149 N·m (110 lb-ft.). WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions. 6. Attach an adequate lifting device to the shock mount plate (10).

J3.14

7. Install the shock mount plate (10) to the shocks (6). 8. Install the washers (9), flatwashers (11) and nuts (12) in to the shock mount plate (10). 9. Torque the nuts to 373 N·m (275 lb-ft.). WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions. 10. Attach an adequate lifting device to the carrier assembly. NOTE: Ensure the carrier plate assembly is fully installed onto the spindle and that the V-ring seal on the spindle does not roll under the edge of the carrier plate assembly during installation. 11. Install the carrier plate assembly into the drum and onto the bearing housing spindle.

Figure 1-9

CARRIER ASSEMBLY

SD-116 SD-116 TF SERIES DRUM AND DRUM DRIVE DRIVE SIDE ASSEMBLY AND INSTALLATION 1. Install a new O-ring (20, Figure Figure 1-10) into the the bearing bearing housing drive (2). 2. Heat the the beari bearings ngs (6) (6) to 107° 107° C (225 (225°° F) for for 15 to 30 30 minutes before installation. WARNING: Wear protective heat resistant gloves when handling heated parts. Contact with hot bearings will c ause severe burns. NOTE: Bearings are to be cooled to -18°C (0° F) for 2 to 4 hours before installation. 3. Lower Lower the tempe temperat rature ure of of the new new bearin bearings gs (6). (6). 4. Install new bearings bearings (6) into into the the bearing bearing housing housing drive (2).

J3.15

WARNING: Safety glasses must be worn when installing the retaining rings. 5. Install Install the retain retaining ing rings rings (7). (7). 6. Attach an adequate adequate lifting lifting device device to the bearing bearing housing drive (2). 7. Install the bearing bearing housing drive (2) into into the drum (1). (1). 8. Apply Apply Loctite Loctite #271 (red) (red) to the the bolts bolts (10) (10).. 9. Install the bolts bolts (10) (10) and and flatwasher flatwashers s (8) into the bearing bearing housing drive (2). 10. Torque the bolts (10) to 373 N·m (275 lb-ft.). WARNING: Safety glasses must be worn when installing the retaining rings.

Figure 1-10

11. Install the retaining ring (19) onto the eccentric (5).

DRUM ASSEMBLY

SD-116 SD-116 TF SERIES DRUM AND DRUM DRIVE 12. Apply petroleum jelly to the new O-ring (9, Figure 1-11). 1-11). 13. Install a new O-ring (9) onto the cover (11). (11). 14. Install the cover (11) (11) onto the bearing housing drive (2). 15. Apply Loctite #242 (blue) (blue) to the capscrews (13). 16. Install the capscrews (12) into the cover (11). (11). 17. Torque the capscrews (13) to 28.5 28.5 N·m (21 lb-ft.).

J3.16

Figure 1-11

DRUM ASSEMBLY

SD-116 SD-116 TF SERIES DRUM AND DRUM DRIVE DRUM DRIVE ASSEMBLY AND INSTALLATION 1. Apply Apply Loctite Loctite #271 #271 to capsc capscrews rews (5, (5, Figure Figure 1-12) 1-12).. 2. Install the mountin mounting g plate plate (3) (3) to the drive drive motor (1). 3. Install the capscrews capscrews (5), flatwash flatwashers ers (4), (4), and nuts (6) into into the mounting plate (3) and the drive motor (1). 4. Torque the capscrew capscrews s (5) to 515 N·m (380 (380 lb-ft.). lb-ft.). WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions. 5. Using an adequate adequate lifting/suppo lifting/supporting rting device, position position the drive motor (1) onto the drive plate (2). 6. Apply Apply loctite loctite #271 #271 to the the caps capscre crews ws (7). (7).

J3.17

7. Install the capscrews capscrews (7) (7) and and flatwashers flatwashers (4) into into the the drive drive plate (2) and drive motor (1). 8. Torque the capscrew capscrews s (7) to 575 N·m (420 (420 lb-ft.). lb-ft.). 9. Apply Loctite Loctite #271 (red) (red) to capscrews capscrews (30, (30, Figure Figure 1-11). 1-11). 10. Install the shock shock mounts (16) to the drum drum (1). 11. Install Install the capscrews (30) and flatwashers flatwashers (29) into into the shock mounts (16). 12. Torque the capscrews (30) to 149 N·m (110 (110 lb-ft.) WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions.

Figure 1-12

13. Attach an adequate adequate lifting/supporting lifting/supporting device device to the drive motor (1, Figure 1-12), drive plate (2) and mounting plate (3).

DRUM DRIVE

SD-116 SD-116 TF SERIES DRUM AND DRUM DRIVE 14. Apply Loctite #271 (red) (red) to the nuts (35, Figure 1-13). 15. Using the lifting device, install the drive plate (2), drive motor (1) and mounting plate (3) to the shock mounts (16). 16. Install the nuts (35), flatwashers (34) and washers (39) into the drum drive plate (2). 17. Torque the nuts (35) to 373 N·m (275 lb-ft.). 18. Check the drum drive and and carrier oil level. level. Refer to the Operation and Maintenance Manual for these models for maintenance instructions.

J3.18

Figure 1-13

DRUM ASEMBLY

SD-116 TF SERIES DRUM AND DRUM DRIVE ASSEMBLY AND INSTALLATION WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions. 1. Attach an adequate lifting device to the drum assembly (1, Figure 1-14). 1. Carefully roll the drum assembly into position in the drum frame. 2. Measure the distance between the frame sides at positions A and D (Figure 1-14). Measurement A should be no more than 25.4 mm (1.0 in.) greater than measurement D. Ensure the gap is consistent between the siderails along the entire length of the siderail.

J3.19

3. Measure the scraper bar length. The difference between the length of the scraper bar and the distance in position A is the required shim pack thickness for the scraper bar installation. WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions. 4. Attach an adequate lifting device to the scraper. NOTE: Locate smooth drum scraper or tooth scraper with a 20 mm (0.79 gap between drum shell and closest edge of scraper. 5. Align scraper into the drum frame (2, Figure 1-15).

Figure 1-14

DRUM ALIGNMENT

SD-116 TF SERIES DRUM AND DRUM DRIVE 6. Preload the drum assembly by shimming the vibration side only. Fill gap on both sides of mounting bracket, then add the smallest thickness 1.5 mm (0.06 in.) shim to each side of mounting bracket. 7. Align the drum mounting holes by rocking the drum forward and backward until the mounting capscrews can be inserted temporarily on each side. Install capscrews (22, Figure 1-15 ), flat washers (21) and nuts (23). 8. Take clearance measurements B and C (Fgure 1-14) on both ends of the drum. Measure between the edge of the drum shell and the drum frame. Shift the drum until these measurements are equal. 9. Measure to determine the shim thickness on each end at the drum mounting location E.

J3.20

10. Compare this to the thickness of the shim packs removed at disassembly. Add or subtract shims equally to both sides as necessary to meet the required thickness. 11. Install required shims (19 and 20, Figure 1-15) at each end of the drum. 12. Apply Loctite #271 to the capscrews (22). 13. Alternately torque the capscrews (22) to 1780 N·m (1310 lb-ft.). NOTE: Scraper shim packs should result in the scraper total length to nearly match, but not exceed the distance between the drum frame siderails. 14. Install scraper shims (19 and 20). 15. Apply Loctite to the capscrews (42). 16. Install the capscrews (42), flatwashers (21), and nuts (23) into the scraper and drum frame.

Figure 1-15

DRUM, DRUM FRAME, AND SCRAPER

SD-116 TF SERIES DRUM AND DRUM DRIVE 17. Torque the cappscrews (42, Figure 1-15) to 1780 N·m (1313 lb-ft.). 18. Connect the hydraulic lines to the drum drive motor (1, Figure 1-12). 19. Apply petroleum jelly to new O-ring (28, Figure 1-16). 20. Install the vibration motor (27, Figure 1-16) and new O-ring (28) into the drum. 21. Apply Loctite #271 (red) to the capscrews (37). 22. Install the capscrews (37) and flatwashers (36) into the vibration motor (27, Figure 1-16) and carrier assembly (23). 23. Torque the capscrews (37) to 107 N·m (79 lb-ft.). 24. Connect the hydraulic lines to the vibration motor (27). 25. Lubricate the drum assembly prior to operation.

J3.21

26. Check the system hydraulic oil. Refer to the Operations and Maintenance Manual for these models for maintenance instructions. 27. Operate the compactor and check for proper operation, and ensure there are no oil leaks.

Figure 1-16

DRUM ASSEMBLY

SD-116 TF SERIES / ECCENTRIC ASSEMBLY TABLE OF CONTENTS............................................. J4.1 ECCENTRIC ASSEMBLY.......................................... J4.2 Tools Required ..................................................... J4.2 Safety ................................................................... J4.2 Disassembly......................................................... J4.2 Cleaning and Inspection....................................... J4.3 Assembly.............................................................. J4.3

Eccentric Assembly

J4.1

032503AA

TABLE OF CONTENTS

SD-116 TF SERIES / ECCENTRIC ASSEMBLY TOOLS REQUIRED: • Safety glasses

•

Basic sockets and wrenches

• Torque wrench

•

Loctite number 271 (red)

• Non-residue type solvent •

Grease

• Hammer

Punch

•

• Lifting device, such as a 3,000 lb. Auto-Crane that is in perfect condition

SAFETY Accidents are caused by failure to follow simple, fundamental safety rules and precautions. Refer to the AEM Safety Manual for safety instructions. Most accidents can be avoided by paying attention, using common sense, and following the instructions.

J4.2

DISASSEMBLY 1. Remove the capscrew (9, Figure 1-1) and flatwasher (7) from the spline coupling (6). 2. Remove the spline coupling (6) from the non-drive side journal (4). 3. Remove and discard the oillite bearing (5) from the nondrive side journal (4). 4. Remove the capscrews (8) and flatwashers (7) from the non-drive side journal (4). 5. Remove the roll pin (10) from the non-drive journal (4) and eccentric shaft (2). 6. Pull the eccentric shaft (2) from the non-drive side journal (4).

Figure 1-1

ECCENTRIC ASSEMBLY

SD-116 TF SERIES / ECCENTRIC ASSEMBLY 7. Remove the capscrews (8, Figure 1-1) and flatwashers (7) from the drive side journal (1). 8. Remove the drive side journal (1) from the eccentric shaft housing (2). 9. Remove and discard the oillite bearing (5) from the eccentric shaft (3). 10. Remove the eccentric shaft (3) from the eccentric shaft housing (2).

CLEANING AND INSPECTION 1. Clean all parts in a non-residue type solvent. 2. Check all mounting hardware for damage and wear. Replace as necessary. 3. Inspect all threaded holes for debris or foreign material.

J4.3

4. Thoroughly clean threaded holes of cosmoline, oil, dirt, metal chips, and any other contaminants that could interfere with the curing of Loctite.

ASSEMBLY 1. Install the eccentric shaft (3) in the shaft housing (2). 2. Polish the drive side journal end of housing. 3. Polish the journal end of housing. 4. Install the new oillite bearing (5) onto the eccentric shaft (3). 5. Install the drive side journal (1) onto the end of eccentric housing (2). 6. Apply enough Loctite #271 (red) to both the capscrews (8) and the hole threads to completely fill the thread engagement length once the capscrews (8) are installed.

Figure 1-1

ECCENTRIC SHAFT ASSEMBLY

SD-116 TF SERIES / ECCENTRIC ASSEMBLY 7. Install the capscrews (8, Figure 1-1) and flatwashers (7) in the drive side journal (1). 8. Torque the capscrews (8) to 61 N·m (45 lb-ft). 9. Install the new bearing (5) into the non-drive side journal (4). 10. Install the non-drive side journal (4) onto eccentric housing (2). 11. Apply Loctite #271 (red) to the capscrews (8). 12. Install the capscrews (8) and flatwashers (7) into the hub non-drive side journal (4). 13. Torque the capscrews (8) to 61 N·m (45 lb-ft). 14. Apply enough Loctite #271 (red) to both the capscrews (9) and the hole threads to completely fill the thread engagement length once the capscrews (9) are installed.

J4.4

15. Install the spline coupling (6) to the non-drive side journal (4) and secure with the capscrews (9) and flatwashers (7). 16. Torque the capscrews (9) to 61 N·m (45 lb-ft.).

Figure 1-1

ECCENTRIC SHAFT ASSEMBLY

ELECTRICAL

d e d d e l o e z l r r z e o o u n f c n r o i r r e t o o v c t o n e n c u s e p f j w l o t w n i c o i d a l m o o d e d u l o m s r - r e e p t d r e t n d n r r o n n u e o c d e o e n u o c i i o g o i o h n l t t r o d d i t n t t t c s t i d s s u o a l o c i t e c i e s r d c r k S g o c g n t e c n o m e e s e d S j t i r c e g u s a n r r o u g e n n f e e f n c e r g e l e l e E n l d i t l u p o d e g h t p a r e i n n c a r t w n j S i s s d / p i w o o m n l t t i e e t s t a d r o r i m m s t o t i n g t c o t U n r m l i e m a s g e l n e g g a S e a t o e t a e t a g s e e u i n n i e p p t i s o t i A t a e t e t u g i w t n n n l n g e l n i l s u u i i u r o h i g r s n k o S C c i o u o a z m m y x l g i i a t f y r r q c c l / r n e n t t z u u s e e n n n r y t s i v n d r a f r s i p l E n n m e e i a i u s o a o / d c p p o o l r h t u f e r n e t p r r i r f i t i s g a L l u C a l l c d r i t n i e t c e n d n t p e e n n h a a c a i B a a g c c a e r e g g u y y s b c e e e o i o n n n l l t r p e o i a f I l u o o n o n r r k e i n n n c f s s t r t i t e e N p o i S m l n i u f u i / i t t e t e n e t i i i l l l e r s r t n t k k g c c c f t v r r c e S C c i v e g g g e e e s a e o e e e a a w g l l l t a l a r i r t r i r l n n n u u u u e l c j j j t t o u a a u o t a a a o t O F i d I n I n I n I n I n L L M M M N S S S n I P A A A B B C D E E E E F F F F G I

e n i g n e g n i k n a r c t o n t u b g n i t a r e p o r o t o m g n i t r a t S

e v i s s e c x e h s a l e v l a V

d e t s u j d a y l t c e r r o c n i s e v l a V

SYMPTOMS

K1

ENGINE

Won't crank or cranks slowly Hard to start or will not start Stalling Surge Noise (excessive) Smoke

4 2

1

4 4 3

5

2 2

7 5 7 5 6 4

1 1 2

1 8

8 8

7

10

6

3

1

4

3 1

5

ELECTRICAL SYSTEMS

No Lights No Gauges

1 1

3 3

9

5

2 6

7

3 3

6

4

3 2

6

2 2

TROUBLESHOOTING NOTE: Possible causes for each symptom are numbered in order of most likely occurance.

HYDRAULICS

S E S U A C E L B I S S O P

) F / X D ( l r t n ) c n t o i t m m l a e r t s l p b s s i i y g e s r r V n e s v d i e l t u ( S i r a e g d e s p d l a u e e p n a l l i c c e b l n v s i e i v - l i m r l l m t r e y i b o t e a t p y a r u n a a b p c c i c c s m C v P p i C V r u i e l o y r r l l l e e m o o e c t t E a s u n s c i g g a t r t r d e n n e s a r r t n p k n v e e C t i c d o p a a n n n i l i c c r e i a r y h h o o o y r c c D l A B B B C C C C C C D E E E E

p r i o m l v u r e a p i e / v t l s e n e a e v e r n e l v r e v i u r o l a i c e e e s n n v a s f f i i s f o f r r t i l l s i v i e e o e c V d o l r s l r e i l l v m o p e n a e v v n t r s e o l e e l r o g l r u n n r f t o u c g l n i r d a g n s i n t s n i a r o n l t o r n e o h h o a u C T c r h o c i s c C r e x l t u t e m e e C p s l l t c g f i c c g p c E u f a a o o n e e t a a l l i p r t v v t M a d e p p k m p p r r t n u e e P e e e o e y l s s i o n I n I n L P H H I R R R S S S L

) l a n o i t s p e v O k l ( c a e e v r e v h k u l c c s a v e s e e r h r l c p o p u r s / f f t m s i e i e n u e l l o p r e r c p r e g n n m m m i o i r t e e t e t e s t s s c e t y y y a r S S S S T

SYMPTOMS VIBRATION

Not working One direction only Frequency low System operating "HOT" Neutral difficult to find Wrong Mode

3

4

7

12 11

4 5 4

3 4

3

9 7

4

2 1 2 6

2

1

6

1

3

5

8

13

6

10 1

1

10 9 2 8 7

5

5 2

3

2

1

STEERING

K2

No Steering Hard to Steer Off and On again Wander or Drift Steering Slip (Intermittant)

3 6

5 4 3 3 6

2 2 2

4 5 4 5

6

1 1 1 1 1

4

2 3

2

3

PROPULSION

No Propulsion One Direction Sluggish Neutral difficult to find System operating "HOT"

3 8 5 11 4

3

4 6

2 1 10 2

4

6 3 9 3

8

9

1

5

7

3 2

1

10 4

7

5

6

12 2

8

1 2

1

3

TROUBLESHOOTING NOTE: Possible causes f or each symptom are numbered in order of most likely occurance.

5

7

4

SD-116 TF SERIES / VIBRATION CONTROL SYSTEM TABLE OF CONTENTS. ............................................K3.1 VIBRATION CONTROL SYSTEM .............................K3.2 Major Components ...............................................K3.2 Troubleshooting....................................................K3.4 Fault Codes..........................................................K3.6 CHARTS Vibration Control Components .............................K3.2 Microprocessor LED Functions ............................K3.3 Troubleshooting Chart..........................................K3.4 Fault Code Troubleshooting Chart .......................K3.6

K3.1

032503AA

TABLE OF CONTENTS

SD-116 TF SERIES / VIBRATION CONTROL SYSTEM VIBRATION CONTROL SYSTEM The variable frequency vibration option controls the speed and direction of rotation of the eccentric weight. There are five VPM set points for the high amplitude range and five VPM set points for the low amplitude range. The system maintains the selected VPM during natural fluctuations in machine performance. This is achieved by supplying a signal from a speed sensor at the eccentric motor to a microprocessor. This microprocessor then regulates the output of the vibration pump to maintain the selected VPM.

MAJOR COMPONENTS Vibration Control Components • A microprocessor (1, Figure 1-2) labeled "SX C. Loop Vibration Control" located in the battery compartment.

K3.2

• A speed sensor located at the vibration motor. • A five-position selector switch located on the instrument panel (1, Figure 1-1). • The electronic displacement control located on the vibration pump. The microprocessor (1, Figure 1-2) contains four LED indicator lights located vertically on the front of the case. Refer to the Microprocessor LED Function Chart.

Figure 1-1

INSTRUMENT PANEL SELECTOR SWITCH

SD-116 TF SERIES / VIBRATION CONTROL SYSTEM Microprocessor LED Functions

K3.3

Powe Powerr

Indi Indica cate tes s powe powerr is bein being g supp suppli lied ed to the the microprocessor.

Syst System em

Indi Indica cate tes s the the micr microp opro roce cess ssor or is func functi tion onin ing g normally.

Mode Mode

Will Will blin blink k ambe amberr when when powe powerr is bein being g supp suppli lied ed to microprocessor. • A blink blink rate of of about 10 times times per second second indicates no application is loaded or an application is loaded with faults. • A blink blink rate of once per per second second indicates indicates an application is loaded with no faults. This would be the normal or required condition.

Status atus

Will Will disp displa lay y a red red four four-b -bli lin nk cod code e onl only y ifif a fa fault ult exists. This code will be a series of short and long blinks. • Short blink lasts approximately approximately 0.5 seconds seconds • Long blink lasts approximately approximately 1 second second When a fault occurs, The status LED will display a four-blink code then pause for approximately 2 seconds and then display the fault code again. It is possible for more than one fault to exist at the same time; therefore several series of codes may need to be observed.

Figure 1-2

MICROPROCESSOR

SD-116 TF SERIES / VIBRATION CONTROL SYSTEM TROUBLESHOOTING If a problem occurs with the variable vibration system the following steps will aid in the troubleshooting process. WARNING: If it is required for the engine to be operating to perform testing or repair, ensure the articulation locking device is installed and the wheels and drum are chocked. Unplug all micro controllers prior to welding.

Troubleshooting Chart Step 1

K3.4

Check Establish that power is being supplied to the microprocessor. Is the power LED illuminated?

2

Is th the sy system LE LED on on the microprocessor illuminated?

Correction Determine power interruption by: • Is the the vibra vibratio tion n on/of on/offf button in the “ON” position? • Is the F5 fuse fuse OK? OK? • Is there there a fault fault in the the vibration on/off button wiring circuit? Refer to Fault Codes. If system LED is not illuminated and the POWER LED is illuminated, an internal problem exists in the microprocessor and it will require replacement

Figure 1-2

MICROPROCESSOR

SD-116 TF SERIES / VIBRATION CONTROL SYSTEM Troubleshooting Chart (Continued) Step 3

Check

Correction

Is st status LE LED di displaying a In order for the fault red four-blink fault code? codes to be illuminated, the ignition switch must remain in the “on position” from the time the fault occurs. To accomplish this, this , stop the machine travel and apply park brake.

K3.5

Observe the status LED on the variable vibration microprocessor with the engine running or shut down the engine with the emergency stop switch. NOTE: Do not turn the ignition switch to the off position, as this will reset the microprocessor.

Figure 1-2

MICROPROCESSOR

SD-116 TF SERIES / VIBRATION CONTROL SYSTEM FAULT FAULT CODES C ODES The following is a list of possible fault codes (S = short and L = long) • LLSS = LLSS = Signal from five-position selector switch is out of range. • LLLS = Signal from speed sensor in vibration motor is out of range. This fault will not shut down vibration, but will default to “open loop”. Under this condition the current from the five-speed selector switch will be sent directly to the control on the pump. The microprocessor will not attempt to “fine tune” the VPM setting. Some changes or variations in VPM may be noticed.

K3.6

• SLLS = SLLS = Coil at EDC on vibration pump is open or shorted. This fault will shut down the vibration until fault is cleared and machine is restarted.

Fault Code Troubleshooting Chart C od e

Symptom

LLSS • The The vibra vibratio tion n shut shuts s down.

Check • Check Check the the inte integr grit ity y of of wiring and connections between the five-position selector switch and microprocessor.

Figure 1-2

MICROPROCESSOR

SD-116 TF SERIES / VIBRATION CONTROL SYSTEM Fault Code Troubleshooting Chart (Continued) Code

Symptom

LLSS • The machine continues (Cont) to vibrate at whatever position the selector switch was in when the fault occurred. Under this condition the speed of the vibration will not change if the selector switch is repositioned.

K3.7

Check Check the function of the five-position selector switch by unplugging the three-pin wire connector at the five-speed selector switch and using a multimeter, check resistance between terminals A & B at each of the five VPM settings.

Note: When this fault occurs, the “signal from speed sensor is out of range” (LLLS) fault may also be displayed. Under these conditions it’s possible that the LLLS fault could be displayed even though the sensor may be functioning correctly. The readings should be as follows: • Setting 1 should be approximately 1000 Ohms • Setting 2 should be approximately 800 Ohms • Setting 3 should be approximately 600 Ohms • Setting 4 should be approximately 400 Ohms • Setting 5 should be approximately 200 Ohms LLLS • Signal from speed • Check the integrity of sensor in vibration is out wiring and of range connections between speed sensor and micro processor.

Figure 1-2

MICROPROCESSOR


Symptom

Check

LLSS • Signal from speed • Check that speed (Cont) sensor in vibration is out sensor is properly of range. (Cont) adjusted. a. To adjust speed sensor, loosen locking nut and turn sensor in until it bottoms out, then back sensor out 3/4 of a turn and tighten locknut.

K3.8

NOTE: This fault will not shutdown vibration, but will default to “open loop”. Under this condition the current from the fivespeed selector switch will be sent directly to the control on the pump. The microprocessor will not attempt to “fine tune” the VPM setting. Some changes or variations in VPM may be noticed. SLLS • Coil at EDC on vibration • Check the integrity of is open or shorted. the wiring and connections between the EDC and the microprocessor. • Check the resistance across the coil at the EDC. There should be 19 ohm resistance between A-B and 16.5 ohm resistance between C-D.

Figure 1-2

MICROPROCESSOR


Symptom

Check

NOTE: When this fault occurs, the “signal from speed sensor is out of range” (LLLS) fault may also be displayed. Under these conditions it’s possible that the LLLS fault could be displayed even though the sensor is functioning correctly.

K3.9

Figure 1-2

MICROPROCESSOR

SD-116 TF SERIES / TRACTION ENHANCEMENT SYSTEM TABLE OF CONTENTS............................................. 43.1 TRACTION ENHANCEMENT SYSTEM....................K4.2 Major Components ...............................................K4.2 Troubleshooting....................................................K4.4 Fault Codes..........................................................K4.6 CHARTS Traction Enhancement Components....................K4.2 Microprocessor LED Functions ............................K4.3 Troubleshooting Chart..........................................K4.4 Fault Code Troubleshooting Chart .......................K4.7

K4.1

032503AA

TABLE OF CONTENTS

SD-116 TF SERIES / TRACTION ENHANCEMENT SYSTEM TRACTION ENHANCEMENT SYSTEM The purpose of the Traction Enhancement system is to limit the amount of slip between the front and rear drive motors. The speed of each motor is transmitted to a microprocessor, which continuously compares the speed of one motor to the other. If one motor begins to over-speed (drum or wheel slip) the microprocessor directs a proportional valve to reduce the flow (depending on the direction of travel) either to or from that motor. This reduction in flow to or from the spinning motor increases the relative tractive effort of the end of the roller (drum or tires) that is not slipping or spinning.

MAJOR COMPONENTS Traction Enhancement Components

K4.2

• A microprocessor (1, Figure 1-2) labeled “SX Traction Control,” is located in the battery compartment. • Two speed sensors; one located on the drum drive motor and one located on the axle drive motor. • A resistor pack is located in the drum speed sensor harness just inside the swivel area. • A traction control valve is located on the inside of the main frame on the right hand side opposite the battery compartment. 032503AA

• A remote loop-flushing valve is located on the inside of the main frame on the left-hand side. Note: The loop-flushing valve in the axle drive motor is disabled on units equipped with the traction enhancement system.

Figure 1-1

TRACTION ENHANCEMENT SYSTEM

SD-116 TF SERIES / TRACTION ENHANCEMENT SYSTEM The microprocessor (1, Figure 1-2) contains four LED indicator lights located vertically on the front of the case. Refer to the Microprocessor LED Function Chart.

Microprocessor LED Functions Power

Indicates power is being supplied to the microprocessor.

System

Indicates the microprocessor is functioning normally.

Mode

Will blink amber when power is being supplied to microprocessor. • A blink rate of about 10 times per second indicates no application is loaded or an application is loaded with faults. • A blink rate of once per second indicates an application is loaded with no faults. This would be the normal or required condition.

Status

Will display a red four-blink code only if a fault exists. This code will be a series of short and long blinks. • Short blink lasts approximately. 0.5 seconds • Long blink lasts approximately. 1 second When a fault occurs, The status LED will display a four-blink code then pause for approximately 2 seconds and then display the fault code again. It is possible for more than one fault to exist at the same time; therefore several series of codes may need to be observed.

K4.3

Figure 1-2

MICROPROCESSOR

SD-116 TF SERIES / TRACTION ENHANCEMENT SYSTEM TROUBLESHOOTING If a problem occurs with the traction enhancement system the following steps will aid in the troubleshooting process. WARNING: If it is required for the engine to be operating to perform any testing or repair, ensure the articulation locking device is installed and the wheels and drum are chocked. Unplug all micro controllers prior to welding. NOTE: The traction enhancement system only functions in the compaction or low travel speed setting.

Troubleshooting Chart

K4.4

Step 1

Check Establish that power is being supplied to the microprocessor. Is the power LED on the microprocessor illuminated?

Correction Determine power interruption by: • Is the Hi/Low travel switch directing current to the F1 terminal on the microprocessor? • Is the F3 fuse OK? • Is the maintenance jumper, which is located in the harness next to the microprocessor, installed?

Figure 1-2

MICROPROCESSOR

SD-116 TF SERIES / TRACTION ENHANCEMENT SYSTEM Troubleshooting Chart (Continued)

K4.5

Step

Check

Correction

2

Is the system LED on the microprocessor illuminated?

3

Is status LED displaying a In order for the fault red four-blink fault code? codes to be illuminated, the ignition switch must remain in the “on position” from the time the fault occurs.

If system LED is not illuminated and the POWER LED is illuminated, an internal problem exists in the microprocessor and it will require replacement

To accomplish this, stop the machine travel and apply park brake. Observe the status LED on the traction control microprocessor with the engine running or shut down the engine with the emergency stop switch. NOTE: Do not turn the ignition switch to the off position, as this will reset the microprocessor.

Figure 1-2

MICROPROCESSOR

SD-116 TF SERIES / TRACTION ENHANCEMENT SYSTEM FAULT CODES The following is a list of possible fault codes (S = short and L = long) • SSLS = Current supplied to front valve coil on the traction valve is out of range. This fault would indicate either a short in the wiring/coil or an open circuit. When this fault occurs a blink code will be displayed on microprocessor and the system will continue to try to perform anti-spin. • LSLS = Current supplied to rear valve coil on the traction valve is out of range. This fault would indicate either a short in the wiring/coil or an open circuit. When this fault occurs a blink code will be displayed on microprocessor and the system will continue to try to perform anti-spin.

K4.6

• SLLS = Front (drum) speed sensor signal out of range. The speed signal from the rear motor is above the minimum (this would indicate that the wheels are turning) but no signal is being received from front motor (this would indicate that the drum is not turning). For this fault to occur the condition described above must exist for a minimum of 30 seconds. • LLLS = Rear (axle) speed sensor out of range. The speed signal from the front motor is above the minimum (this would indicate that the drum is turning) but no signal is being received from rear motor (this would indicate that the tires are not turning). For this fault to occur the condition described above must exist for a minimum of 30 seconds.

Figure 1-2

MICROPROCESSOR

SD-116 TF SERIES / TRACTION ENHANCEMENT SYSTEM Fault Code Troubleshooting Chart Code

Symptom

SSLS • Current supplied to front valve coil on the traction valve is out of range

Check • Check continuity of the wire that runs from the B1 terminal at the microprocessor to the front valve coil at the traction valve. • Check continuity of the wire that runs from the front valve coil to ground/frame.

K4.7

• Check the resistance across the coil to determine condition of coil. Resistance should be approximately. 6.0 ohms) LSLS • Current supplied to rear • Check continuity of valve coil on the the wire that runs from traction valve is out of the B2 terminal at the range. microprocessor to the rear valve coil at the traction valve. • Check continuity of the wire that runs from the front valve coil to ground frame.

Figure 1-2

MICROPROCESSOR

SD-116 TF SERIES / TRACTION ENHANCEMENT SYSTEM Fault Code Troubleshooting Chart (Continued) Code

Symptom

Check

LSLS • Current supplied to rear • Check the resistance (Cont) valve coil on the across the coil to traction valve is out of determine condition of range. (Cont) coil. (Resistance should be approximately. 6.0 ohms) SLLS • Front (drum) speed sensor signal out of range.

K4.8

• Check the integrity of the wiring at the front drive-motor speed sensor. a. Check continuity of the signal wire between the sensor and the microprocessor. It should be noted that there is a resistor pack located in this circuit. A reading of 1900 to 2100 Ohms of resistance would be typical. b. With the key switch in the run position confirm that system voltage is present at the “A” or B+ terminal of the sensor connector.

Figure 1-2

MICROPROCESSOR


Symptom

SLLS • Front (drum) speed (Cont) sensor signal out of range. (Cont)

K4.9

Check c. Check continuity between the “C” or “B-“ terminal of the sensor connector and ground/ frame. • After the wiring and connectors have been inspected reset the microprocessor by cycling the ignition switch to the off position. Restart the machine and test the operation of traction system. The unit must be propelled for at least 30 seconds at 1 mph in one direction for a fault (if present) to be displayed. • If the problem persists the speed sensor may be damaged or out of adjustment.

Figure 1-2

MICROPROCESSOR


Symptom

SLLS • Front (drum) speed (Cont) sensor signal out of range. (Cont)

Check a. If upon inspection it is found that there is evidence of scratching or scuffing on the end of the sensor, it is very likely that it has been damaged and it should be replaced. b. To determine if the sensor is out of adjustment, the sensor would have to be removed and reinstalled with a new clearance tab applied and then the unit test run.

K4.10

c. When installing the speed sensor in the drum drive motor, the following procedure applies: LLLS • Rear (axle) speed sensor (1, Figure 1-3) out of range.

• Check the integrity of the wiring and connectors between the speed sensor on axle drive motor and microprocessor.

Figure 1-3

REAR AXLE SPEED SENSOR


Symptom

LLLS • Rear (axle) speed (Cont) sensor (1, Figure 1-3) out of range. (Cont)

Check a. Check continuity of the signal wire between terminal ‘B” at the sensor connector and terminal “E1” at the microprocessor. b. With the key switch in the run position confirm that system voltage is present at the “A” terminal of the sensor connector.

K4.11

c. Check continuity between the “C” terminal of the sensor connector and ground/frame. • After verifying the integrity of wiring and connectors, reset microprocessor by cycling ignition switch to the off position and then restarting the machine.

Figure 1-3



Symptom

LLLS • Rear (axle) speed (Cont) sensor (1, Figure 1-3) out of range. (Cont)

Check • The unit must be propelled for at least 30 seconds at 1 mph in one direction for a fault (if present) to requester. • If after resetting microprocessor the traction system fails to operate correctly, verify the axle drive motor speed sensor is properly adjusted.

K4.12

a. Loosen the locking nut on speed sensor. Turn speed sensor in until it bottoms out, then back speed sensor out 3/4 turn and re-tighten lock nut. • If after adjusting the rear speed sensor the traction system fails to operate correctly, replace the speed sensor.

Figure 1-3


SD-116 TF SERIES / TRACTION ENHANCEMENT SYSTEM NOTE: There is a paper tab on the inboard end of speed sensor. This tab must remain on the sensor when installing. Its purpose is to ensure that the proper clearance is maintained between sensor and motor block. If an existing speed sensor is removed for inspection a new clearance tab would have to be applied before that sensor could be reinstalled. Extra speed sensor clearance tabs are available under part number 13284203. With paper tab in place install the sensor into the motor until it bottoms out. Orient the notch located at the connector end of the sensor so that it points toward the center of the motor. This will result in the connector being positioned in the manner displayed in Figure 1-3. Once the sensor has been bottomed out and the notch is correctly positioned, the sensor may be secured in place.

K4.13

Figure 1-3


Hydraulic Symbol Quick Reference Chart Operation Methods

Manual

Motors & Cylinders Fixed Displacement, Unidirectional, Rotary Hydraulic Motor

Miscellaneous Symbols Pressure Gauge

Pumps Fixed Displacement, Unidirectional Hydraulic Pump

Valves Check Valve

Manual Shut Off Valve Pedal Or Treadle

Temperature Gauge Fixed Displacement, Bidirectional, Rotary Hydraulic Motor

Push Button

Level

Cooler

Variable Displacement, Bidirectional, Rotary Hydraulic Motor

L1 Pilot Pressure

Fixed Displacement, Bidirectional Hydraulic Pump

Double Acting Cylinder

Needle Valve Variable Displacement, Non-Compensating, Bidirectional Hydraulic Pump

Pressure Switch

Filter or Strainer

Component Enclosure Line

Hydraulic Lines Working Hydraulic Line

Lines Joining

Closed Center, Three Position Directional Control Valve

Open Center, Three Position Directional Control Valve

Tandem Center, Three Position Directional Control Valve

Solenoid

Spring

Pressure Relief Valve

Line to Tank (Above Fluid Level)

Pilot Line

Float Center, Three Position Directional Control Valve

Lines Passing

Servo

Line to Tank (Below Fluid Level)

Drain Line

Fixed Restriction

Plug or Plugged Connection

Two Position Multiple Flow Path Valve (Arrows show direction of flow)

Electrical Schematic Code Reference Chart Wire Color Codes Gray/Black

L2

GY/BK

Orange/Black

OE/BK

Black/Yellow

BK/YW

White/Violet

WE/VT

White/Gray

WE/GY

Gray/Yellow

GY/YW

Dr Blue/White

DBE/WE

Yellow/Brown

YW/BN

Black/Orange

BK/OE

Dr Green/Orange

DGN/OE

White/Orange

WE/OE

White/Blue

WE/BE

Dr Blue/Yellow

DBE/YW

Dr Blue/Black

DBE/BK

Lt Green/Black

LGN/BK

White/Green

WE/GN

Dr Green/Red

DGN/RD

Gray/Red

GY/RD

Dr Blue/Red

DBE/RD

Yellow/Red

YW/RD

Purple/Red

PE/RD

Pink/Red

PK/RD

Orange/Red

OE/RD

Brown/Red

BN/RD

White/Red

WE/RD

Black/Red

BK/RD

White/Brown

WE/BN

White/Yellow

WE/YW

Tan/White

TN/WE

Lt Green/White

LGN/WE

Lt Blue/White

LBE/WE

Gray/White

GY/WE

Dr Blue/White

DBE/WE

Yellow/White

YW/WE

Red/White

RD/WE

Purple/White

PE/WE

Pink/White

PK/WE

Orange/White

OE/WE

White/Black

WE/BK

Brown/White

BN/WE

Black/White

BK/WE

Dk Green

DGN

Lt Green

LGN

Lt Blue

LBE

Gray

GY

Dk Blue

DBE

Yellow

YW

Red

RD

Purple

PE

Pink

PK

Orange

OE

White

WE

Brown

BN

Black

BK

C I L U A R D Y H S E I R E S F T 6 1 1 D S

C I T A M E H C S C I L U A R D Y H E N I H C A M

D13238902

3 L

C I L U A R D Y H S E I R E S F T 6 1 1 D S

C I T A M E H C S C I L U A R D Y H E N I H C A M

D13238902

4 L

L A C I R T C E L E S E I R E S F T 6 1 1 D S

C I T A M E H C S L A C I R T C E L E E N I H C A M

D59292995 Rev. 4

5 L



D59292995 Rev. 4

6 L



D59292995 Rev. 4

7 L

T h e w a r r a n t y s t a t e m e n t i s p r o v i d e d w i t h i n t h e m a n u a l k i t s h i p p e d w i t h t h e m a c h i n e .

EN SD116 TF - VOE21A1004254H

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