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En Sd116 Tf - Voe21a1004254h

manual compactador de solo volvo

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M O R E C A R E . B U IL T IN . S d 11 6 S E R V IC E M A N U A L V O L V O C O N S T R U C T IO N E Q U IP M E N T W a h s h a n d s a ft e r h a n d li n g . c a n c e r a n d o th e r re p ro d u c ti v e h a rm . c h e m ic a ls k n o w n to th e S ta te o f C a li fo rn ia to c a u e s a c c s e s o ri e s c o n ta in le a d a n d le a d c o m p o u n d s , B a t te ry p o s ts , te rm in a ls a n d o th e r re la t d e P ro p o C s A it io L n IF 6 O 5 R WN a IA rn in g b ir t h d e fe c ts , a n d o th e r re p ro d u c ti v e h a rm . a re k n o w n to th e S ta te o f C a li fo rn ia to c a u s e c a n c r, e D ie e s l e n g in e e x h a u s t a n d s o m e o f it s c o n s ti tu e n ts P ro p o C s A it io L n IF 6 O 5 R WN a IA rn in g SD-116 TF SERIES Table of Contents...................... ............ ............ A1 Features of This Manual................ ............. ...... B1 Safety Information ............ ............ ............ ........ C1 Illustrated Hose Schematic Option Wit hout Traction Con trol ............ . D1 Option With T raction Control................... D2 HYDRAULIC Propulsion / Braking Schematics ........... ............. ............. ............. E1 A1 Overview Standard Parallel on D & F................ E2 Standard on DX, Optional on D & F .. E3 Neutral - Brakes Applied Standard Parallel on D & F................ E4 Standard on DX, Optional ................ E5 Forward - Brakes Released Standard Parallel on D & F..... ........... E6 Standard on DX, Optional on D & F .. E7 Reverse - Brakes Released Standard Parallel on D & F..... ........... E8 Standard on DX, 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 Component Teardown & Rebuild Propulsion Pump............................................... E13 Axle ................................................................... E14 Axle Motor......................................................... E15 Loop Flush Valve .............................................. E16 T A B L E O F C O N T E N T S Reverse - Brakes Released (Tire Spin) Standard on DX, Optional on D & F..E12 EFF. W/ ALL S/N SD-116 TF SERIES Vibration Schematics ........... ............. ............. ............ . F1 Overview................. .................................F2 Neutral, No Vibration ...............................F3 Clockwise, High Amplitude ......................F4 Counterclockwise, Low Amplitude........... F5 Component Teardown & Rebuild Vibration Pump ......................... ............... F6 Vibration Motor ........................................ F7 Steering A2 Schematics ........... ............. ............. ............ G1 Overview................ ................................. G2 Neutral....................... ............................. G3 Steer Right................. ............................. G4 Steer LeftG5 Component Teardown & Rebuild Steering Pump ........................................ G6 Steering Valve............ ............................. G7 Steering Cylinder (S/Ns 169494,169572) ........................... G8 Steering Cylinder(All other S/Ns)............ G9 T A B L E O F C O N T E N T S 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 Release d ....... 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 T A B L E O F C O N T E N T S 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 o peration and maintenance manual and the AEM Safety Manual for Safety Instructions. C1 S A F E T Y IN F O R M A T IO N 032503AA EFF. W/ ALL S/N SD-116 TF SERIES OPTION WITHOUT TRACTION CONTROL Suction Filter Hydraulic Tank Check Valve 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 VibrationMotor Drum Drive Motor IL L U S T R A T E D H O S E S C H E M A T IC 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 IL L U S T R A T 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 E D H O S E S C H E M A T IC EFF. W/ ALL S/N SD-116 TF SERIES Table of Contents Overview Standard Parallel on D & F........................E2 Standard on DX, Optio nal on D & F ..........E3 Neutral - Brakes Applied Hydraulic Tank Standard Parallel on D & F........................E4 Oil Cooler Standard on DX, Optio nal on D & F ..........E5 Forward - Brakes Released Brake Valve Loop Flush Valve Propulsion Pump Standard Parallel on D & F........................E6 Standard on DX, Optio nal on D & F ..........E7 Reverse - Brakes Released Standard Parallel on D & F........................E8 Axle Standard on DX, Optio nal on D & F ..........E9 E1 Thermal Bypass Valve Axle Drive Motor Forward - Brakes Released (Tire Spin) Standard on DX, Optio nal on D & F ........E10 Forward - Brakes Released (Drum Spin) Standard on DX, Optio nal on D & F ........E11 Reverse - Brakes Released (Tire Spin) Standard on DX, Optio nal on D & F ........E12 Settings and S pecifications - P ropulsion* EngineRPM(Hi/Low) FlowatInputSpeed System Relief Pressure (psi/bar) ChargeReliefPressure(psi) Drum Drive Motor 116D 116F 2457/950 219.3l/m 57.9g/m X X 6090/420 350 X X X X Traction Control Valve Charge Filter P R O P U L S IO N / B R A K IN G X X * For specific application settings, contact your authorized service personnel. 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 SD-116 TF SERIES PROPULSION HYDRAULIC TANK SUCTION STRAINER DUMP / BRAKE / 2 SPEED MANIFOLD OIL COOLER LOOP FLUSH VALVE 140 F CRACKING 165 F OPEN THERMAL BYPASS AXLE MOTOR M1 A 25 psi B M2 E3 L2 CHARGE FILTER PROPULSION PUMP 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 SD-116 TF SERIES PROPULSION HYDRAULIC TANK SUCTION STRAINER DUMP / BRAKE / 2 SPEED MANIFOLD 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 SD-116 TF SERIES PROPULSION HYDRAULIC TANK SUCTIO N STRAINER DUMP / BRAKE / 2 SPEED MANIFO LD OIL COOLER LOOP FLUSH VALVE 140 F CRACKING 165 F OPEN 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 140 F CRACKING 165 F OPEN 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 dashed lines indicate low pressure FORWARD - BRAKES RELEASED STANDARD PARALLEL ON D & F SD-116 TF SERIES PROPULSION HYDRAULIC TANK SUCTION STRAINER DUMP / BRAKE / 2 SPEED MANIFOLD OIL COOLER LOOP FLUSH VALVE 140 F CRACKING 165 F OPEN 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 STANDARD ON DX OPTIONAL ON D & F SD-116 TF SERIES PROPULSION HYDRAULIC TANK SUCTION STRAINER DUMP / BRAKE / 2 SPEED MANIFOLD OIL COOLER LOOP FLUSH VALVE 140 F CRACKING 165 F OPEN 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 dashed lines indicate low pressure REVERSE - BRAKES RELEASED STANDARD PARALLEL ON D & F SD-116 TF SERIES PROPULSION HYDRAULIC TANK SUCTION STRAINER DUMP / BRAKE / 2 SPEED MANIFOLD OIL COOLER LOOP FLUSH VALVE 140 F CRACKING 165 F OPEN 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 STANDARD ON DX OPTIONAL ON D & F SD-116 TF SERIES PROPULSION HYDRAULIC TANK SUCTION STRAINER DUMP / BRAKE / 2 SPEED MANIFOLD OIL COOLER LOOP FLUSH VALVE 140 F CRACKING 165 F OPEN 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 FORWARD - BRAKES RELEASED dashed lines indicate low pressure TIRE SPIN - STANDARD ON DX OPTIONAL ON D & F SD-116 TF SERIES PROPULSION HYDRAULIC TANK SUCTION STRAINER DUMP / BRAKE / 2 SPEED MANIFOLD OIL COOLER LOOP FLUSH VALVE 140 F CRACKING 165 F OPEN 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 FORWARD - BRAKES RELEASED dashed lines indicate low pressure DRUM SPIN - STANDARD ON DX OPTIONAL ON D & F SD-116 TF SERIES PROPULSION HYDRAULIC TANK SUCTION STRAINER DUMP / BRAKE / 2 SPEED MANIFOLD OIL COOLER LOOP FLUSH VALVE 140 F CRACKING 165 F OPEN 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 TF SERIES PROPULSION PUMP TABLE OF CONTENTS...........................................E13.1 LIP SEAL AND SHAFT............................................E13.2 Disassembly .......................................................E13.2 Inspection ...........................................................E13.2 Assembly............................................................E13.3 MULTI-FUNCTION VALVE CARTRIDGES..............E13.4 Disassembly .......................................................E13.4 Inspection ...........................................................E13.4 Assembly............................................................E13.4 CHARGE RELIEF VALVE........................................E13.5 Disassembly .......................................................E13.5 Inspection ...........................................................E13.5 Assembly............................................................E13.5 E13.1 CHARGE PUMP ......................................................E13.6 Disassembly .......................................................E13.6 Inspection ...........................................................E13.6 Assembly............................................................E13.7 REMOTE CHARGE PRESSURE FILTRATION.......E13.8 Disassembly .......................................................E13.8 Inspection ...........................................................E13.8 Assembly............................................................E13.8 MANUAL DISPLACEMENT CONTROL ..................E13.9 Disassembly .......................................................E13.9 Assembly............................................................E13.9 Propulsion Pump TABLE OF CONTENTS NOTICE: SD-116 TF SERIES PROPULSION PUMP 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 screws (1, Figure 1-1) securing the retainer plate (2). 3. Remove the retainer plate (2) and seal carrier (3) from the housing (4). 4. Remove the O-ring (5) from the seal carrier (3). 5. Press out the lip seal (6) from the seal carrier (3). 6. If necessary, remove the shaft (9) and bearing assembly (8) from the housing (4). E13.2 7. Remove the retaining ring (7) that secures the be aring assembly (8) on the shaft (9). 8. Remove the bearing assembly (8) from the shaft (9) and discard the shaft (9). INSPECTION 1. Inspect the seal carrier (3), new lip seal (6) and O-ring (5) 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 SD-116 TF SERIES PROPULSION PUMP 1. If necessary, install the original bearing assembly (8, Figure 1-1) or a new bearing assembly (8) on a new shaft (9). 2. Secure the bearing assembly (8) on th e shaft (9) wit h the retaining ring (7). 3. Install the shaft (9) and 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). 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 the O-ring (5) and the inside diameter of the lip seal (6) with clean petroleum jelly. 8. Install the seal carrier (3) into the housing (4) bore. 9. Install the cover (2) into the housing (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 SD-116 TF SERIES PROPULSION PUMP 1. Remove the multi-function valve cartridges (1, Figure 1-2) from the end cap (2). 2. Remove and discard the O-rings (3) from the multi-function valve cartridges (1). INSPECTION 1. Inspect the multi-function valve cartridge for 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 the new O-rings (3) with clean petroleum jelly. E13.4 2. Install new O-rings (3) onto the multi-function valve cartridges (1). 3. Install the multi-function valve cartridges (1) in the end cap (2). 4. Torque the multi-function valve 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 srcinal 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 SD-116 TF SERIES PROPULSION PUMP 1. Remove the screws (1, Fig ure 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 SD-116 TF SERIES PROPULSION PUMP 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 29 8 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 SD-116 TF SERIES PROPULSION PUMP 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 th e 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 SD-116 TF SERIES PROPULSION PUMP 1. Clean external surfaces prior to removal. 2. Remove the screws (1, Fig ure 1-6) that secure the manual displacement control (2) to the housing (8). 3. Remove the manu al displacement control (2) wit h 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 SD-116 TF SERIES AXLE 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 Disassembly .....................................................E14.17 Assembly..........................................................E14.19 Axle TABLE OF CONTENTS DISASSEMBLY SD-116 TF SERIES AXLE 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 cyl inder in an al ternate 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 disca rd the O-rings (85 and 86) from the pist on (84). 12. Remove the checki ng and guiding scre ws (79) from the pressure plate (87). Figure 1-1 BRAKES SD-116 TF SERIES AXLE NOTE: Loosen the screws (79, Figure proportionally. 1-1) in sequence and 13. Remove the press ure plate (79) fr om 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 sprin gs (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 extrac t the brake disc clearance adju stment crown wheel (88). Figure 1-1 BRAKES ASSEMBLY SD-116 TF SERIES AXLE 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. SD-116 TF SERIES AXLE 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 cylin der in place on the cente r 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 cylinde r 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 exter nal pump to the union pie ce “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, Figu re 1-1) and safety plat e (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 SD-116 TF SERIES AXLE 10 N.m (6 to 7 lb-ft.). 21. Rotate the pinio n (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 safe ty plate (90) and secur e 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 SD-116 TF SERIES AXLE 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 applyi ng counter press ure 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-rin g (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). SD-116 TF SERIES AXLE 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 gea r 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 sea l (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 PLANETARY REDUCTION AND AXLE SHAFT ASSEMBLY SD-116 TF SERIES AXLE 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. PLANETARY REDUCTION AND AXLE SHAFT 11. Install the hub (7, Figure 1-2) onto the axl e arm hub. SD-116 TF SERIES AXLE 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 gea r (72). 15. Lubricate the outer edge of the ring gear suppor t (69), then install the ring gear support (69) into the ring gear (72). 16. Coat the screws (53) wi th Loctite 270 and ins tall them into the ring gear support (69). 17. Tighten the screws (53) in two stages, using the criss-cr oss 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 assemb ly (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 PLANETARY REDUCTION AND AXLE SHAFT REMOVAL SD-116 TF SERIES AXLE 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 (alu minium, etc.) between the differential housing and the toothed portion of the beveled gear (46). 11. With the beveled gea r (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 SD-116 TF SERIES AXLE 13. Remove the differ ential 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 SD-116 TF SERIES AXLE 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 st ay from th e 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 scr ews (40). DIFFERENTIAL SD-116 TF SERIES AXLE 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 tor que 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 torq ue them to 129 to 143 N.m (95 to 105 lb-ft.). 14. Remove the bolt (35) and lock ing 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 intermedia te cover on the opposite end of the differential housing. 17. Remove the sprin g 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 surf ace of the differenti al housing with Loctite 510 and install the reduction gear assembly and pinion assembly (46, Figure 1-3). SD-116 TF SERIES AXLE 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 directio ns 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 directi ons to check the existing clearance between the pinion (46) and the beveled gear (46). 25. Mark the position of the ring nuts (33) in re lation 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). SD-116 TF SERIES AXLE 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 driver and a plastic hammer, install the driving (2) intoa the reduction gear housing. Apply Loctite 510 togear the mounting surface of the reduction gear housing and install the cover. 30. Secure the cover in place with the spri ng 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 ass embly of the axle by insta lling the axle arms. Figure 1-3 DIFFERENTIAL SD-116 TF SERIES AXLE DISASSEMBLY 1. Remove the axle arms from the differential unit. 2. Loosen and remove the sc rews (1 and 9, Fi gure 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 SD-116 TF SERIES AXLE 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) fro m the pinion (46). 13. Position the pinion (46) unde r 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 REDUCTION GEAR AND PINION ASSEMBLY SD-116 TF SERIES AXLE 1. Mark the cup and face plate of one o f the the b earings (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 gau ged 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 value 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 REDUCTION GEAR AND PINION 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 REDUCTION GEAR AND PINION 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 ad ded 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 space r (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 REDUCTION GEAR AND PINION SD-116 TF SERIES AXLE 17. Install the bear ing (3, Figure 1-4) into the reduct ion gear housing. 18. Install the gear (6) onto the pini on (46). Coat the nut (30) with Loctite 242 and hand-tighten it onto the end of the pinion (46). 19. Between the redu ction 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 doe s 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 reducti on gear unit from the differenti al 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 REDUCTION GEAR AND PINION SD-116 TF SERIES AXLE MO TOR 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 SD-116 TF SERIES AXLE MO TOR 1. If necessary, install the srcinal 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 SD-116 TF SERIES AXLE MO TOR 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 MO TOR 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 SD-116 TF SERIES AXLE MO TOR 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 or ifice check va lve (20) from the hou sing (6). 3. Remove and di scard the O-r ing (19) from the orif ice 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 SD-116 TF SERIES AXLE MO TOR NOTE: Install the orifice check valve (18, 19, and 20, Figure 1-4) AFTER installing the electric 2-position 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 (2 5 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 Prior to performing repairs on this component, contact a service representative concerning issues of warranty. 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 srcinal 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 Vibrat ion .......... F3 Clockwise - High AmplitudeF4 Counterclockwise Low Amplitude......... ........ F5 Settings a nd S pecifications - Vibration* EngineRPM(Hi/Low) 116D 116F 2457/950 FlowatInputSpeed 90.5l/m23.9g/m System Relief Pressure (psi/bar) 5000/345 ChargeReliefPressure(psi) 285 X X X X X X X X * For specific application settings, contact your authorized service personnel. Hydraulic Tank Oil Cooler Vibration Motor F1 Suction Filter V IB R A T IO N Thermal Bypass Valve Vibration Pump EFF. W/ ALL S/N SD-116 TF SERIES VIBRATION HYDRAULIC TANK SUCTION STRAINER SUCTION FILTER OIL COOLER 140 F CRACKING 165 F OPEN THERMAL BYPASS VALVE 25 PSI VIBRATION PUMP M3 D F2 A VIBRATION MOTOR M4 M1 M1 M5 B A M2 M2 B L1 S OVERVIEW L2 SD-116 TF SERIES VIBRATION HYDRAULIC TANK SUCTION STRAINER SUCTION FILTER LEG EN D OIL COOLER BYPASS THERMAL BYPASS VALVE 25 PSI dashed lines indicate low pressure VIBRATION PUMP M3 D F3 VIBRATION MOTOR A M4 M1 M1 M5 B A M2 M2 B L1 S NEUTRAL - NO VIBRATION L2 SD-116 TF SERIES VIBRATION HYDRAULIC TANK SUCTION STRAINER LEG SUCTION FILTER EN D OIL COOLER 140 F CRACKING THERMAL BYPASS VALVE 25 PSI dashed lines indicate low pressure VIBRATION PUMP M3 D F4 A VIBRATION MOTOR M4 M1 M1 M5 B A M2 M2 L2 B L1 S CLOCKWISE - HIGH AMPLITUDE SD-116 TF SERIES VIBRATION HYDRAULIC TANK SUCTION STRAINER SUCTION FILTER LEG EN D OIL COOLER 165 F OPEN THERMAL BYPASS VALVE 25 PSI dashed lines indicate low pressure VIBRATION PUMP M3 D F5 A VIBRATION MOTOR M4 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 LIP SEAL ...................................................................F6.2 Disassembly .........................................................F6.2 F6.1 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 srcinal 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 ch arge 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 scr ews (1, Figure 1-5) from the ho using (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 theeach screws the servo and 17) on side (14) of thefrom housing (19). piston covers (15 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 bu rrs 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 t he 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 bu rrs 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 n ew 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 1 4 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 n eedle 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* EngineRPM(Hi/Low) 116D 2457/950 FlowatInputSpeed 24.2l/m 6.4g/m System Relief Pressure (psi/bar) 2610/180 X X 116 F X X X X * For specific application settings, contact your authorized service personnel. Steering Cylinders G1 Return Filter S T E E R IN 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 LEG END STEERING PUMP V dashed lines indicate low pressure STEERING VALVE NEUTRAL SD-116 TF SERIES STEERING HYDRAULIC TANK STEERING CYLINDERS SUCTION STRAINER RETURN F ILTER V G4 LEG END STEERING PUMP V dashed lines indicate low pressure STEERING VALVE STEER RIGHT SD-116 TF SERIES STEERING HYDRAULIC TANK STEERING SUCTION STRAINER CYLINDERS RETURN F ILTER V G5 LEGE N D STEERING PUMP V dashed lines indicate low pressure STEERING VALVE STEER LEFT 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 SD-116 TF SERIES STEERING PUMP NOTICE: Prior to performing repairs on this component, contact a service representative concerning issues of warranty. 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 t able 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 bu rrs 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 sha ft 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 t he 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 si de. Be careful no t 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 thepattern screwsshown (3) to in 50Figure to 55 1-1. N·m (36.9 to 40.5 lb-ft.). Follow the 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 vis e. 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 valv e (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 (10), (16) housing has come out.therefore check that the outer bearing race 16. Push the pin (20) fro m the spool (14) and slee ve (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) an d the O-ring (23) fro m the housing (10). Be careful not to damage the housing (10). 19. Remove the pressure rel ief 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 pressur e 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 m ating 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 cent ering springs (21) tog ether 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 bo re 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 par t 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 sleev e (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 valv e port of the housing (10). 22. Install the thre aded 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 hydrauli c 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 ass embly (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 mount ing 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 washer s (3) in the end cap (4). 33. Cross tighten the screws (1) and speci al screw (2) and torque the screws (1) and special screw (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) in to 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 piston rod (2) until the piston (3) bottoms out on the headthe (4). 4. Loosen and remove the se t 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 pisto n (3), head (4), and head cap (6) from the piston rod (2). 11. Remove and discard the O-ring (8) from the piston rod (2). 12. Remove and disca rd the wiper (9), lip seal (1 0), 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 disca rd 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 g roove on the ou tside 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 pist on 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 pisto n 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 pisto n rod (2, Figure 1-1) assemb ly 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 plu g (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 SD-116 TF SERIES STEERING CYLINDER NOTICE: (All Other S/Ns) 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 cy linder rod (4) assembly on a sui table 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 discar d the seal (14) and wear ring (15) from the piston (3). Figure 1-1 SEAL KIT INSPECTION SD-116 TF SERIES STEERING CYLINDER (All Other S/Ns) 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 g roove on the ou tside 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 c lean 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 cyl inder 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 IC 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 87A 85 87A 30 30 IGNITION SWITCH 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 RD 1.0 H2 1 . 0 2.0 BATTERIES RD RD + RD 5.0 5.0 TO OPTIONAL FRONT LIGHT RELAY .8 RD .8 RD CAP B+ STARTER SOLENOID STARTER MOTOR MASTER SWITCH (OPTIONAL) TO OPTIONAL REAR LIGHT RELAY. W STATOR O O O O OO OOO OO O O O O O O O O O O O O r to 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 1450 1425 23.8 1825 30.4 24.2 1350 22.5 1225 20.4 1250 20.8 1550 25.8 1650 2750 Air Filter Restriction Switch Throttle Solenoid Emergency Stop Switch Power Port Backup Alarm Switch (Behind Hood) E L E C T R IC A L Seat Timer Diode (In Harness) Backup Alarm 2025 33.8 VPM HZ H3 Fuses Throttle Switch Park Brake 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 RD/BE CLOSES AT 180 F 11 - GY/OE FUSES TO INSTRUMENT CLUSTERF12 15A SEE GAUGES SD-116 TF SERIES ELECTRICAL TO HORN SWITCH HORN 34 - BN 1 SPARE 10 - BK/OE F11 10A TO CAB OPTIONS F9 10A BACK UP ALARM AIR FILTER RESTRICTION SWITCH 36 - LGN TO I TERM. ON GAUGES F10 10A 2 HYDRAULIC OIL HIGH TEMP. SWITCH 11 - GY/OE 11 - GY/OE F2 10A POWER RELAY A F5 5A 16 - DBE/RD TO ANTI SPIN CONTROL OPTION 17 - GY/GN 87A 86 HIGH / LOW SPEED SWITCH 12 - LGN/WE F7 10A 87 10 - RD/WE 18 - RD/BK 3 BK F8 30A B BACK UP ALARM SWITCH TO LIGHT OPTIONS 13 - DBE/YW F6 5A 30 12 - LGN/WE 12 - LGN/WE F3 10A F4 15A 2 1 POWER PORT 85 LOW 32 - WE 6 - LBE PARK BRAKE SWITCH 27 - DPE/WE H4 HIGH IGNITION SWITCH 6 - LBE OFF 9 ON 3 1 7 1A 2A 2 1B 2B 5 START P 4 B A C 16 - DBE/RD PARK BRAKE PRESSURE SWITCH 6 IGNITION 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 BRAKE TEST SWITCH 3 HIGH 1 27 - DPE/WE 6 2 4 LOW 5 16 - DBE/RD TO AUTO / MANUAL VIBRATION SELECT SWITCH OPTION 4 DRIVE 27 - DPE/WE 27 - DPE/WE 25 - RD/BK + F1 15A 27 - DPE/WE 22 - GY/RD SEAT SWITCH THROTTLE SOLENOID TIMER BK B C TO FUEL SOLENOID N/O B A N/C COM A 32 - WE 29 - LGN/BK INIT SEAT TIMER DIODE SEAT TIMER HOLD A B C RD WE BK WE SGL RD BK 3 TEST 1 6 GRN 3 - OE/RD B A C 16 - DBE/RD THROTTLE SOLENOID 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 23.8 182 5 30.4 24.2 135 0 22.5 122 5 125 0 20.4 20.8 155 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 IC A L Ignition Switch Power Relay Starter Relay Fuel Solenoid Relay START EFF. W/ ALL S/N SD-116 TF SERIES ELECTRICAL 34 - BN FUSES HOLD TO INSTRUMENT CLUSTER F12 15A SEE GAUGES F11 10A HYD. OIL TEMP . 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 POWER RELAY F5 5A F6 5A 30 F7 10A 87 10 - RD/WE 86 85 6 - LBE AIR FILTER RESTRICTION SWITCH IGNITION SWITCH H6 TO AUDIBLE ALARM CIRCUIT TO EITHER OPTION CIRCUIT 6 - LBE 1A 1B OFF IGNITION 7 2 9 - YW/BE 5 8 - DGN/OE START EMERGENCY STOP PE GRID RELAY OUT E GN BN START IN 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 26 - OE/WE HIGH 1 28 - GY/BK 87A 30 87 5 C 6 4 LOW 28 - GY/BK 86 THROTTLE SWITCH B 62 - WE/BE A GRN 3 - OE/RD GRID RELAY OUT F IGN PR LIGHT OUT C D OE PARK BRAKE SWITCH 2A 2B 71 - PK NEUTRAL SWITCH DIODE 85 2 - DBE F1 15A BK B IGN RD B 30 - LGN/BE F8 30A 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 Brake Test Switch Emergency Stop Switch Neutral Start Switch Diode (In Harness) 1625 27 .1 1450 1425 1350 22 .5 204 . 12 50 20 . 8 Brake Test Diode (In Harness) 1825 24 .2 238 . 12 25 30 .4 15 50 258 . 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 IC 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 PARK BRAKE PRESSURE SWITCH TEST 27 - DPE/WE 2 1A 2A 1B 2B EMERGENCY STOP 19 - LGN/YW BRAKE TEST DIODE 5 49 - PK/WE 85 4 81 - YW/RD A 86 BK 6 9 ON 3 1 2 19 - LGN/YW 3 1 PARK BRAKE SWITCH 7 BRAKE LATCHING RELAY BRAKE TEST SWITCH 87 B 30 87A DRIVE 20 - LGN/YW 6 5 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 NEUTRAL SWITCH DIODE 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 C 29 - LGN/BK SEAT TIMER DIODE OPERATOR OUT OF SEAT + N/C N/O B 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 Brake Test Switch Emergency Stop Switch Neutral Start Switch Diode (In Harness) 1625 27 .1 1450 1425 1350 22 .5 204 . 12 50 20 . 8 Brake Test Diode (In Harness) 1825 24 .2 238 . 12 25 30 .4 15 50 258 . 1650 27 50 2025 33 .8 VPM HZ Park Brake Switch H9 Seat Switch (Under Seat) Seat Timer Diode (In Harness) Fuses Seat Timer E L E C T R IC A L Brake Latching Relay Pump Return To Normal Solenoid Brake Release Solenoid Park Brake Pressure Switch BRAKE/SHUTDOWN BRAKES RELEASED EFF. W/ ALL S/N SD-116 TF SERIES ELECTRICAL 21 - BN/BK P PARK BRAKE PRESSURE SWITCH 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 RELEASED BRAKE RELEASE SOLENOID 23 - RD/DGN PUMP RETURN TO NEUTRAL SOLENOID A A B B 20 - YW/BK 27 - DPE/WE H10 NEUTRAL SWITCH DIODE 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 Brake Test Switch Emergency Stop Switch Neutral Start 16 Switch Diode (In Harness) Brake Test Diode (In Harness) 25 271 . 14 14 18 242 . 13 50 225 . 25 204 . 50 25 238 . 12 12 50 20 . 8 25 304 . 15 50 2 5 .8 16 50 27 50 20 25 338 . V PM HZ H11 Park Brake Switch Seat Switch (Under Seat) Seat Timer Diode (In Harness) Fuses E L E C T R IC A L Seat Timer Brake Latching Relay Pump Return To Normal Solenoid Brake Release Solenoid Park Brake Pressure Switch BRAKE/SHUTDOWN BRAKES RELEASED OPERATOR OUT OF SEAT EFF. W/ ALL S/N SD-116 TF SERIES ELECTRICAL 21 - BN/BK P PARK BRAKE PRESSURE SWITCH TEST 27 - DPE/WE 2 1A 2A 2 1B 2B 5 19 - LGN/YW 19 - LGN/YW BRAKE TEST DIODE 5 49 - PK/WE 4 81 - YW/RD A 87 B 30 87A DRIVE 1 20 - LGN/YW 6 4 86 BK 6 9 ON 3 85 3 1 PARK BRAKE SWITCH 7 BRAKE LATCHING RELAY BRAKE TEST SWITCH 20 - YW/BK 20- YW/RD OFF EMERGENCY STOPBRAKES RELEASED BRAKE RELEASE SOLENOID 23 - RD/DGN PUMP RETURN TO NEUTRAL SOLENOID A A B B 20 - YW/BK 27 - DPE/WE H12 NEUTRAL SWITCH DIODE 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 C B 29 - LGN/BK + N/C N/O INIT SEAT TIMER SEAT SEAT TIMER DIODE 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 In Seat ........... H14 Brake Test Switch E L E C T R IC A L Emergency Stop Switch Neutral Start 16 Switch Diode (In Harness) Brake Test Diode (In Harness) 25 271 . 14 50 14 25 18 242 . 238 . 13 50 225 . 12 25 2 0 .4 12 50 20 . 8 25 3 0 .4 15 50 258 . 16 50 27 50 20 25 3 38. V PM HZ H13 Park Brake Switch Seat Switch (Under Seat) Seat Timer Diode (In Harness) Fuses Seat Timer Brake Latching Relay Pump Return To Normal Solenoid Brake Release Solenoid Park Brake Pressure Switch BRAKE/SHUTDOWN BRAKE TEST OPERATOR IN SEAT EFF. W/ ALL S/N SD-116 TF SERIES ELECTRICAL 21 - BN/BK P PARK BRAKE PRESSURE SWITCH TEST 27 - DPE/WE 2 1B 2A 2B 7 2 19 - LGN/YW BRAKE TEST DIODE 9 ON 3 85 4 49 - PK/WE A 86 BK 6 5 87 B 81 - YW/RD 1 20 - LGN/YW 6 5 4 30 87A DRIVE 20 - YW/BK 20- YW/RD OFF EMERGENCY STOP BRAKES APPLIED BRAKE RELEASE SOLENOID 23 - RD/DGN H14 19 - LGN/YW 3 1 PARK BRAKE SWITCH 1A BRAKE LATCHING RELAY BRAKE TEST SWITCH PUMP RETURN TO NEUTRAL SOLENOID A A B B 20 - YW/BK 27 - DPE/WE NEUTRAL SWITCH DIODE 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 IC A L Speedometer 1625 27. 1 1450 1425 23. 8 1350 24. 2 22. 5 1225 1250 20. 4 20. 8 VPM 1825 30. 4 1550 25. 8 1650 2025 2750 33. 8 HZ Fuses Hi/Low Speed Switch H15 Rear Anti-Spin Control Solenoid Front Anti-Spin Control Solenoid Anti-Spin 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 GY / GN A1 A2 I G BK A3 B1 RD / WE LBE / BL B2 B3 LGN LBE / BK C1 C2 BK / WE RD / WE C3 REAR SPEED SENSOR B DBE / RD A C FUSES D1 D2 D3 WE SGL RD BK BK / WE E1 E2 BK 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 X A A1 F2 10A IGN F3 10A ANALOG IN 0 F4 15A F5 5A F7 10A 3 PK / RD 2 LGN / WE 1 F8 30A VALVE 1 ANALOG IN 2 DIGITAL OUTPUT X ANALOG IN 3 X X B2 HARNESS 4 PIN CONNECTION CAN LOW CAN HIGH D WE X LOW HARNESS 4 PIN CONNECTION ANALOG IN 1 E1 HIGH B1 VALVE 0 X D3 HIGH / LOW SPEED SWITCH F6 5A 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 C1 X LGN X C2 DBE / BK A3 X BK 6200 CX GY / GN DRUM SPEED SENSOR SGL BK + BN - BE B A C LBE 2000 B A C HARNESS 4 PIN CONNECTIONS BK X C ANTI-SPIN CONTROL NO TR AVEL SD-116 TF SERIES Table of Contents Anti-Spin Control Travel............................. H18 E L E C T R IC A L Speedometer 1625 27. 1 1425 23. 8 1450 1350 22. 5 1225 1250 20. 4 20. 8 VPM HZ 1825 30. 4 24. 2 1550 25. 8 2025 1650 2750 33. 8 Fuses Hi/Low Speed Switch H17 Rear Anti-Spin Control Solenoid Front Anti-Spin Control Solenoid Anti-Spin Control Module Drum Speed Sensor Rear Speed Sensor ANTI-SPIN CONTROL TRAVEL EFF. W/ ALL S/N SD-116 TF SERIES ELECTRICAL SPEEDOMETER CONNECTOR AT ANTI SPIN MODULE S GY / GN A1 A2 I BK A3 G RD / WE B1 LBE / BL B2 B3 LGN C1 C2 BK / WE LBE / BK REAR SPEED SENSOR D1 D2 B A C DBE / RD FUSES WE SGL RD BK X FRONT ASC SOLENOID LBE D3 BK / WE E1 BK E2 E3 F1 HARNESS 4 PIN CONNECTIONS RD / WE C3 WE F2 B F3 F12 15A REFERENCE TO CONNECTOR PIN XC F11 10A REAR ASC SOLENOID F9 10A GY / GN F10 1/A H18 ANTI - SPIN CONTROL MODULE GY / GN X X A A1 F2 10A IGN F3 10A ANALOG IN 0 F6 5A F7 10A 3 PK / RD 2 LGN / WE HIGH 1 F8 30A ANALOG IN 1 VALVE 1 ANALOG IN 2 DIGITAL OUTPUT X ANALOG IN 3 D WE X LOW E1 CAN LOW X CAN HIGH DIGITAL 0 F1 HARNESS 4 PIN CONNECTION PK/RD DIGITAL 1 DIGITAL 2 6200 X X B2 / BOOT GND A3 MAINTENANCE JUMPER B1 VALVE 0 X D3 HIGH / LOW SPEED SWITCH F5 5A LBE / BK SENSOR POWER BK / WE F4 15A C1 TxD RxD X X C2 HARNESS 4 PIN CONNECTION LGN DBE / BK X C BK X GY / GN DRUM SPEED SENSOR SGL BK BN + - BE B A C LBE 2000 B A C HARNESS 4 PIN CONNECTIONS BK X C ANTI-SPIN CONTROL TRAVEL SD-116 TF SERIES Table of Contents Anti-Spin Control Drum Spin ..................... H20 E L E C T R IC A L Speedometer 1625 27. 1 1425 23. 8 1350 22. 5 1225 1250 20. 4 20. 8 VPM HZ 1450 24. 2 1825 30. 4 1550 25. 8 2025 1650 2750 33. 8 Fuses Hi/Low Speed Switch H19 Rear Anti-Spin Control Solenoid Front Anti-Spin Control Solenoid Anti-Spin Control Module Drum Speed Sensor Rear Speed Sensor ANTI-SPIN CONTROL DRUM SPIN EFF. W/ ALL S/N SD-116 TF SERIES ELECTRICAL SPEEDOMETER CONNECTOR AT ANTI SPIN MODULE 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 HARNESS 4 PIN CONNECTIONS FUSES E3 F1 XB F3 REFERENCE TO CONNECTOR PIN F11 10A F9 10A GY / GN GY / GN X F10 1/A H20 WE F2 F12 15A A A1 IGN F3 10A ANALOG IN 0 F4 15A F5 5A F7 10A 3 PK / RD 2 LGN / WE 1 F8 30A ANALOG IN 1 VALVE 1 ANALOG IN 2 DIGITAL OUTPUT X ANALOG IN 3 E1 HIGH D WE X X DIGITAL 0 DIGITAL 1 DIGITAL 2 PK/RD / BOOT C1 TxD GND X RxD LGN X C2 DBE / BK BK C GY / GN B A C HARNESS 4 PIN CONNECTION A3 X 6200 SGL BK + BN - BE X B2 CAN LOW F1 MAINTENANCE JUMPER DRUM SPEED SENSOR X CAN HIGH LOW HARNESS 4 PIN CONNECTION B1 VALVE 0 X D3 HIGH / LOW SPEED SWITCH F6 5A LBE / BK SENSOR POWER BK / WE REAR ASC SOLENOID ANTI - SPIN CONTROL MODULE X F2 10A XC X LBE 2000 B A C HARNESS 4 PIN CONNECTIONS BK X 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 IC A L Speedometer 1625 27. 1 1425 23. 8 1450 1350 24. 2 22. 5 1225 1250 20. 4 20. 8 VPM HZ 1825 30. 4 1550 25. 8 1650 2750 2025 33. 8 Fuses Hi/Low Speed Switch H21 Rear Anti-Spin Control Solenoid Front Anti-Spin Control Solenoid Anti-Spin Control Module Drum Speed Sensor Rear Speed Sensor ANTI-SPIN CONTROL WHEEL SPIN EFF. W/ ALL S/N SD-116 TF SERIES ELECTRICAL SPEEDOMETER CONNECTOR AT ANTI SPIN MODULE S GY / GN A1 A2 I G BK A3 RD / WE LBE / BL B1 B2 B3 B A C D1 D2 D3 SGL FRONT ASC SOLENOID LBE BK / WE E1 BK E2 E3 F1 HARNESS 4 PIN CONNECTIONS FUSES WE RD BK RD / WE C3 REAR SPEED SENSOR DBE / RD WE F2 F3 XB F12 15A REFERENCE TO CONNECTOR PIN F11 10A F9 10A GY / GN GY / GN F10 1/A H22 LGN LBE / BK C1 C2 BK / WE X X A A1 F2 10A X B1 ANALOG IN 0 F4 15A F5 5A F7 10A 3 PK / RD 2 LGN / WE 1 F8 30A ANALOG IN 1 VALVE 1 ANALOG IN 2 DIGITAL OUTPUT X ANALOG IN 3 E1 HIGH X X B2 HARNESS 4 PIN CONNECTION CAN LOW CAN HIGH D WE X LOW X DIGITAL 0 / BOOT F1 DIGITAL 1 TxD RxD DIGITAL 2 HARNESS 4 PIN CONNECTION VALVE 0 X D3 HIGH / LOW SPEED SWITCH F6 5A LBE / BK SENSOR POWER BK / WE REAR ASC SOLENOID ANTI - SPIN CONTROL MODULE IGN F3 10A C PK/RD GND C1 X LGN X C2 DBE / BK A3 X MAINTENANCE JUMPER 6200 C BK X GY / GN LBE DRUM SPEED SENSOR SGL BK + BN - BE B A C 2000 B A C HARNESS 4 PIN CONNECTIONS BK X 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 23 .8 1225 1825 242 . 304 . 1350 1550 22 .5 25 .8 1250 20 .4 20 .8 16 50 27 50 20 25 33 .8 VPM HZ H23 Hi/Low Speed Switch High Speed Drum Motor Solenoid E L E C T R IC 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 23 .8 1225 1825 242 . 304 . 1350 1550 22 .5 25 .8 1250 20 .4 20 .8 16 50 27 50 20 25 33 .8 VPM HZ H25 Hi/Low Speed Switch High Speed Drum Motor Solenoid E L E C T R IC 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. 1450 24 2. 1350 1550 25 8. 1825 30 4. 22 5. 1225 1250 20 4. 20. 8 1650 2750 2025 33 8. V PM 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 IC A L Vibration Speed Sensor Rear Speed Sensor AUTOMATIC VIBRATION/ IMPACT METER VIBRATION OFF EFF. W/ ALL S/N SD-116 TF SERIES ELECTRICAL AUTO/MANUAL VIBRATION SELECT SWITCH VIBRATION ON/OFF HIGH VIBRATION SOLENOID HIGH / LOW AMPLITUDE SWITCH AUTO. F5 5A 1 16- DBE / RD 39LPE 2 3 40-YW BN / 2 3 1 MANUAL 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 4 LOW VIBRATION SOLENOID ZENER DIODE 500 OHM 5.1 V 5 WATT F10 1/A 36- LGN RESISTOR H28 500 OHM 3 WATT 43- LBE / RD YW IGN SENSOR POWER 44 - DGN/YW ANALOG IN 0 VALVE 0 ANALOG IN 1 B A 45- BK / WE C VALVE 1 ANALOG IN 2 WE SGL RD DIGITAL OUTPUT ANALOG IN 3 BK CAN LOW CAN HIGH BK VIBRATION SPEED SENSOR 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 AUTO VIBRATION & IMPACT METER CONTROL MODULE BK REAR SPEED SENSOR AUTOMATIC VIBRATION / IMPACT METER - VIBRATION OFF SD-116 TF SERIES Table of Contents Automatic Vibration/Impact Meter Manual/Low Amplitu de..... H30 Impact Meter Vibration On/Off Switch VPM Meter Speedometer 1625 27 1. 1425 23 8. 1450 24 2. 1350 1550 25 8. 1825 30 4. 22 5. 1225 1250 20 4. 20. 8 1650 2750 2025 33 8. V PM HZ Automatic/Manual Vibration Switch H29 Fuses High/Low Amplitude Switch Low Vibration Solenoid High Vibration Solenoid Automatic Vibration & Impact Meter Control Module E L E C T R IC A L Vibration Speed Sensor Rear Speed Sensor AUTOMATIC VIBRATION/ IMPACT METER MANUAL/LOW AMPLITUDE EFF. W/ ALL S/N SD-116 TF SERIES ELECTRICAL AUTO/MANUAL VIBRATIONVIBRATION SELECT SWITCH ON/OFF HIGH / LOW AMPLITUDE SWITCH HIGH VIBRATION SOLENOID AUTO. F5 5A 1 39LPE 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 2 16- DBE / RD SPEEDOMETER S VPM METER S I S I G G 3 IMPACT METER BK I G Zd1 F10 1/A 4 LOW VIBRATION SOLENOID ZENER DIODE 500 OHM 5.1 V 5 WATT 36- LGN RESISTOR 500 OHM H30 3 WATT 43- LBE / RD YW IGN SENSOR POWER 44 - DGN/YW ANALOG IN 0 VALVE 0 ANALOG IN 1 B A 45- BK / WE C WE RD VALVE 1 ANALOG IN 2 SGL DIGITAL OUTPUT ANALOG IN 3 BK CAN LOW CAN HIGH BK DIGITAL 0 VIBRATION SPEED SENSOR / BOOT 67- LGN TxD DIGITAL 1 RxD DIGITAL 2 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 AUTO VIBRATION & IMPACT METER CONTROL MODULE AUTOMATIC VIBRATION / IMPACT METER - MANUAL/LOW AMPLITUDE SD-116 TF SERIES Table of Contents Automatic Vibration/Impact Meter Manual/High Amplitude.... H32 Impact Meter Vibration On/Off Switch VPM Meter Speedometer 1625 27 1. 1425 23 8. 1450 24 2. 1350 1550 25 8. 1825 30 4. 22 5. 1225 1250 20 4. 20. 8 1650 2750 2025 33 8. V PM HZ Automatic/Manual Vibration Switch H31 Fuses High/Low Amplitude Switch Low Vibration Solenoid High Vibration Solenoid Automatic Vibration & Impact Meter Control Module E L E C T R IC A L Vibration Speed Sensor Rear Speed Sensor AUTOMATIC VIBRATION/ IMPACT METER MANUAL/HIGH AMPLITUDE EFF. W/ ALL S/N SD-116 TF SERIES ELECTRICAL AUTO/MANUAL VIBRATION VIBRATION SELECT SWITCH ON/OFF HIGH / LOW AMPLITUDE SWITCH HIGH VIBRATION SOLENOID AUTO. F5 5A 1 39LPE 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 2 16- DBE / RD VPM 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 H32 500 OHM 3 WATT 43- LBE / RD YW IGN SENSOR POWER 44 - DGN/YW ANALOG IN 0 VALVE 0 ANALOG IN 1 B A 45- BK / WE C WE RD BK VALVE 1 ANALOG IN 2 SGL DIGITAL OUTPUT ANALOG IN 3 CAN LOW CAN HIGH BK DIGITAL 0 VIBRATION SPEED SENSOR / 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 AUTO VIBRATION & IMPACT METER CONTROL MODULE 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 Vibration On/Off Switch VPM Meter Speedometer 1625 27 1. 1425 23 8. 1450 24 2. 1350 1550 25 8. 1825 30 4. 22 5. 1225 1250 20 4. 20. 8 1650 2750 2025 33 8. V PM HZ Automatic/Manual Vibration Switch H33 Fuses High/Low Amplitude Switch Low Vibration Solenoid High Vibration Solenoid Automatic Vibration & Impact Meter Control Module E L E C T R IC A L Vibration Speed Sensor Rear Speed Sensor AUTOMATIC VIBRATION/ IMPACT METER AUTOMATIC/LOW AMPLITUDE EFF. W/ ALL S/N SD-116 TF SERIES ELECTRICAL AUTO/MANUAL VIBRATION VIBRATION SELECT SWITCH ON/OFF F5 5A AUTO. 1 16- DBE / RD 39LPE 2 HIGH / LOW AMPLITUDE SWITCH 3 40-YW BN / 2 3 MANUAL 1 HIGH HIGH VIBRATION SOLENOID 89- YW / WE 1 2 LOW 3 BK 4 38- WE / OE 1 55- DBE / BK VPM METER IMPACT METER 3 BK SPEEDOMETER S S I S I G G 2 16- DBE / RD I G Zd1 F10 1/A 36- LGN H34 4 LOW VIBRATION SOLENOID 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 VIBRATION SPEED SENSOR 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 AUTO VIBRATION & IMPACT METER CONTROL MODULE BK REAR SPEED SENSOR AUTOMATIC VIBRATION / IMPACT METER - AUTOMATIC/ LOW AMPLITUDE SD-116 TF SERIES Table of Contents Automatic Vibration/Impact Meter Automatic/High Amplitu de... H36 Impact Meter Vibration On/Off Switch VPM Meter Speedometer 1625 27 1. 1425 23 8. 1450 24 2. 1350 1550 25 8. 1825 30 4. 22 5. 1225 1250 20 4. 20. 8 1650 2750 2025 33 8. V PM HZ Automatic/Manual Vibration Switch H35 Fuses High/Low Amplitude Switch Low Vibration Solenoid High Vibration Solenoid Automatic Vibration & Impact Meter Control Module E L E C T R IC A L Vibration Speed Sensor Rear Speed Sensor AUTOMATIC VIBRATION/ IMPACT METER AUTOMATIC/HIGH AMPLITUDE EFF. W/ ALL S/N SD-116 TF SERIES ELECTRICAL AUTO/MANUAL VIBRATIONVIBRATION SELECT SWITCH ON/OFF HIGH / LOW AMPLITUDE SWITCH HIGH VIBRATION SOLENOID AUTO. F5 5A 1 39LPE 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 VPM METER 2 16- DBE / RD IMPACT METER 3 BK S S I S I G G LOW VIBRATION SOLENOID 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 YW IGN SENSOR POWER 44 - DGN/YW 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 VIBRATION SPEED SENSOR / 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 AUTO VIBRATION & IMPACT METER CONTROL MODULE AUTOMATIC VIBRATION / IMPACT METER - AUTOMATIC/ HIGH AMPLITUDE SD-116 TF SERIES Table of Contents Automatic/Variable/ Impact Meter ................ H38 Impact Meter Vibration On/Off Switch VPM Meter Speedometer 1625 27 1. 1425 23 8. 1450 24 2. 1350 1550 25 8. 1825 30 4. 22 5. 1225 1250 20 4. 20. 8 1650 2750 2025 33 8. V PM HZ Automatic/Manual Vibration Switch H37 Fuses High/Low Amplitude Switch Low Vibration Solenoid High Vibration Solenoid Automatic Vibration & Impact Meter Control Module E L E C T R IC A L Vibration Speed Sensor Rear Speed Sensor AUTOMATIC/VARIABLE/ IMPACT METER EFF. W/ ALL S/N S S I S I I G G SD-116 TF SERIES ELECTRICAL IMPACT METER VPM METER SPEEDOMETER G 200 OHM EACH F10 1/A 36- LGN 2 D E E P S 1 D E E P S 43- LBE / RD 200 OHM TO VIB SPEED SENSOR SIGNAL B TERMINAL 3 D E E P S 4 D E E P S 5 D E E P S 200 OHM 43- LBE / RD AUTO/MANUAL VIBRATION SELECT SWITCH 45 - BK / WE HIGH / LOW AMPLITUDE SWITCH VIBRATION ON/OFF AUTO. 3 2 39-LPE 3 40YW BN / 13 1 1 MANUAL 16 VARIABLE FREQUENCY SWITCH 11 HIGH 54- LBE / BK 55- DBE / BK 2 15 14 12 BK LOW 48- WE / BK F5 5A C B A 38 - WE / OE HIGH VIBRATION SOLENOID 16 - DBE / RD 16- DBE / RD 54- LBE / BK 41- DPE 1 16- DBE / RD Zd1 H38 REAR SPEED SENSOR ZENER DIODE 500 OHM 5.1 V 5 WATT 48- WE / BK 2 3 BK 4 RESISTOR 500 OHM 3 WATT L G S E DK WR B 1 IGN B A C K B 45- BE / WE 44- DGN / YW C A B B R W K D E S G L VALVE 0 ANALOG IN 1 VALVE 1 ANALOG IN 2 DIGITAL OUTPUT 90-YW VIBRATION SPEED SENSOR ANALOG IN 0 VALVE 0 ANALOG IN 1 VALVE 1 ANALOG IN 2 DIGITAL OUTPUT ANALOG IN 3 ANALOG IN 3 CAN LOW CAN LOW 40- YW / BN / BOOT DIGITAL 0 TxD DIGITAL 1 RxD DIGITAL 2 DIGITAL 2 GND BK BK 42- GY / WE 4 LOW VIBRATION SOLENOID CAN HIGH DIGITAL 0 DIGITAL 1 AUTO VIB. & IMPACT METER CONTROL MODULE 3 SENSOR POWER ANALOG IN 0 CAN HIGH BK 2 IGN SENSOR POWER / BOOT 60- PK / WE TxD RxD GND 61- LGN / OE 64- RD / BE 63- GY BK 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 IC A L Grid Heaters 1 62 5 2 7.1 1 45 0 1 42 5 1 82 5 2 4.2 2 3.8 1 35 0 2 2.5 1 22 5 1 25 0 20 .4 20 .8 3 0.4 1 55 0 2 5.8 1 65 0 2 75 0 2 02 5 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 A A C C B B 87 71- PK 86 RD FUEL SOLENOID BK WE PULL 85 50- RD GRID HE ATER CONTROL MODULE GRID HEATER 52- LGN / RD BK BE A LIGHT OUT RD B GRID RELAY OUT OE C GRID RELAY OUT PE D START IN GN E N/A BN F IGN H40 YW BK B RD GRID HEATER RELAYS 53- LGN WE 51- RD A . P M E T D N G RD 37 - BN /RD RD 5.0 RD 37- BN / RD BK GRID HE ATER INDICATOR BK CAP B+ W A STATOR 92- RD / BK B O O O O O O O O O OO O O O O O O A TEMPERATURE SENSOR O O O O O O r o t la u g BK e R 34- BN D+ ALTERNATOR F9 10A GRID HEATER GRID HE ATER SD-116 TF SERIES Table of Contents Gauges ....................................H42 VPM Meter 2 3 .8 1450 2 4 .2 1350 2 2 .5 1225 2 0 .4 1250 2 0 .8 1825 3 0 .4 1550 2 5 .8 1650 2750 Engine Oil Hydraulic Oil Temperature Gauge 1625 2 7 .1 1425 E L E C T R IC A L Engine Oil Pressure Gauge Pressure Sender 2025 3 3 .8 V PM HZ Voltmeter Speedometer Impact Meter H41 Fuses Vibration Speed Sensor 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 0E - 73 0E - 73 S P EE D O M E T E R 0E - 73 V P M M ET ER IMPACT 0E - 73 73 - 0E 36 - LGN LGN 36 - 36 - LGN 36 - LGN LGN 36 - 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 VIBRATION SPEED SENSOR 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 Indicator (In Hydraulic OilInstrument Temperature Indicator (In 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 2025 2750 33. 8 VPM HZ E L E C T R IC 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 ENGINE COOLANT TEMERATURE GAUGE I LOW OIL PRESSURE INDICATOR FUEL LEVEL GAUGE TACHOMETER I I RPM G T T G DIODE G AIR FILTER RESTRICTION INDICATOR BACK LIGHT BACK LIGHT BACK LIGHT GRID HE ATER 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 AIR FILTER RESTRICTION SWITCH 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 IC A L Beacon Light Air Filter Backup Alarm Engine Oil Pressure Gauge Coolant Level Sensorr Speedometer 1625 21 7. 1450 1425 23 8. 1225 20 4. 1825 30 4. 22 4. 1350 25 2. 1250 2 0 .8 1550 28 5. 1650 2025 2750 33 8. V PM 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 AMPERE RATING CIRCUIT F1 15 AMP KEY SWITCH, E-STOP, IGNITION, FUEL & THROTTLE SOLENOID HOLDCIRCUITS, SEAT SWITCH AND PARK BRAKE F2 10 AMP F3 10AMP TWOSPEEDCIRCUIT&BACKUPALARM F4 15AMP WORKLIGHTS, BEACON & TURN SIGNAL/ HAZARD LIGHTS F5 5AMP AUTO/MANUALVIBRATION&IMPACTMETER F6 5AMP ANTI-SPINCONTROL F7 10 AMP POWERPORT F8 30AMP THROTTLESOLENOIDPULL-INCIRCUIT F9 10 AMP INSTRUMENT CLUSTER F10 10 AMP F11 10AMP CABOPTIONS F12 10AMP STRIKEOFFBLADEOPTION FUSE NO H46 HORN, AIR FILTER, HYDRAULIC OIL TEMPERATURE & COOLANT LEVEL CIRCUITS VOLTMETER, OIL PRESSURE, SPEEDOMETER, VPM &IMPACT METER GAUGES 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 ca pscrews (2), hex nu ts (4), and fla twashers (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 ROLLOVER PROTECTIVE STRUCTURE (ROPS) SD-116 TF SERIES/ ROPS/FOPS REPLACEMENT INSPECTION 1. Check the ROPS/FOPS (1, Figure 1-1) for signs of fa tigue 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 ob structions and lif t 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 ROLLOVER PROTECTIVE STRUCTURE (ROPS) 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 • Feelergauges • Petroleumjelly • 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 TOOLS REQUIRED AND SAFETY 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, Fig ure 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 oscil lating pin (5). 11. Remove the pin (5), washer (7) an d nut (6) from the swive l and drum frame. 12. Remove the hitch pin (16 ) and remove the lock pin (9) . 13. Move the drum fra me clear of the sw ivel. 14. Remove and discar d 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 en d 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 cyli nder rod end from the swiv el (3). 19. Remove and disca rd 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 devi ce to the swivel (3, Figure 15). 22. Remove the capscrews (27) and was hers (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 wash er (7) from the pin (5). 25. Remove the pin (5) from the swive l (3) and rear frame. 26. Using the lifting device, remove the swivel (3). J2.7 27. Remove and disca rd 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 DRUM FRAME AND SWIVEL BEARINGS 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 washe r (7) and stop nut (6) onto the oscillatin g 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 capscrew s (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 bushin gs (10). 18. Install the new bushings (10) into the top of the swivel (13). Figure 1-7 DRUM FRAME AND SWIVEL BEARINGS SD-116 TF SERIES SWIVEL BEARING REPLACEMENT 19. Connect the steer cyl inder (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 hydrauli c lines to the steer cylinders as tagged during disassembly. 23. Apply a coat of grease to the new beari ngs (4). NOTE: Bearings are to be cooled to -18°C (0°F) for 2 to 4 hours before installation. 24. Lower the temper ature of the beari ngs (4). 25. Install the bearings (4) into the drum frame (2). J2.10 26. Install the dust seals (24 and 25) onto the drum fra me (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 adequa te 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 temporari ly installed oscillating pin (5) from the swivel (3). swivel horizo ntal 30. Apply a light coat of Never -Seize to the lar ge diameter of the pin (5). Figure 1-7 DRUM FRAME AND SWIVEL BEARINGS 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 cente red 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 capscrew s (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 assemb ly (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 electri cal harness betwee n 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 machi ne and check for proper opera tion and leaks. 44. It is recommended that after the firs t 50 to 100 hours of operation, the articulation joint fasteners be checked for proper torque. Figure 1-7 DRUM FRAME AND SWIVEL BEARINGS 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 J3.1 ...................................................................... J3.7 Drum Drive Side Disassembly ...................... J3.8 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 • BlueLoctite • Feelergauges • Sledge hammer • Heat resistant gloves • Non-residue type solvent • Acetylene torch • Straps or chains • Loctite primer-T • Anti-seize • Petroleumjelly • 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 TOOLS REQUIRED AND SAFETY 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 TOOLS REQUIRED AND SAFETY 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 th e center articulation joint to rai se the fr ame, (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 lif ting device, remove the scra per from the dru m 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 capscre ws (37) and flatwashers (36) securi ng the vibration motor (27) to the carrier assembly (23). 12. Remove the vibra tion motor (27) and O-r ing (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 capscre ws (22, Figure 1-4), flatwashe rs (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 ca pscrews (5), flatwashers (4), an d 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, Fi gure 1-6) from th e 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) sec uring 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 b earing 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 re taining ring (18) from the spi ndle (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 requir ed, 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 non residue 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 cra cks, 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 cause 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). Use WARNING: 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 bolt s(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 eccent ric assembly (5, Figure 1-8) unti l the bearing housing drive (2) is installed. 18. Coat the contact areas of both ends of the spli ned 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 sh ocks (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 TF SERIES DRUM AND DRUM DRIVE DRIVE SIDE ASSEMBLY AND INSTALLATION 1. Install a new O-ring (20, Figure 1-10) into the bearing housing drive (2). 2. Heat the bearings (6) 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 cause severe burns. NOTE: Bearings are to be cooled to -18°C (0° F) for 2 to 4 hours before installation. 3. Lower the temperature of the new bearings (6). 4. Install new bearings (6) into the bearing housing drive (2). J3.15 WARNING: Safety glasses must be worn when installing the retaining rings. 5. Install the retaining rings (7). 6. Attach an adequate lifting device to the bearing housing drive (2). 7. Install the bearing housing drive (2) into the drum (1). 8. Apply Loctite #271 (red) to the bolts (10). 9. Install the bolts (10) and flatwashers (8) into the 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 TF SERIES DRUM AND DRUM DRIVE 12. Apply petroleum jelly to the new O-ring (9, Figure 1-11). 13. Install a new O-ring (9) onto the cover (11). 14. Install the cover (11) onto the bearing housing drive (2). 15. Apply Loctite #242 (bl ue) to the capscrews (13). 16. Install the capscrews (12) into the cover (11). 17. Torque the capscrews (13) to 28.5 N·m (21 lb-ft.). J3.16 Figure 1-11 DRUM ASSEMBLY SD-116 TF SERIES DRUM AND DRUM DRIVE DRUM DRIVE ASSEMBLY AND INSTALLATION 1. Apply Loctite #271 to capscrews (5, Figure 1-12). 2. Install the mounting plate (3) to the drive motor (1). 3. Install the capscrews (5), flatwashers (4), and nuts (6) into the mounting plate (3) and the drive motor (1). 4. Torque the capscrews (5) to 515 N·m (380 lb-ft.). WARNING: Use care when attaching and securing the lifting device to avoid risk and of accidents. Use acapacity lifting device that is in perfect condition with sufficient for lifting components being serviced or repaired. Check for overhead obstructions. 5. Using an adequate lifting/supporting device, position the drive motor (1) onto the drive plate (2). 6. Apply loctite #271 to the capscrews (7). J3.17 7. Install the capscrews (7) and flatwashers (4) into the drive plate (2) and drive motor (1). 8. Torque the capscrews (7) to 575 N·m (420 lb-ft.). 9. Apply Loctite #271 (red) to capscrews (30, Figure 1-11). 10. Install the shock mounts (16) to the dru m (1). 11. Install the capscrews (30) and flat washers (29) int o the shock mounts (16). 12. Torque the capscrews (30) 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. Figure 1-12 13. Attach an adequat e lifting/supporting device to the drive motor (1, Figure 1-12), drive plate (2) and mounting plate (3). DRUM DRIVE SD-116 TF SERIES DRUM AND DRUM DRIVE 14. Apply Loctite #271 (re d) 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 an d carrier oil lev el. 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 thethe drum. between the edge the drum ends shell of and drumMeasure frame. Shift the drum until of these measurements are equal. 9. Measure to determine the shim thickness on eac h end at the drum mounting location E. J3.20 10. Compare this to the thickness of the shim packs remo ved 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 capscrew s (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 hydr aulic 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 caps crews (37). 22. Install the capscrews (37) and flatwa shers (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 hydrau lic lines to the vibration motor (27) . 25. Lubricate the drum assembly prior to operatio n. J3.21 26. Check the system hydra ulic oil. Refer to the Operations and Maintenance Manual for these models for maintenance instructions. 27. Operate the compa ctor and check for proper operati on, 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 •H ammer 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, Fig ure 1-1) and flatwasher (7) from the spline coupling (6). 2. Remove the spl ine coupling (6) from th e 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 f latwashers (7) from th e 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 th e eccentric shaft housing (2). 9. Remove and discard the oillite bearing (5) from the eccentric shaft (3). 10. Remove the eccentri c 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 6 1 N·m (45 l b-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 cap screws (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 Loc tite #271 (red) to both the capscre ws (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 d le e u fr e v o p m u p n o ti c e j in / n o tic n u fl a m C F A ELECTRICAL S E S U A C E L IB S S O P d e g g lu p r lte if r/ e n a e l c ri A m e t s y s l e u f in ri A d e t c rit s e r n o ti a tr o tf a h s k n a r C w lo e g r a h c y r ry tte tte a a B B l a e u q s lt e b e v ri ts ic u ri c l a ic t c e l D E w lo o to d e e p s g in k n a r c e n i g n E d e g a g n e tis n u e v ri d e n i g n E ld o c o o t d e t a g n i in n m n a t u r n e o c n i l g e n u E F d e g g u l p r tle fi l e u F d te c rit s e r y l p p u s l e u F s e s u F e is o n n i a tr r a e G w lo o o t d e e p s le Id e r u d e c o r p g n rti ta s t c rre o c In n io t c n u lf a m t c rre o c in g n i m it n io t c n u lf a m lz e z o n r to c je In p m u p n o ti c e j n I p m u p n o ti c e j n I d te c rit s e r s k a e l t m s u te a s h y x s /e ir ir a a e e k k a a t t n n I I e i n g n e g in g g u L l e fu o N / w o L s r o t c e j in g n i n o ti c n u fl a M le z z o n r o t n c j w e o n i d r te u d h n s u e s in re g h n e s a g n lw i n a e o s ti c le n p u it lf l a u M M id o n le o S r te r a t d e d e S o t e g a tl o v o N e n d i a g in rt ta S n o ti c n u fl a m r o t o m g n tir a t S r o d i o n e l o S d e d o rr o c r o e s o lo s n o it c e n n o c t ic u ri C g in rt ta S SYMPTOMS K1 ENGINE Won't crank cranks or slowly Hard start to will not or start Stalling Surge (excessive) Noise Smoke 4 2 1 4 2 4 3 5 7 5 1 8 7 5 6 4 4 2 1 8 3 2 7 6 10 1 2 6 3 6 2 4 7 9 8 6 3 3 1 5 3 1 5 ELECTRICAL SYSTEMS Lights No Gauges No 1 1 3 3 2 2 TROUBLESHOOTING NOTE: Poss ible causes for each symptom are numbered in order of most likely occurance. e in g n e g in k n a r c t o n t u b g in t a r e p o rto o m g in rt ta S e iv s s e c x e h s la e v l a V d te s ju d a ly t c re r o c in s e v l a V S E S U A C E L IB S S O P HYDRAULICS r e d n m li te p y s m C y s u n p e in d k ir a ro A B B re u s s e r P e rg a h C e lv a v s s a p y B ) n io t a r ib (V p m u p e rg a h C ) F / X D ( lr t n c t m e t s y S d te a n i m ta n o C le b a C l o tr n o C s s a e p lv -y a b V r l o e tr d n iln o y C C g in l p u o c e v ir D s g n ir a e b irc t n e c c E lm p is d l a c rti c le E C D E l e v le li o irc t n e c c E ir o v r e s e r n i l e v e l li o r e g n a h c x E t a e H it u c ir c l a ic t c le E ic l u a r d y H p m u p / e lv a v f ie l e r g r h c t c e p s In r e lti f t e l n I e ic ifr o l o tr n o C t c e p s In r e v le d n a e g a k in L e v l a v n o it c n u -if tl u m p m u P e lv a V l o tr n o C e c la p e R re n u io s s s is e r m p s l n o rt ra n T o e C c o la p M rv e P e R R S l a ti n e r e ffi d re u s s re p o rv e S le o s n o c n o s g n tit e S e v l a v g in h s u fl p o o L k c e h c re u p s m s u re p p g n m ri e e ts e t y S S s e lv a v k c e h c /f e il re m te s y S )l a n o it p (O re e u v s l s a v re l p o f rt e n li o re c n m io t e t c s a y r S T SYMPTOMS VIBRATION working Not direction One only Frequency low System operating "HOT" Neutral difficult find to ModeWrong 3 4 7 4 12 11 1 9 2 7 6 1 3 5 3 4 4 4 2 1 6 5 8 13 10 9 2 6 2 1 10 1 8 3 7 5 5 3 2 2 1 STEERING K2 Steering No Steer to Hard again On and Off Wander Drift or Steering Slip (Intermittant) 3 5 6 4 4 3 2 6 1 5 2 3 2 2 1 1 3 4 6 2 1 5 4 2 6 1 3 PROPULSION Propulsion No Direction One Sluggish Neutral difficult find to System operating "HOT" 3 4 8 1 5 11 4 4 3 6 2 3 10 8 9 1 5 7 3 2 9 1 3 10 4 7 5 12 2 6 8 1 2 1 3 5 TROUBLESHOOTING NOTE: Pos sible causes f or each symptom are nu mbered in order of most likely occurance. 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 vi bration 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 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. K3.3 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. 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 the system LED on the microprocessor illuminated? Correction Determine power interruption by: • Is the vibration on/off button in the “ON” position? • Is the F5 fuse OK? • Is there a fault in 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 Is status LED displaying a red four-blink fault code? Correction In order for the fault codes to be illuminated, the ignition switch must remain in the “on position” from the time the fault occurs. To accomplish 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 C ODES The following is a list of possible fault codes (S = short and L = long) • 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 = 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 Code Symptom LLSS • The vibration shuts down. Check • Check the integrity 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 SD-116 TF SERIES / VIBRATION CONTROL SYSTEM Fault Code Troubleshooting Chart (Continued) Code 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 bottoms backitsensor outout, 3/4then 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 SD-116 TF SERIES / VIBRATION CONTROL SYSTEM Fault Code Troubleshooting Chart (Continued) Code Symptom Ch e c k 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 left-hand Note: The loop-flushing valve in the on axlethe drive motor side. 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 Mode K4.3 Status normally. 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. 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. 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) Step Check Correction 2 Is the system LED on the microprocessor illuminated? If system LED is not illuminated and the POWER LED is illuminated, an internal problem exists in the microprocessor and it will require replacement 3 Is status LED displaying a red four-blink fault code? In order for the fault codes to be illuminated, the ignition switch must remain in the “on position” from the time the fault occurs. K4.5 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 C ODES 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 SD-116 TF SERIES / TRACTION ENHANCEMENT SYSTEM Fault Code Troubleshooting Chart (Continued) Code Symptom SLLS • Front (drum) speed (Cont) sensor signal out of range. (Cont) Check c. Check cont inuity between the “C” or “B-“ terminal of the sensor connector and ground/ frame. • After the wiring and K4.9 connectors havethe been inspected reset 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 SD-116 TF SERIES / TRACTION ENHANCEMENT SYSTEM Fault Code Troubleshooting Chart (Continued) Code 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) speed1-3) sensor (1, Figure out of range. • Check the and integrity of the wiring connectors between the speed sensor on axle drive motor and microprocessor. Figure 1-3 REAR AXLE SPEED SENSOR SD-116 TF SERIES / TRACTION ENHANCEMENT SYSTEM Fault Code Troubleshooting Chart (Continued) Code 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 cont inuity 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 therestarting off position then theand machine. Figure 1-3 REAR AXLE SPEED SENSOR SD-116 TF SERIES / TRACTION ENHANCEMENT SYSTEM Fault Code Troubleshooting Chart (Continued) Code 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 the microprocessor 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 REAR AXLE SPEED SENSOR 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 REAR AXLE SPEED SENSOR Hydraulic Symbol Quick Reference Chart O p e r at i o n M e t h o d s Manual Mo to rs & C yl i n d ers Fixed Displacement, Unidirectional, Rotary Hydraulic Motor M i s c e l l a n e o u sS y m b o l s Pressure Gauge P u m ps Fixed Displacement, Unidirectional Hydraulic Pump Va l v e s Check Valve Manual Shut Off Valve Pedal Or Treadle Temperature Gauge Fixed Displacement, Bidirectional, Rotary Hydraulic Motor Fixed Displacement, Bidirectional Hydraulic Pump Pressure Relief Valve Push Button Cooler Level Variable Displacement, Bidirectional, Rotary Hydraulic Motor L1 Pilot Pressure 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 Open Center, Three Position Directional Control Valve Tandem Center, Three Position Directional Control Valve Solenoid Spring Closed Center, Three Position Directional Control Valve Line to Tank (Above Fluid Level) Float Center, Three Position Directional Control Valve Pilot Line 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 L2 Gray/Black GY/BK Orange/Black OE/BK Black/Yellow BK/YW White/Violet WE/VT White/Gray WE/GY Gray/Yellow GY/YW DrBlue/White DBE/WE Yellow/Brown YW/BN DGN/OE Black/Orange BK/OE Dr Green/Orange White/Orange WE/OE White/Blue WE/BE Dr Blue/Yellow DBE/YW Dr Blue/Black DBE/BK Lt Green/Black DrGreen/Red LGN/BK DGN/RD White/Green Gray/Red WE/GN GY/RD DrBlue/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 LtGreen/White LGN/WE LtBlue/White LBE/WE Gray/White GY/WE DrBlue/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 Black/White BK/WE DkGreen BN/WE DGN LtGreen Gray LGN GY LtBlue Dk Blue LBE 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 3 L C I L U A R D Y H S E I R E S F T 6 1 1 D S 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 D59292995 Rev. 5 L L A C I R T C E L E S E I R E S F T 6 1 1 D S D59292995 Rev. 6 L L A C I R T C E L E S E I R E S F T 6 1 1 D S D59292995 Rev. 7 L T h e w a r ra n ty s ta te m e n t is p ro v id e d w it h in th e m a n u a l k ti s h ip p e d w ith th e m a c h in e . 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