EN SD116 TF - VOE21A1004254H

MORE CARE. BUILT IN.VOLVO CONSTRUCTION EQUIPMENT SERVICE MANUAL Sd116 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. CALIFORNIA Proposition 65 Warning Battery posts, terminals and other related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and other reproductive harm. Wash hands after handling. SD-116 TF SERIES A1 HYDRAULIC Propulsion / Braking Schematics .................................................. E1 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 Reverse - Brakes Released (Tire Spin) Standard on DX, Optional on D & F..E12 Component Teardown & Rebuild Propulsion Pump............................................... E13 Axle ................................................................... E14 Axle Motor......................................................... E15 Loop Flush Valve .............................................. E16 TABLE OF CONTENTS Table of Contents.............................................. A1 Features of This Manual................................... B1 Safety Information ............................................ C1 Illustrated Hose Schematic Option Without Traction Control ............. D1 Option With Traction Control ................... D2 EFF. W/ ALL S/N SD-116 TF SERIES TABLE OF CONTENTS A2 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 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 EFF. W/ ALL S/N ......................................................................................... High Amplitude........ H29 Automatic Vibration/Impact Meter Manual.................................................... High Amplitude..................... H1 Ignition ............K2 Vibration Control System . H21 High/Low Speed Low Speed/Anti-Spin Activated ........................................................... Low Amplitude... H27 Automatic Vibration/Impact Meter Manual............................ H17 Anti-Spin Control/Drum Spin ..........K3 Traction Enhancement system .. H7 Brake/Shutdown ............................................. Low Amplitude ....... H31 Automatic Vibration/Impact Meter Automatic................. H11 Brake/Shutdown .. J3 Eccentric Assembly ...SD-116 TF SERIES Automatic/Variable/Impact Meter .........Brakes Released/ Operator Out of Seat....... J4 TROUBLESHOOTING Hydraulic.................................................................... H37 Grid Heater ................... H3 Start ....... H19 Anti-Spin Control/Wheel Spin................................ L1 Electrical Schematic Wire Color Code Reference Chart ........ H1 Battery . H33 Automatic Vibration/Impact Meter Automatic..............L2 Hydraulic Schematic ................................ H15 Anti-Spin Control/Travel ........................................................ J1 Swivel Bearing Replacement.... H45 MACHINE Component Teardown & Rebuild ROPS/FOPS Replacement................................... H41 Instrument Cluster ............................................................... H13 Anti-Spin Control/No Travel ....................................Brakes Test/ Operator In Seat ........................ H23 High/Low Speed High Speed/Anti-Spin Inactive...................... H43 Fuses .Brakes Released ......Brakes Applied ....................... H25 Automatic Vibration/Impact Meter Vibration Off ...K4 REFERENCE CHARTS AND SCHEMATICS Hydraulic Symbol Quick Reference Chart. W/ ALL S/N ............................. H35 EFF.......... J2 Drum and Drum Drive........................................ H39 Gauges ...................................... H5 Brake/Shutdown .........................................................................K1 Electrical ..... H9 Brake/Shutdown ..L5 TABLE OF CONTENTS A3 ELECTRICAL Schematics...........................................................................L3 Electrical Schematic.............................................................................................................................. ........................... CHARGE RELIEF VALVES Figure 1-3.. Check and adjust the charge pressure as required.........4 Assembly... E13................ Inspect the charge relief valve (4) and mating seat in the Assembly...................... W/ ALL S/N ........................... the locknut (8)................................... B1 • Troubleshooting chart w/ symptoms & prioritized possible causes....................................................... E13................... SD-122 TF SERIES PROPULSION HYDRAULIC TANK SUCTION S TRAINER • Each page is specific to one functional subsystem....5 2......... INSPECTION Assembly...4ly............ FEATURES OF THIS MANUAL Assembly......................................................E13............................................................REMOTE CHARGE PRESSURE FILTRATION.............................. E13.... • Settings and specifications....................2 MANUAL DISPLACEMENT CONTROL...............4 1..........E13....... E13.....BRAKES RELEASED STANDARD PARALLEL ON D & F S ept embe r 2 002 EFF........ E13............................................. E13.E13....4 1...............3 Disassembly................ CAUTION: Do not interchange parts with another valve..9 DISASSEMBLY NOTE: To maintain original adjustment....5 INSPECTION INSPECTION 1.......... Inspection.... • Wire color code reference chart........................................................ E13..........5 R authorized rebuilt components 3............ E13........................................ Remove the spring (5) and charge relief valve (4) from the plug (7).............1 REVERSE .1 SD-70/77TF SD 122TF SERIES PROPULSION PUMP DISASSEMBLY Disassembly.....................................8 LIP SEAL AND SHAFT....................... and the housing (2)..... Loosen the locknut (8) and remove the plug (7) by DISASSEMBLY unscrewing the plug (7) from the housing (2)....E13.............5 Inspection.....5 Disassembly......................................... • Hydraulic symbol quick reference chart.............................................. 25 PSI B M2 E8 L2 CHARGE FILTER PROPULSION PUMP M6 M3 D E M1 DRUM MOTOR A M1 M5 M4 HI / LO L R B BR AK AKEE M2 L2 M2 L1 • Standard symbols are used......................................................6 Assembly..... 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).................. Assembly................................... refer to Figure 1-3....... E13................... Remove and diskard the O-ring (6) from the plug (7)....................5 3.........5 Disassemb Inspection..........6 ASSEMBLY Save time and money by contac ting your author ized E13.........2 t ic s & a m ting SD-122 TF SERIES PROPULSION PUMP TABLE OF CONTENTS.........................................................E13.....E13.7 oo E13.......................................................8 Disassembly.... CHARGE PUMP.............................................................................. mark the plug(7)....... Tr h oubles 4........................................ E13...........................................E13............................................ E13................................ E13............2 S c he Inspection................ repr esentative for infor mation regar ding Authorized Rebuilt Components.......................... E13..........E13.......................................................... E13...... TABLE OF CONTENTS CHARGE RELIEF VALVES • Hose routing diagram w/ components labeled................................... Install a new O-ring (6) onto plug (7)...... DUM P / BRAKE / 2 SP EED MANIFOLD LOOP FLUSH VALVE 140 F CR ACK ING 165 F OPEN THERMAL BYPASS VALVE M1 AXLE MOTOR A • Operational status is identified by color.. E13..... S dashed lines indicate low pressure • Colors are standard throughout manual................... E13.................................................. CHARGE RELIEF VALVE.E13...........................6 Disassembly..........E13... PropulsionPump 2........E13................ Install the charge relief valve (4) and spring (5) onto the plug (7)......................................8 Inspection......9 Assembly........ Inspection.....8 Disassembly......5 CHARGE RELIEF VALVE...............................................9 MULTI-FUNCTION VALVE CARTRIDGES.......................................................E13............5 end cap for damage or foreign material. 032503AA EFF. W/ ALL S/N . refer to the Safety section of the SD-116 TF SERIES operation and maintenance manual and the AEM Safety Manual for Safety Instructions.SD-116 TF SERIES C1 SAFETY INFORMATION Before performing any maintenance or service procedures on your SD-116 TF SERIES. OPTION WITHOUT TRACTION CONTROL Suction Filter Check Valve Hydraulic Tank Steering Valve Propulsion Pump Vibration Pump Steering Pump Right Steering Cylinder D1 Charge Filter Oil Cooler Left Steering Cylinder Thermal Bypass Valve Brake Valve Axle Suction Filter Axle Motor Drum Drive Motor Vibration Motor ILLUSTRATED HOSE SCHEMATIC SD-116 TF SERIES EFF. W/ ALL S/N . W/ ALL S/N .OPTION WITH TRACTION CONTROL Suction Filter Hydraulic Tank Check Valve Steering Valve Propulsion Pump Vibration Pump Steering Pump Right Steering Cylinder D2 Oil Cooler Left Steering Cylinder Charge Filter Traction Control Valve Brake Valve Axle Suction Filter Axle Motor Thermal Bypass Valve Drum Drive Motor Vibration Motor ILLUSTRATED HOSE SCHEMATIC SD-116 TF SERIES EFF. Optional on D & F ........ Optional on D & F ....Brakes Applied Hydraulic Tank Standard Parallel on D & F. W/ ALL S/N ..Brakes Released (Drum Spin) Standard on DX.....Brakes Released Brake Valve Loop Flush Valve Propulsion Pump Standard Parallel on D & F.........E10 Forward .Propulsion* Engine RPM (Hi/Low) Flow at Input Speed System Relief Pressure (psi/bar) Charge Relief Pressure (psi) Drum Drive Motor 116D 116F 2457/950 X X 219............Brakes Released (Tire Spin) Standard on DX...........9 g/m X X 6090/420 X X 350 X X * For specific application settings.....E6 Standard on DX........E2 Standard on DX.......E8 Axle Standard on DX.. E11 Reverse ...... Optional on D & F ..E9 E1 Forward .. Optional on D & F ...Brakes Released (Tire Spin) Thermal Bypass Valve Axle Drive Motor Standard on DX.... Optional on D & F ... Optional on D & F .........E12 Settings and Specifications ... Traction Control Valve Charge Filter PROPULSION / BRAKING Overview EFF.................. contact your authorized service personnel.E7 Reverse .E3 Neutral ...3 l/m 57.................E5 Forward ... Optional on D & F ....Brakes Released Standard Parallel on D & F........SD-116 TF SERIES Table of Contents Standard Parallel on D & F....E4 Oil Cooler Standard on DX.............. 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 PROPULSION PUMP E3 L2 CHARGE FILTER M6 M3 D E M1 A X DRUM MOTOR BR M5 M4 G A B BRAKE B X M2 L1 S OVERVIEW STANDARD ON DX OPTIONAL ON D & F T . BRAKES APPLIED STANDARD PARALLEL ON D & F .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 . 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 PROPULSION PUMP M6 M3 D L2 TRACTION ENHANCEMENT VALVE CHARGE FILTER 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 . BRAKES RELEASED STANDARD PARALLEL 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 . 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 . BRAKES RELEASED 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 E9 A X DRUM MOTOR BR M5 M4 A B B BRAKE X T M2 L1 S dashed lines indicate low pressure REVERSE . STANDARD ON DX OPTIONAL ON D & F .BRAKES RELEASED dashed lines indicate low pressure TIRE SPIN .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 . 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 dashed lines indicate low pressure FORWARD .BRAKES RELEASED DRUM SPIN . 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 E13.2 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). 7. Remove the retaining ring (7) that secures the bearing 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 E13.3 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 the shaft (9) with 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). 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 E13.4 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. 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 2. ASSEMBLY E13. 3.). 1. INSPECTION 1. Inspect the charge relief valve (4) and mating seat in the end cap for damage or foreign material. Install the charge relief valve (4) and spring (5) onto the plug (7). 2. Check and adjust the charge pressure as required. Figure 1-3). Remove the spring (5) and charge relief valve (4) from the plug (7).DISASSEMBLY SD-116 TF SERIES PROPULSION PUMP NOTE: To maintain original adjustment. mark the plug (7. Remove and discard the O-ring (6) from the plug (7). 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. Figure 1-3 CHARGE RELIEF VALVE . and the housing (2). 4. 1. Loosen the locknut (8. Install a new O-ring (6) onto plug (7).5 CAUTION: Do not interchange parts with another valve. Figure 1-3) and remove the plug (7) by unscrewing the plug (7) from the housing (2). 3. the locknut (8). Discard the O-ring (9).DISASSEMBLY E13. Remove the charge pump shaft (13) and key (14) from the end cap (17). 6. washers (5). Remove the charge pump cover (10). Discard the O-ring (3). 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.6 SD-116 TF SERIES PROPULSION PUMP 1. Remove the screws (1. Figure 1-4 CHARGE PUMP . 5. INSPECTION 1. 2. Remove the charge pump gerotor assembly (15) and alignment pin (16). Inspect for abnormal wear or damage. bushing (11). Remove the screws (4). Remove the screws (7). 4. 3. and coupling (12). 2. Figure 1-4) flange cover (2) and Oring (3). retaining plate (8) and O-ring (9). and flange adapter (6) from the end cap (17). Surfaces need to be clean and free of any foreign material or paint prior to assembly. Note the orientation of the gerotor assembly (15). Torque the screws (4) to 298 N·m (220 lb-ft. The internally splined end of the shaft must engage the main pump shaft.5 N·m (10 lb-ft. 6. bushing (11). Install a new O-ring (3). Apply a small amount of petroleum jelly to the charge pump gerotor assembly (15. and screws (1) onto the flange adapter (6). 2. Install a new O-ring (9) around the charge pump cover (10). washers (5). 4. Figure 1-4) with the drain hole located on the same side of the end cap (17) as the charge inlet port. Install the flange adapter (6). and charge pump cover (10). Install the charge pump gerotor assembly (15) and alignment pin (16). and screws (4) onto the end cap (17). 8. Install the coupling (12). flange cover (2). always install the charge pump cover (10.ASSEMBLY E13.).). 1. both inside diameter and outside diameter. Install the charge pump shaft (13) and key (14) into the end cap (17).7 SD-116 TF SERIES PROPULSION PUMP NOTE: Be sure to install the charge pump in the proper orientation. CAUTION: In order to avoid loss of charge pressure. 5. Install the retaining plate (8) and secure the retaining plate (8) with screws (7). Figure 1-4 CHARGE PUMP . 7. 3. 10. Torque the screws (7) to 13. Figure 1-4). 9. Install a new filter canister per manufacturer’s instructions.DISASSEMBLY SD-116 TF SERIES PROPULSION PUMP 1.). Figure 1-5 REMOTE CHARGE PRESSURE FILTRATION . ASSEMBLY E13. Place filter manifold (17) in the desired position. Rotate the filter manifold (17) so the threads engage with the threads in the end cap (21). INSPECTION 1. 4. Remove the filter manifold (17) from the end cap (21). continue to rotate clockwise 6 or 7 turns. 5. 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. Torque the swivel locknut (19) to 122 N·m (90 lb-ft. Inspect the filter manifold (17) and tube (18) for blockage or foreign material. Loosen the swivel locknut (19. 3. Remove and discard the O-ring (20) from the filter manifold (17). 3. Figure 1-5).8 1. 2. Install a new O-ring (20) onto the filter manifold (17). 2. This may allow oil to bypass the filter and enter the charge system. Figure 1-6) that secure the manual displacement control (2) to the housing (8). the spring (4).). and the spring retainer (5) into the manual displacement control (2). Remove the screws (1. the spring retainer (5).9 1. Figure 1-6) “neutral” must be readjusted after reassembling the manual displacement control module. 2. If there is a lack of centering torque. repeat step 3. Install the orifice check valve (3). Readjust the neutral start switch (9) per manufacturer’s instructions.DISASSEMBLY SD-116 TF SERIES PROPULSION PUMP 1. Clean external surfaces prior to removal. Align the new gasket (6) with the housing (8) and install the screws (2). 6. Figure 1-6 MANUAL DISPLACEMENT CONTROL . Check for proper engagement of the control linkage pin by moving the control handle (7) off center creating center torque. and the gasket (6) from the housing (8). 3. NOTICE: The neutral start switch (9. 7. CAUTION: Protect exposed surfaces and cavities from damage and foreign material. ASSEMBLY E13. 3. Torque the screws (2) to 16 N·m (12 lb-ft. 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. Remove the manual displacement control (2) with neutral start switch (9). the spring (4). Install a new gasket (6) on the housing (8). All at once. 4. 2. the orifice check valve (3). 5. ..............................................E14..........E14.....................................E14........................................7 Assembly.9 DIFFERENTIAL .............................E14.......................E14.............4 PLANETARY REDUCTION AND AXLE SHAFT ..........................E14.........................................19 SD-116 TF SERIES AXLE Axle TABLE OF CONTENTS .............................................E14...............................E14....2 Disassembly ..............................12 Assembly..............11 Removal ......................................................................................................E14.............................................. ........E14..........17 E14...13 Installation ...................................17 Assembly.......7 Disassembly ...........TABLE OF CONTENTS..E14................... E14............................11 Disassembly .................2 Assembly.................................1 BRAKES ....E14....... E14.....E14..............................1 Disassembly .......13 REDUCTION GEAR AND PINION ........... 10. Remove the arm from the cylinder. Slowly introduce low-pressure compressed air through the connection member for the negative brake. noting the orientation of the washers. as it may be suddenly ejected and damaged. Figure 1-1) back. Remove the lower plug from the axle arm and drain the oil.DISASSEMBLY E14. Loosen the screws (93) on the cylinder in an alternate manner and remove them. 11. 2. 6. Attach a suitable lifting device to the axle arm to be removed. 7. Loosen and remove the screws (29. together with the brakes and axle shaft. complete with piston (84). Remove and discard the O-rings (85 and 86) from the piston (84).2 SD-116 TF SERIES AXLE 1. 8. 4. Remove the Belleville washers (82). Remove the checking and guiding screws (79) from the pressure plate (87). Using the sling for support. stand the arm on end with the open end facing up. 5. CAUTION: Hold the piston (84. 12. in order to remove the piston (84). Figure 1-1 BRAKES . 9. Remove and discard the O-rings (18) from the cylinder. Move the cylinder outward while supporting the Belleville washers (82). 3. Figure 1-1) and nuts (17) securing the axle arm to the axle cylinder. Remove the cylinder from the center housing. Remove the pinion (89) and O-ring (92) from the axle arm. Remove the springs (78) from the axle arm.E14. Remove the pressure plate (79) from the axle arm. Unscrew and extract the brake disc clearance adjustment crown wheel (88). Discard the O-ring (92). 13. noting the orientation. avoid changing their position. The flow regulator wall and oil drain holes must face the oil drain plug. NOTE: Check the springs for warping or other deformation. NOTE: If the discs are not to be replaced. 15. Any deformation of the springs requires spring replacement. 16. 17. 14. Remove the brake discs (76 and 77). Figure 1-1) in sequence and proportionally. SD-116 TF SERIES AXLE Figure 1-1 BRAKES . NOTICE: Note the orientation of the components.3 NOTE: Loosen the screws (79. SD-116 TF SERIES AXLE Figure 1-1 BRAKES . 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. Tighten the screws (79) to 20 to 30 N. Figure 1-1) to ensure the flow regulator and oil drains are oriented toward the axle arm’s oil drain plug. 10. 2. Figure 1-1) and screw it into the axle arm as far as it will go. NOTICE: The oval holes of the friction discs (77. Lubricate the threaded portion of the crown wheel (88.m (16 to 22 lb-ft. 4. 9. Lightly lubricate a new O-ring (92) and install it onto the pinion (89). 6. 3. 11. alternating steel discs (76) and friction discs (77). then install it into the axle arm.4 1. Lubricate the first friction disc (77). 8. Lightlyghtly lubricate new O-rings (85 and 86) and install the O-rings onto the piston (84). Lock the pressure plate (87) into position with screws (79). Position the springs (78) into the slots of the arm. Figure 1-1) in sequence and a little at a time.). 5. inserting the pinion teeth into the crown wheel (88) teeth. Lubricate and install the pinion (89) into the slot provided on the axle arm. Complete the brake disc assembly. NOTICE: Tighten the screws (79. then install it into the axle arm. NOTICE: Check the orientation of the pressure plate (87. Lightly lubricate the first steel brake disc (76). 7.ASSEMBLY E14. Figure 1-1) must be aligned. E14. Secure the cylinder in place on the center housing with the screws (93). 14. 19. slightly move the wheel hub. 15. Check to ensure the axle arms are level. ensuring that the piston relief is facing downward. Torque the screws (93) to 86 to 89 N. Torque the screws to 182 to 202 N. Install the axle arm onto the cylinder and center housing. using screws (29) adequately coated with Loctite 242. Position the cylinder on the studs of the center housing without fastening. 18. Secure the arm into its final position.). NOTE: To assist with axle shaft centering. Tighten the screws using the criss-cross method. 16.m (63 to 66 lb-ft). 13. Tighten the nuts (17) lightly to make the axle arm touch the cylinder and center housing. Position the Belleville washers (82) into the cylinder.5 12. Lubricate the piston (84. Figure 1-1) for proper direction and relative centering. Lightly lubricate new O-rings (18) and install the O-rings onto the cylinder.m (134 to 149 lb-ft. Figure 1-1) and install the piston into the cylinder. 17. SD-116 TF SERIES AXLE Figure 1-1 BRAKES . NOTE: Check the Belleville washers (82. Temporarily secure the axle arm with nuts (17) previously coated with Loctite 242. Connect an external pump to the union piece “A” of the negative brake and introduce pressure of 15 to 30 bar (218 to 435 psi). 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. Rotate the adjustment pinion (89) counterclockwise to eliminate all existing clearance between the brake discs. 22. Install the safety plate (90) and secure in place with the screw (91). 21. Torque the screw to 10 to 11 N.m (7 to 8 lb-ft.25 mm (1 mm = 4 turns). Rotate the pinion (89) up to a torque of 8 to 10 N.). Figure 1-1) and safety plate (90) from the axle arm.20.6 Figure 1-1 BRAKES . SD-116 TF SERIES AXLE E14. Remove the screw (91.).m (6 to 7 lb-ft. NOTE: A turn of the adjuster produces a clearance of 0. Rotate the pinion (89) clockwise 4 turns to determine the required clearance of 1 mm. pry the planet gear carrier assembly (59) away from the hub (7). Discard the O-ring (73).7 1. 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). 4. 11. Remove the ring gear support (69) from the hub (7). Using a puller and applying counter pressure to the screws (53). Re-install and partially tighten five of the ten screws (53) in an alternate and proportional manner. Remove the O-ring (73) from the hub (7). mark a position between one of the teeth of the axle shaft (54) and the ring gear (72). 6. Remove the locking screws (61. 8. Figure 1-2) can only be removed after the planet gear carrier assembly (59) has been removed. 12. Remove the partially-tightened screws (53) and the ring gear (72) from the hub (7). Remove the snap ring (71) from the ring gear (72). 5. Figure 1-2) from the planetary cover. Loosen the screws (53) securing the the ring gear support (69) to the hub (7) and remove the screws (53). Using two screwdrivers or two levers inserted in the slots provided. SD-116 TF SERIES AXLE Figure 1-2 PLANETARY REDUCTION AND AXLE SHAFT . Rotate the hub (7) until one of the screw holes in the planet gear carrier assembly (59) appears at the top.DISASSEMBLY E14. disengage the ring gear (72) from the hub (7). NOTE: The axle shaft (54. 3. 7. 10. 2. Remove the axle shaft (54) from the axle arm. If the ring gear (72) is not being disassembled. 9. shift the hub (7) and the external bearing (74). 18. If necessary. 22. then remove the friction washer (56). SD-116 TF SERIES AXLE Figure 1-2 PLANETARY REDUCTION AND AXLE SHAFT . Figure 1-2). Attach a suitable lifting device to the hub (7. 15. needle bearing (64). use a puller to remove the friction washer (62) from the planet gear carrier. complete with the seal (74) and internal bearing (74). 14. Remove the seal (75) from the hub (7) and discard the seal (75). Remove the planet gear assemblies from the planet gear carrier.8 13. then partially tighten a screw (53) and with the help of a hammer. Remove the bolts (67) and locking plates (66) securing the rear cover to the planet gear carrier (59). and friction washer (56). noting the orientation of the centering ring (49) and seal (48).E14. Remove the internal bearing cone (74) from the hub (7). then remove the rear cover from the planet gear carrier (59). Remove the hub (7). Hammer in an alternate sequence to prevent deformation of the bearing cups. Remove the internal and external bearing cups (74) from the hub (7) using a pin-driver. To disassemble the planet gear assembly. Remove the bearing cone (74) and the hub (7) from the axle arm. 21. remove the snap ring (55) from the planet pin (57). Repeat for the remaining planet gear assemblies. remove the O-ring (58) and snap ring (55) from the opposite end of the planet pin (57). 16. Discard the O-ring (58) and snap rings (55). planet gear (65). Using a puller. remove the centering ring (49) and the seal (48). If necessary. 20. NOTE: Note the orientation of the planetary gears. 17. 19. needle bearing (64). Position the seal (75) into the hub (7). 9. Turn the hub (7) upside down. Lubricate and install the centering ring (49) and snap ring (48) into the axle arm. and friction washer (56). using a suitable driver. planet gear (65).9 1. To assemble the planet gear assembly. Install the bearing cone (74) into the hub (7). 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. 5. 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). 3. Install a new snap ring (55) on the end of the planet pin (57). 4. Apply an appropriate sealant to the outer surface of the seal (75). Lighly lubricate the planet pin (57) and install the friction washer (56). Figure 1-2) must face the bottom of the planet pin (57). 8. 2. paying particular attention to the orientation of the rings. CAUTION: The jointed portion of the internal ring of the needle bearings (64. checking for correct orientation. tap it into the planet gear carrier (59). Press the seal (75) into its seat in the hub (7). apply a sealant for removable seals to the outer surface of the friction washer (15) and. 7.ASSEMBLY E14. Lubricate the seat of the external bearing cup (74) and press the bearing cup into the hub (7). SD-116 TF SERIES AXLE Figure 1-2 PLANETARY REDUCTION AND AXLE SHAFT . Lubricate the inside diameter of the seal (75) and the outside of the axle arm hub. Repeat for the remaining planet gear assemblies. Figure 1-2) under a press. Install the rear cover onto the planet gear carrier (5) and secure it in place with the locking plates (66) and bolts (67). Position the wheel hub (7. 10. E14. 19.m (89 lb-ft. Torque the screws (53) to an initial torque of 120 N. 22. making sure that it is properly inserted into the braking discs and the differential unit. Torque the screws to 40 N. Install a new snap ring (71) into the ring gear (72).m (30 lb-ft. SD-116 TF SERIES AXLE Figure 1-2 PLANETARY REDUCTION AND AXLE SHAFT . centering ring (49). Lubricate a new O-ring (73) and install it into the hub (7). 12. NOTE: Move the bearing cone (74. 15. 21. Figure 1-2) to the limit stop by hammering lightly all around the edge.). then install the ring gear support (69) into the ring gear (72). 20. Tighten the screws (53) in two stages.11. Lubricate the outer edge of the ring gear support (69). Lubricate the seal (48). using the criss-cross method. Install the hub (7.). 14. Install the external bearing cone (74) into the hub (7). 16. 13. NOTICE: Line up the locating release points.). Coat the screws (53) with Loctite 270 and install them into the ring gear support (69). Secure the planet gear carrier (59) to the hub (7) with screws (61).10 18. Install the ring gear (72) into the hub (7) and drive it into place using a suitably-sized driver. Install the axle shaft (54) into the axle arm. and the toothed portions and sealing surface of the axle shaft (54).m (162 to 178 lb-ft. then to a final torque of 219 to 242 N. 17. Figure 1-2) onto the axle arm hub. Install the planet gear carrier assembly (59) onto the hub (7). Using a suitable driver. Using a suitable driver. then remove the ring nut (33) from the intermediate cover. 11. Remove the bolt (35) and locking plate (34). Remove the bolt (35) and locking plate (34). Position a stop block made from a soft metal (aluminium.) between the differential housing and the toothed portion of the beveled gear (46). 4. remove the bearing cup (41) from the intermediate cover. Remove the stud screws (23. 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). 10. etc. 5.11 cover. SD-116 TF SERIES AXLE Figure 1-3 DIFFERENTIAL . Remove the axle arms and the reduction unit from the differential housing. 2. then remove the ring nut (33) from the intermediate cover. 8. remove the bearing cup (41) from the intermediate cover. 7.REMOVAL 1. 3. push the differential carrier (37) away from the beveled gear (46) to disengage the differential carrier (37) from the beveled gear (46). 12. 9. Remove and discard the O-ring (18) from the intermediate E14. Figure 1-3) from the intermediate cover and remove the intermediate cover from the side of the differential opposite the beveled gear (46). remove the screws (40) and spring washers (39) securing the differential carrier (37) to the beveled gear (46). With the beveled gear (46) resting on the stop block. Using a suitable driver. 6. Remove and discard the O-ring (18) from the intermediate cover. Remove the no-spin unit (38) from the differential unit main body (37). Remove the screws (36) joining the differential unit half box (37) to the main body (37). Remove the differential carrier (37. noting the coupling marks. 2.12 Figure 1-3 DIFFERENTIAL . remove the bearing cones (41) from each end of the differential carrier (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. separate the half box (37) from the main body (37). 14. SD-116 TF SERIES AXLE DISASSEMBLY No-Spin Differential Unit 1.13. Figure 1-3) from the beveled gear (46) and the differential housing. 3. E14. 4. Remove the beveled gear (46) from the differential housing. Using a plastic hammer. Using a suitable puller. Install the differential carrier (37) into the differential housing. install a bearing cone (41) into each of the intermediate covers. 6. install the first bearing cone (41). 4. inserting the spacer (42) and using the stay. Turn the unit upside down and position the differential carrier (37) under a press. INSTALLATION E14. 4. Figure 1-3). Using an appropriately-sized driver. 3. Coat the screws (36) with Loctite 270 and install them into the differential unit half-box (37). ensuring that the coupling marks align. Using a suitable press.13 1. install the second bearing cone (41). 3. Install the spring washers (39) onto the screws (40). Install the differential unit half-box (37) onto the main body (37). using 2. 5. an appropriately-sized driver. Position the differential carrier (37) under a press and.m (63 to 66 lb-ft. Install the beveled gear (46) onto the differential carrier (37). Remove the stay from the differential carrier (37). 7. 2. Install the beveled gear (46) into the differential housing.). 5. Ensure that the holes of the differential carrier flange (37) match those of the beveled gear (46). Tighten the screws (36) using the criss-cross method and torque them to 86 to 89 N.ASSEMBLY SD-116 TF SERIES AXLE No-Spin Differential Unit 1. Assemble the no-spin unit (38. Figure 1-3 DIFFERENTIAL . and fasten it to the flange. Install the no-spin unit (38) into the differential unit main body (37). m (95 to 105 lb-ft. E14. While holding the beveled gear (46) resting on the stop block.8. Apply Loctite 242 to the ring nut (33). 10. Install the stud screws (23) and torque them to 129 to 143 N.14 13. tighten the screws (40). Using a suitable wrench. Ensure that the differential carrier (37) is tightly engaged in the intermediate cover. SD-116 TF SERIES AXLE Figure 1-3 DIFFERENTIAL . 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).m (95 to 105 lb-ft. then re-install the ring nut (33) into the intermediate cover.).). to a torque of 135 to 138 N. using the criss-cross method. Lubricate and install a new O-ring (30) onto the remaining intermedate cover. Remove the spring ring (21) and cap (22) from the rear of the differential housing to allow checking of the clearance between the pinion (46) and the beveled gear (46) to take place. 12.).m (100 to 102 lb-ft. 17. Remove the bolt (35) and locking plate (34) from one of the intermediate covers. Figure 1-3) with Loctite 270 and install the them hand tight into the beveled gear (46). 14. Coat the screws (40. 16. 9. Repeat steps 14 and 15 for the intermediate cover on the opposite end of the differential housing. then install the intermediate cover on the side of the differential housing opposite the beveled gear (46). 11. Install the stud screws (24) and torque them to 129 to 143 N. 15. remove the ring nut (33) from the intermediate cover and remove any residue of thread locking substances. Position the stop block between the differential housing and the toothed portion of the beveled gear (46). 007 to 0.15 CAUTION: If bearings are old. 21. 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. using the criss-cross method.18 to 0.cm (12 to 18 lb-in. Introduce a dial indicator through the rear cap (22) hole. 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 140 to 210 N. 22. 23. checked using a torque meter. Allow the pinion (46) to turn a few times in both directions to allow the bearings to set. Coat the bolts (5 and 7) with Loctite 242 and install the bolts (5 and 7) into the reduction gear assembly.). If new.906 in). 25. Tighten the bolts (5 and 7).18. pre-set it to 1 mm and reset it to zero.23 mm (0. Coat the mounting surface of the differential housing with Loctite 510 and install the reduction gear assembly and pinion assembly (46. 20. Manually move the beveled gear (46) in both directions to check the existing clearance between the pinion (46) and the beveled gear (46).m (95 to 105 lb-ft. Position the dial indicator on the center of one of the beveled gear teeth (46). 24. check continuous torque. 19. SD-116 TF SERIES AXLE Figure 1-3 DIFFERENTIAL . Mark the position of the ring nuts (33) in relation to the intermediate covers. 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. Figure 1-3). E14.). Using a suitable wrench. Normal clearance is 0. check static torque. 26. then unscrew the ring nut (33) by approximately 1/4 turn. to a torque of 129 to 143 N. Torque the screws (1 and 9) to 82 to 91 N. 30. SD-116 TF SERIES AXLE Figure 1-3 DIFFERENTIAL . Figure 1-3) on the ring nuts (33) and secure them with the screws (35).09 mm (0. E14. Using a driver and a plastic hammer. 32.m (26 to 37 lb-ft. Torque the screws to 10 to 11 N. Using a suitable driver.).m (60 to 67 lb-ft. 29. Figure 1-3) should not exceed 0.m (7 to 8 lb-ft.004 in). install the cap (22) into the rear of the differential housing and position it in its seat with the snap ring (21). 27.16 31. Install the vent (4) into the reduction gear housing and tighten the vent to a torque of 35 to 50 N. Complete the assembly of the axle by installing the axle arms.NOTE: The difference between the MINIMUM and MAXIMUM clearance for the entire circumference of the beveled gear (46. Secure the cover in place with the spring washers (8) and the screws (1 and 9).). Apply Loctite 510 to the mounting surface of the reduction gear housing and install the cover.). Install the locking plates (34. 28. install the driving gear (2) into the reduction gear housing. 10. complete with bearing (3). 7. Use a lever to remove the driving gear (14). 2. Remove the plugs (10 and 11) for oil fill and oil drain. 4. 3. E14. NOTE: While removing the cover. Figure 1-4) and spring washers (8) securing the cover to the reduction gear housing. Loosen and remove the pinion locking nut (30). remove the complete reduction gear unit from the differential unit (remove screws [5 and 7. Loosen and remove the screws (1 and 9. Using a plastic hammer. Connect the reduction gear housing to a suitable lifting device and remove the screws (5) previously left in place for safety. Place a stop block of soft metal (aluminium. then remove the vent (4). then remove the two remaining screws (9) and remove the cover. Figure 14) in position for safety. Figure 1-4]).DISASSEMBLY 1. Loosen all screws (5 and 7) and remove the upper screws (7) securing the reduction gear housing to the differential unit. 8. Using a plastic hammer. NOTE: If operations on the differential unit need to be performed. tap the reduction gear housing to remove it from the differential unit. etc. loosen the cover.) between the reduction gear housing and the gear (6) of the pinion. Leave the two lower screws (5) in position for safety. leave two of the screws (9. Remove the axle arms from the differential unit. 9. 6.17 5. Use a suitable puller to remove the bearing (3) from the driving gear (2). SD-116 TF SERIES AXLE Figure 1-4 REDUCTION GEAR AND PINION . Remove the pinion gear (6) and the driving gear (2). 18 Figure 1-4 REDUCTION GEAR AND PINION .11. complete with the shim (32). SD-116 TF SERIES AXLE E14. Remove the spacer (44) and shim (43) from the pinion (46). 13. Figure 1-4). Position the reduction gear housing under a press and. Position the pinion (46) under a press and remove the bearing cone (31) and shim (32) from the pinion (46). 12. using a driver. remove the pinion (46. 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. With the help of a suitable driver. Note the orientation of the seal (45). 14. bearing cone (31). shim (43) and spacer (44). remove the bearing cups (31) and seal (45) from the reduction gear housing. 13=0.12 mm): S=St ± X=0. Mark the cup and face plate of one of the the bearings (31. add the negative value of “X” to “St” or.: 0. Figure 1-4).05 mm as possible. The measurement obtained (e. 6. 5.12=0. Figure 1-4). 4.19 beveled gear coupling. then allow the bearing to set by rotating it in both directions while applying a vertical thrust. On the bar-hold of the pinion (46).69 mm NOTICE: Round off to as close to 0. Lubricate the outer surface of the seal (45).: 42. Using a driver. mount the seal (45) in the reduction gear housing. SD-116 TF SERIES AXLE Figure 1-4 REDUCTION GEAR AND PINION .” the number not in brackets.81 mm) is the theoretical thickness of the shim “St” (32) to be inserted under the bearing cup (31). subtract the positive value of “X”. With a digital depth gauge. 3. Lay two 20 mm gauged blocks on the face of the reduction gear housing.13 mm): S=St+X=0. alternatively. check the overall thickness of the bearing (e. For example: Deviation X=(±0. Place the reduction gear housing under a press and install the bearing cup (31) that was not countermarked in step 1.ASSEMBLY 1. measure the space between the blocks and the striking surface of the bearing (31).94 mm Deviation X=(+0.g.81 ± 0. With the depth gauge set to zero. 2. is the number of the pinion/ E14.35 mm) and set the gauge to zero again. NOTE: “Y.g. To calculate the final thickness “S”. Carefully check the orientation of the seal (45). check the value “X” (in brackets) relative to the deviation from the theoretical centre distance.81+0. This number will correspond to a number stamped on the inside of the beveled gear (46. Figure 14) into the reduction gear housing. Position a depth comparator in one of the four radial holes of tool T11.” then install the countermarked bearing cup (31. 8. 9. Install special tool T12 (see below) onto tool T11 (see below). Turn the reduction gear housing upside down and insert shim “S. then install the bearing cones (31) onto tool T11 so that they are opposed to each other and separated by the spacer (44). then set it to zero.7.20 Figure 1-4 REDUCTION GEAR AND PINION . Tool T11 SD-116 TF SERIES AXLE Tool T12 E14. Preset the comparator to 3 to 4 mm. Install the reduction gear housing (11) onto the differential housing without the differential unit. perform a few rotations to set the bearings. Install the shim (32) onto the pinion (46).10. in one of the four radial holes and measure.15 mm in order to obtain the correct size for shim “S1” (43). Ensure that the countermarked bearing cone is fitted into the countermarked bearing cup already installed in the centering hub of the reduction gear housing. SD-116 TF SERIES AXLE Figure 1-4 REDUCTION GEAR AND PINION . 11. A variation of 0.m (15 to 30 lb-ft. E14. 13. The deviation found is to be added to a fixed value of 0. While tightening the tool. 16. Install the pinion (46).21 NOTICE: Perform accurate measurements. Remove the bearing cones (31. the shim (43). which is to be inserted between the bearing (31) and the spacer (44). Secure in place temporarily with the two lower screws (5). The deviation from zero indicates the nominal value “H” relative to the shims that are to be inserted.001 mm causes a variation in the torque by 20 to 40 N. Figure 1-4) from tool T11 and fit them in the bearing cups (31) installed in reduction gear housing. This will produce the specified bearing pre-load. 14. then press the countermarked bearing cone (31) onto the pinion (46). Figure 1-4) with oil. 12. NOTICE: Lubricate the pinion (46. Introduce the previously reset depth comparator.). 15.13 divided by 0. the spacer (44) and the remaining bearing cone (31) into the reduction gear housing and assemble the components with a press. Install tool T11 into the gear reduction housing and tighten it manually to obtain a safe rolling torque. Allow the pinion to rotate a few times in both directions to enable bearings to set. Using a torque meter. 20. NOTICE: If the torque exceeds the maximum value. check the torque of the pinion (46).). Remove the reduction gear unit from the differential housing. Figure 1-4) needs to be reduced. until a maximum value of 700 N. 21. The proper torque should be 140 to 150 N.m (369 lb-ft. 22. 18. 19.). NOTICE: If the torque does not reach the minimum value.17. it is necessary to bear in mind that a 0. Figure 1-4) placed between bearing (31) and the spacer (44) needs to be increased. in different stages. increase the tightening torque setting of the nut (30). Figure 1-4) into the reduction gear housing. place the stop block used for disassembly.cm (28 to 57 oz-in.m (516 lb-ft.22 (43. SD-116 TF SERIES AXLE Figure 1-4 REDUCTION GEAR AND PINION . 23. Figure 1-4) results in the torque of the pinion (46) varying by 20 to 40 N. Between the reduction gear housing and the gear (6) of the pinion. Coat the nut (30) with Loctite 242 and hand-tighten it onto the end of the pinion (46).) is obtained. Install the bearing (3.01 mm variation in the size of the shim (43.). then the shim “S1” E14. then tighten the nut (30) to a minimum tightening torque of 500 N. NOTICE: In order to be able to calculate the increase or reduction of shim “S1”. Install the differential unit into the differential housing.cm (198 to 212 oz-in. then install the reduction gear unit and the axle arms onto the differential unit. Install the gear (6) onto the pinion (46). then the shim “S1” (43. If the torque does not reach the set value. .....4 Disassembly ...................3 LOOP FLUSHING VALVE .....1 Assembly..............................................................5 Inspection ...........2 Inspection ..........E15.........................5 E15....E15....4 Assembly.....................5 Disassembly .......................E15..........6 Assembly........................7 Axle Drive Motor TABLE OF CONTENTS .E15...........................E15......................E15.................................6 Disassembly .......1 LIP SEAL AND SHAFT.......................................................4 CONTROL SUPPLY ORIFICE AND ORIFICE CHECK VALVE ...................................................E15........................E15.......E15.............E15........E15...................................................E15.....................................................................2 Disassembly ....................E15.........5 ORIFICE CHECK VALVE AND ELECTRIC 2-POSITION CONTROL VALVE ...........4 Inspection .................................................................................................................................................................SD-116 TF SERIES AXLE MOTOR TABLE OF CONTENTS...........E15....2 Assembly.............E15......E15...... 6. Inspect the sealing area on the shaft (9) for rust. Use a new bearing assembly (8) as required.SD-116 TF SERIES AXLE MOTOR NOTICE: Prior to performing repairs on this component.2 1. 2. Inspect the seal carrier (3) for any damage or nicks. Position the motor with the shaft end facing up. 7. INSPECTION 1. Figure 1-1) securing the retainer plate (2). remove the shaft (9) and the bearing assembly (8) from the housing (4). Inspect the bearing assembly (8) for damage. Remove the screws (1. Remove the bearing assembly (8) from the shaft (9). Press out and discard the lip seal (6) from the seal carrier (3). 2. Remove the retainer plate (2) and the seal carrier (3) from the housing (4). or contamination. 3. wear. Remove and discard the O-ring (5) from the seal carrier (3). 4. Polish the sealing area on the shaft (9) as necessary. Remove and discard the retaining ring (7) that secures the bearing assembly (8) on the shaft (9). If necessary. DISASSEMBLY E15. Figure 1-1 LIP SEAL AND SHAFT . 3. 8. contact a service representative concerning issues of warranty. WARNING: Safety glasses must be worn when removing the retaining ring (7). 5. Install the seal carrier (3) and retainer plate (2) into the housing (4) bore and secure with the screws (1). 8. 3. wrap the spline or key end of the shaft (9) with thin plastic. install the original bearing assembly (8. Install the shaft (9) and the bearing assembly (8) into the housing (4). Secure the bearing assembly (8) on the shaft (9) with a new retaining ring (7). 7. Lubricate the new O-ring (5) and the inside diameter of the new lip seal (6) with clean petroleum jelly. Torque the screws (1) to 9. Figure 1-1 LIP SEAL AND SHAFT . Lightly lubricate the outside diameter of the new lip seal (6) with Loctite High Performance Sealant #59231. CAUTION: To prevent damage to the lip seal (6. Install a new O-ring (5) on the outside diameter of the seal carrier (3). 2.ASSEMBLY E15. 5. If necessary.). 4. Press the new lip seal (6) into the seal carrier (3). Figure 1-1). 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).3 SD-116 TF SERIES AXLE MOTOR 1. 6. 9.5 N·m (7 lb-ft. ). Inspect the parts for damage or foreign material. 4. the spring guides (3). Install the flushing valve shuttle spool (5) into the valve orifice of housing (6). Remove the springs (2) and the spring guides (3) from the flushing valve shuttle spool (5). Remove the springs (2). INSPECTION 1.4 1. Install the spring guides (3) with the shoulders facing out and the springs (2) on each side of the flushing valve shuttle spool (5). Note the orientation of the spring guides (3). 4. Install the plugs (1) into both sides of the valve orifice and torque the plugs (1) to 41 N·m (30 lb-ft. and the flushing valve shuttle spool (5) from the valve orifice in the housing (6). ASSEMBLY E15. Install the new O-rings (4) on each plug (1). Remove and discard the O-rings (4) from each plug (1). Remove the plugs (1. 3. 2.DISASSEMBLY SD-116 TF SERIES AXLE MOTOR 1. 2. 3. Figure 1-2 LOOP FLUSHING VALVE . Figure 1-2) from both sides of the valve orifice. Torque the orifice check valve (12) to 37 N·m (27 lb-ft. Make sure they are not plugged or contain foreign material. INSPECTION E15.). 2. 6. Inspect the filter screen (17) and the control supply orifice (26). Install the new backup rings (14 and 16) and the new Orings (13 and 15) on the orifice check valve (12).5 1. Inspect the orifice check valve (12) and make sure it is not plugged. Remove the control supply orifice (26. Inspect that the orifice check valve seat is secure in the orifice check valve (12) and that the check ball is free. Figure 1-3 CONTROL SUPPLY ORIFICE AND ORIFICE CHECK VALVE . ASSEMBLY 1. 2. Install the control supply orifice (26) into the housing (6). Install the new backup rings (14) and the new O-rings (13 and 15) on the control supply orifice (26). Torque the control supply orifice (26) to 37 N·m (27 lb-ft. NOTICE: Do not interchange control supply orifice (26. 2. 3. 5.SD-116 TF SERIES AXLE MOTOR DISASSEMBLY 1. Remove the orifice check valve (12) from the housing (16). Remove and discard the O-rings (13 and 15) and the backup rings (14 and 16) from the orifice check valve (12). Install the orifice check valve (12) into the housing (6). 3. Figure 1-3) from the housing (6). 4. Remove and discard the O-rings (13 and 15) and the backup rings (14) from the control supply orifice (26).). 4. Figure 1-3) with orifice check valve (12). 3. Figure 1-4 ORIFICE CHECK VALVE AND ELECTRIC 2-POSITION CONTROL VALVE . Remove the solenoid valve (22) from the housing (6). Figure 1-4). Disconnect the electrical connection (23). 2. DISASSEMBLY E15. before removing the electric 2-position control. 6. Remove the nut (24) and the solenoid (25) from the solenoid valve (22). Remove and discard the O-ring (19) from the orifice check valve (20). 3. 7.6 1. 5. Figue 1-4) from the orifice check valve (20). 4.SD-116 TF SERIES AXLE MOTOR NOTE: Remove the orifice check valve (20. Remove and discard the O-rings (21) from the solenoid valve (22). Loosen and remove the seal nut (18. Remove the orifice check valve (20) from the housing (6). ). Install the orifice check valve (20) into the housing (6). 8.). Install a new O-ring (19) and the seal nut (18) onto the orifice check valve (20). 19. 4. Figure 1-4) on the solenoid valve (22). Torque the orifice check valve (20) to 15 N·m (11 lb-ft. ASSEMBLY E15. Over torquing may result in the valve spool sticking.). and 20. Install the solenoid valve (22) and torque the solenoid valve (22) to 47 N·m (35 lb-ft. 6.SD-116 TF SERIES AXLE MOTOR NOTE: Install the orifice check valve (18. 5. 7. Install the solenoid (25) and the nut (24) on the solenoid valve (22). Figure 1-4) AFTER installing the electric 2-position control. Torque the nut (24) to 5 N·m (44 in-ft. CAUTION: Do not over torque the solenoid valve. Torque the seal nut (18) to 34 N·m (25 lb-ft. Install the new O-rings (21.). 3. Figure 1-4 ORIFICE CHECK VALVE AND ELECTRIC 2-POSITION CONTROL VALVE . 2.7 1. ..1 TABLE OF CONTENTS ......................................................3 Loop Flush Valve E16............................................2 Inspection ..............................3 Inspection ........................E16.............................E16........................1 LOOP FLUSHING VALVE ...............................E16.............E16...............................2 CHARGE RELIEF VALVE.....E16.....................E16......................................E16..........................................................................3 Disassembly ........2 Disassembly .......3 Assembly......2 Assembly..SD-116 TF SERIES LOOP FLUSH VALVE TABLE OF CONTENTS.................E16................E16..... ). 4. Figure 1-1 LOOP FLUSHING VALVE . Remove the plugs (1. 3. contact a service representative concerning issues of warranty. 2. Install the shuttle spool (5) into the valve housing (6).NOTICE: SD-116 TF SERIES LOOP FLUSH VALVE Prior to performing repairs on this component. Figure 1-1). Install new O-rings (2) on each plug (1). INSPECTION 1. Remove and discard the O-rings (2) from each plug (1). Figure 1-1) from both sides of the valve housing (6). Install the spring guides (4) with the shoulders facing out and springs (3) on each side of the shuttle spool (5). NOTE: Note the orientation of the spring guides (3. 2. and flushing valve shuttle spool (5) from the valve housing (6). DISASSEMBLY 1. E16. Remove the springs (3). 3. Inspect the parts for damage or foreign material. Install plugs (1) into both sides of the valve housing (6) and torque the plugs (1) to 41 N·m (30 lb-ft.2 ASSEMBLY 1. spring guides (4). Figure 1-2). 4. ASSEMBLY E16. Figure 1-2 CHARGE RELIEF VALVE . Remove the spring (11) and charge relief valve (9) from the plug (10). 2. mark the plug (10. Loosen the locknut (7. 3. 2. Inspect the charge relief valve (9) and mating seat in the valve housing for damage or foreign material.).3 NOTICE Do not interchange parts with another valve. Remove and discard the O-ring (8) from the plug (10). Check and adjust the charge pressure as required. Figure 1-2) and remove the plug (10) by unscrewing the plug (10) from the housing (6). and the housing (6). INSPECTION 1.DISASSEMBLY SD-116 TF SERIES LOOP FLUSH VALVE NOTE: To maintain original adjustment. locknut (7). Install a new O-ring (8) onto plug (10). Install the charge relief valve (9) and spring (11) onto the 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. 1. 1. ..........High AmplitudeF4 Counterclockwise Low Amplitude..No Vibration .........F2 Neutral ..... contact your authorized service personnel......... Hydraulic Tank Oil Cooler Vibration Motor F1 Suction Filter VIBRATION Overview .................. F5 Settings and Specifications ........... F3 Clockwise ... W/ ALL S/N .....Vibration* Thermal Bypass Valve Vibration Pump EFF...9 g/m X X 5000/345 X X 285 X X System Relief Pressure (psi/bar) Charge Relief Pressure (psi) * For specific application settings..SD-116 TF SERIES Table of Contents Engine RPM (Hi/Low) Flow at Input Speed 116D 116F 2457/950 X X 90.5 l/m 23. SD-116 TF SERIES VIBRATION HYDRAULIC TANK SUCTION STRAINER SUCTION FILTER OIL COOLER THERMAL BYPASS VALVE 140 F CRACKING 165 F OPEN 25 PSI VIBRATION PUMP M3 D F2 A M4 VIBRATION MOTOR M1 M1 M5 B A M2 M2 B L1 S OVERVIEW L2 . SD-116 TF SERIES VIBRATION HYDRAULIC TANK SUCTION STRAINER SUCTION FILTER L E G E N D OIL COOLER BYPASS THERMAL BYPASS VALVE dashed lines indicate low pressure 25 PSI 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 L SUCTION FILTER E G E N D OIL COOLER 140 F CRACKING THERMAL BYPASS VALVE 25 PSI dashed lines indicate low pressure VIBRATION PUMP M3 D F4 VIBRATION MOTOR A 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 L E G E N D OIL COOLER 165 F OPEN THERMAL BYPASS VALVE 25 PSI dashed lines indicate low pressure VIBRATION PUMP M3 D F5 A M4 VIBRATION MOTOR M1 M1 M5 B A M2 M2 B L1 S COUNTERCLOCKWISE LOW AMPLITUDE L2 . .............F6.............F6...............................................2 Disassembly ......................7 Inspection .........................4 CHARGE RELIEF VALVE.......................................F6..........................................1 LIP SEAL ........................4 Assembly........SD-116 TF SERIES VIBRATION PUMP TABLE OF CONTENTS ...................................3 CHARGE CHECK AND HIGH PRESSURE RELIEF VALVE .............................................................................1 F6....................................F6...............F6.....5 FILTER ADAPTER....................................................................9 Disassembly .....................................10 Vibration Pump TABLE OF CONTENTS ..........................F6...............................................9 Inspection ................F6....F6............F6.......................F6..........F6............................F6...................2 Inspection .......3 Assembly........F6...................F6.....................2 BYPASS VALVE...........................................................................................................F6.........F6.....7 Disassembly .........F6..........3 Disassembly .....................5 Disassembly ...............................................9 Assembly....F6......................6 Disassembly ..............................................................................................F6................2 Assembly...........7 Assembly...F6.........5 Assembly......F6......5 Inspection ...............................................................................................REVERSE CONTROL (SD-116D Only) .........................................4 Disassembly .....................................................................F6....6 ELECTRICAL DISPLACEMENT CONTROL (SD-116DX/F Only) ...................................................................................8 FORWARD ..................3 Inspection ..............................................NEUTRAL ......F6..F6....6 Assembly.....................F6.................F6......F6..............F6...............................4 Inspection .......... wear. Inspect the sealing area on the shaft (4) for rust. 2. ASSEMBLY F6. Figure 1-1 LIP SEAL . Figure 1-1). DISASSEMBLY 1. Polish the sealing area on the shaft (4) as necessary. 3.SD-116 TF SERIES VIBRATION PUMP NOTICE: Prior to performing repairs on this component. Slide the new lip seal (3) over the shaft (4) and press it into the housing (2) bore. contact a service representative concerning issues of warranty. Lightly lubricate the outside diameter of the new lip seal (3) with Loctite High Performance Sealant #59231. A slide type hammer may be used to remove the lip seal (3). Remove the retaining ring (1. INSPECTION 1. 2. wrap the spline or key end of the shaft (4) with thin plastic. Carefully remove the lip seal (3) from the housing (2) bore. Figure 1-1) from the housing (2).2 1. or contamination. Install the retaining ring (1). CAUTION: To prevent damage to the lip seal (3. 3.3 1. 2.SD-116 TF SERIES VIBRATION PUMP DISASSEMBLY 1. Inspect the bypass valve (5) and mating seat for damage or foreign material. Use new parts as required. 2. Remove the bypass valve (5. Figure 1-2 BYPASS VALVE .). Install a new backup ring (7) and O-ring (6) onto the bypass valve (5).6 N·m (7 to 10 lb-ft.5 to 13. INSPECTION 1. Figure 1-12) from the housing (2). Torque the bypass valve (5) to 9. ASSEMBLY F6. Lubricate the new O-ring (6) with clean hydraulic fluid and install the bypass valve (5) into the housing (2). Remove and discard the O-ring (6) and backup ring (7) from the bypass valve (5). Remove the charge check and high pressure relief valve plug (8. new spring (10). Remove the spring (10) and poppet or valve cartridge (11) from the housing (2). 2. CAUTION: The high pressure relief valves are factory set and should not be tampered with except for replacing the entire poppet or valve cartridge. Figure 1-3 CHARGE CHECK AND HIGH PRESSURE RELIEF VALVE .SD-116 TF SERIES VIBRATION PUMP DISASSEMBLY 1. a new vibration pump must be used and the original must be returned to the manufacturer for warranty repair or replacement.). 3. 3. F6. Install a new poppet or valve cartridge (11). 2. Torque the charge check and high pressure relief valve plug (8) to 41 to 95 N·m (30 to 70 lb-ft. If the seat in the housing (2) is damaged. NOTE: Always replace ball type check valves with the poppet type. INSPECTION 1. and charge check and high pressure relief valve plug (8) into the housing (2). Remove and discard the O-ring (9) from the charge check and high pressure relief valve plug (8).4 ASSEMBLY 1. Disassembly may change the setting and cause system malfunctions or premature failure. Inspect the poppet or valve cartridge (11) and mating seat in the housing (2) for damage or foreign material. Install a new O-ring (9) on the charge check and high pressure relief valve plug (8). Figure 1-3). Use new parts as required. Remove and discard the shims (14) from the charge relief valve plug (12).SD-116 TF SERIES VIBRATION PUMP DISASSEMBLY 1. Figure 1-4). 2. Install new shims (14) in the inside diameter of the charge relief valve plug (12). Remove and discard the O-ring (13) from the charge relief valve plug (12). and charge relief valve plug (12) with shims (14) into the housing (2). INSPECTION 1. Remove the charge relief valve plug (12. 4. Install a new O-ring (13) on the charge relief valve plug (12). new spring (15). Remove the spring (15) and poppet (16) from the housing (2). Figure 1-4 CHARGE RELIEF VALVE .5 1. Inspect the poppet and mating seat in the end cap for damage or foreign material.). Torque the charge relief valve plug (12) to 41 to 95 N·m (30 to 70 lb-ft. 2. 3. 4. ASSEMBLY F6. Install a new poppet (16). 3. SD-116 TF SERIES VIBRATION PUMP DISASSEMBLY 1. Figure 1-5) from the housing (19).). F6. 2. Remove the screws (1. Remove the filter adapter (2) and gasket (3) from the housing (19). 2. ASSEMBLY 1. Install a new gasket (3) and filter adapter (2) onto the housing (19).6 Figure 1-5 FILTER ADAPTER . 3. Torque the screws (1) to 22 to 28 N·m (16 to 21 lb-ft. Install the screws (1) to secure the filter adapter (2) onto the housing (19). Clean all sealing surfaces. Remove the servo piston covers (15 and 17). Remove and discard the gaskets (16).7 1. which will require readjustment. Remove the O-rings (11 and 12) from the control (6). 4. Remove any burrs or sharp edges as required. 5. Clean all parts in a suitable solvent and allow to air dry. 3. Figure 1-6 ELECTRICAL DISPLACEMENT CONTROL . Remove the screws (4 and 5.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. Inspect all machined surface for burrs and sharp edges. (SD-116DX/F Only) DISASSEMBLY 1. 2. Figure 1-6). INSPECTION F6. Remove the screws (14) from the servo piston covers (15 and 17) on each side of the housing (19). 2. Carefully lift the electrical displacement control (6) off the housing (19). 3. 6. Figure 1-6).8 (SD-116DX/F Only) 1.). NOTICE: After installing the servo piston cover (15. Performance of the pump neutral adjustment may adjust the position of the displacement limiter. the pump neutral adjustment MUST be performed before the machine is put back into service. torque the screws to 13 to 14 N·m (10 to 11 lb-ft.). Install the servo piston covers (15 and 17) and secure each with screws (14). 4.SD-116 TF SERIES VIBRATION PUMP ASSEMBLY F6. Torque the screws (14) to 8 to 11 N·m (11 to 15 lb-ft. Figure 1-6 ELECTRICAL DISPLACEMENT CONTROL . Install the screws (4 and 5). 2. Figure 1-6) for each servo piston cover (15 and 17). 3. Carefully install the spool of the electrical displacement control (6) on the housing (19). Install new O-rings (11 and 12) on the control (6). Install a new gasket (16. 7. 6. Perform pump neutral adjustment. 5. 5. Inspect all machined surfaces for burrs and sharp edges. Remove the control (6) from the gasket (7). Remove the servo piston covers (15 and 17). 3.9 1.NEUTRAL REVERSE CONTROL . Figure 1-7 FORWARD . Remove and discard the O-rings (8 and 9) from the gasket (7). Remove the gasket (7) from the housing (19). Remove and discard the gaskets (16). Clean all parts in a suitable solvent and allow to air dry. 4.SD-116 TF SERIES VIBRATION PUMP (SD-116D Only) DISASSEMBLY 1. 6. Remove any burrs or sharp edges as required. 2. Remove the screws (4. 8. Remove the screws (14) from each side of the housing (19). Remove the screws (5) from the gasket (7). 2. Clean all sealing surfaces. INSPECTION F6. Discard the gasket. 3. Figure 1-7). 7. Install the screws (5) onto the gasket (7). Install the control (6) onto the gasket (7). Figure 1-7). 7. Install a new gasket (16.). Perform pump neutral adjustment. Figure 1-7) for each servo piston cover (15 and 17). Install the gasket (7) onto the housing (19) 6. Torque the screws (5) to 8 to 11 N-m (11 to 15 lb-ft. Torque the screws (14) to 8 to 11 N·m (11 to 15 lb-ft. 3. Figure 1-7 FORWARD . the pump neutral adjustment MUST be performed before the machine is put back into service.NEUTRAL REVERSE CONTROL . Install the servo piston covers (15 and 17) and secure each with screws (14). 4. 10.10 (SD-116D Only) 1. NOTICE: After installing the servo piston cover (15. Install new O-rings (8 and 9) onto a new gasket (7). 8. torque the screws to 13 to 14 N·m (10 to 11 lb-ft. 5. Install the screws (4).).). 9.SD-116 TF SERIES VIBRATION PUMP ASSEMBLY F6. 2. ............................ F7..........2 Disassembly ...................................................................... F7.1 TABLE OF CONTENTS .....2 Inspection ................................. F7...........SD-116 TF SERIES VIBRATION MOTOR TABLE OF CONTENTS... F7.......................................... F7.1 SHAFT SEAL................3 Vibration Motor F7.................................................................2 Assembly........ Remove the support washer (10) and lip seal (7) from the motor housing (8). 8. Remove the end cap (9) from the motor housing (8). If necessary. 9. Figure 1-1 SHAFT SEAL . Remove the second retaining ring (6) from the motor housing 4. 2. 7. INSPECTION 1. Inspect parts for damage or wear. remove the shaft from inside the motor housing. Remove the retaining ring (6. Locate and loosen the screws that connect the end cap gasket (9) to the motor housing (8). DISASSEMBLY F7. Figure 1-1) located on the shaft end of the motor (8). use new parts as required. Remove the O-rings and ball bearing from the motor housing. Turn the vibration motor over with the motor shaft end facing down. 5. 6.SD-116 TF SERIES VIBRATION MOTOR NOTICE: Prior to performing repairs on this component. Discard the O-rings. contact a service representative concerning issues of warranty.2 1. Remove the end gasket (2) from the end cap (9) and discard. 3. Remove the needle bearing (1) from the end cap motor. Install the support washer (10) and retaining ring (6). Install the new lip seal (7) into the shaft end of the motor housing (8). Place the motor end cap (9) on the motor shaft (8).SD-116 TF SERIES VIBRATION MOTOR ASSEMBLY F7. Figure 1-1) and a new gasket (2) on the motor end cap (9). Figure 1-1 SHAFT SEAL . 7. 5. 3.3 1. Using the screws provided. 2. Place the first retaining ring (6) 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). Lightly lubricate the outside of the diameter of the new lip seal (7) with Loctite High Performance Sealant #59231. fasten the end cap motor (9) to the motor shaft (8). 6. Place a new needle bearing (1. Lubicate the new O-rings (4) with petroleum jelly and in them along with the ball bearing (5) on the motor shaft . 4. ........ W/ ALL S/N ............4 g/m X X 2610/180 X X System Relief Pressure (psi/bar) * For specific application settings...................SD-116 TF SERIES Table of Contents Overview.....................G3 Steer Right..............G2 Neutral ........ G1 Return Filter Hydraulic Tank STEERING Steering Cylinders Steering Valve Steering Pump EFF.G5 Settings and Specifications .............2 l/m 6......................... contact your authorized service personnel... G4 Steer Left ...Steering* Engine RPM (Hi/Low) Flow at Input Speed 116D 116 F 2457/950 X X 24.. SD-116 TF SERIES STEERING STEERING CYLINDERS HYDRAULIC TANK SUCTION STRAINER RETURN FILTER V G2 V STEERING PUMP V STEERING VALVE OVERVIEW . SD-116 TF SERIES STEERING STEERING CYLINDERS HYDRAULIC TANK RETURN FILTER V SD-70/77 TF SERIES G3 L STEERING PUMP E G E N V V dashed lines indicate low pressure STEERING VALVE NEUTRAL D . SD-116 TF SERIES STEERING HYDRAULIC TANK STEERING CYLINDERS SUCTION STRAINER RETURN FILTER V G4 L STEERING PUMP E G E N V V dashed lines indicate low pressure STEERING VALVE STEER RIGHT D . SD-116 TF SERIES STEERING HYDRAULIC TANK STEERING CYLINDERS SUCTION STRAINER RETURN FILTER V G5 L STEERING PUMP E G E N V V dashed lines indicate low pressure STEERING VALVE STEER LEFT D . .......................... G6..........2 Inspection ...................................1 Steering Pump TABLE OF CONTENTS ........ G6..... G6...........................................3 Assembly.......3 G6............1 SEAL KIT ................................................................................................ G6........................................ G6....2 Disassembly .......SD-116 TF SERIES STEERING PUMP TABLE OF CONTENTS . contact a service representative concerning issues of warranty. Figure 1-1). 5. Place the flange (2) down on the work surface with a shop towel beneath the flange. Carefully remove and discard the anti-extrusion ring (5) then the seal (6) from the cover (9).NOTICE: SD-116 TF SERIES STEERING PUMP Prior to performing repairs on this component. 6. 3. Carefully remove and discard the O-ring seal (11) from both ends of the pump housing (1). 8. Remove the flange (2) and dowel pins (4) from the pump housing (1). 10. Place the pump in a vise from the flange side. 4. 7. Figure 1-1 SEAL KIT .2 1. Place the pump on a table with the shaft end facing up. 11. Clean up any oil left on the work surface after removing the cover (9). WARNING Safety glasses must be worn when removing the retaining ring (7. Remove the cover (9) and dowel pins (10) from the pump housing (1). Be careful not to damage the pump housing (1. Loosen and remove the screws (3) from the pump housing (1) and flange (2). Carefully remove and discard the anti-extrusion ring (5) then the seal (6) from the flange (2). 9. 2. Figure 1-1) or flange (2). Clean up any oil left on the work surface after removing the flange (2). Remove the retaining ring (7) and shaft seal (8) from the flange (2). DISASSEMBLY G6. Inspect all machined surfaces for burrs and sharp edges. 2.3 1. Figure 1-1) and seals (6) with petroleum jelly. Secure the seal (6) in the cover (9) by installing a new antiextrusion ring (5) to the outside diameter of the seal (6). WARNING Safety glasses must be worn when installing the retaining ring (7). Install the dowel pins (10) and cover (9) onto the pump housing (1). ASSEMBLY G6. Lightly lubricate the new O-ring seals (11. Install the new O-ring seals (11) on both ends of the pump housing (1). 2. Install a new seal (6) in the cover (9).INSPECTION SD-116 TF SERIES STEERING PUMP 1. Install the dowel pins (4) in the pump housing (1). 9. Press a new shaft seal (8) into the flange (2) and secure shaft seal (8) with the retaining ring (7). 7. 6. Secure the seal (6) in the flange (2) by installing a new antiextrusion ring (5) to the outside diameter of the seal (6). 8. Carefully clean and dry all machined surfaces thoroughly. 4. Install a new seal (6) in the flange (2). Figure 1-1 SEAL KIT . Remove burrs and sharp edges as required. 3. 5. Torque the screws (3) to 50 to 55 N·m (36. Place the pump in a vise from the flange side.). 11. Figure 1-1) over the shaft and down onto the pump housing (1). G6. Figure 1-1). Follow the pattern shown in Figure 1-1. 10. Be careful not to damage the pump housing (1) or flange (2). 13.5 lb-ft. Carefully install the flange (2.4 Figure 1-1 SEAL KIT . Install the screws (3) to secure the cover (9) and the pump housing (1) to the flange (2).9 to 40.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. 12. ............................................................................................................2 Inspection ....1 TABLE OF CONTENTS ...........2 Disassembly ....................4 Steering Valve G7.............................................. G7............. G7..................... G7.... G7.4 Assembly......... G7...................................1 STEERING VALVE ......SD-116 TF SERIES STEERING VALVE TABLE OF CONTENTS. Remove and discard the seals (7) from the gerotor assembly (5). Figure 1-1). Loosen and remove the screws (1). Carefully remove the gerotor assembly (5) from the spacer plate (6). DISASSEMBLY G7. Remove the check valve (8) from the housing (10). special screw (2) and washers (3) from the housing (10). 5.SD-116 TF SERIES STEERING VALVE NOTICE: Prior to performing repairs on this component. Carefully remove the ball (13) from the valve port by tipping the housing (10). 10. 6. Remove the housing (10) from the vise. 9. 7. Remove and discard the seal (11) from the housing (10). Remove the spacer plate (6) and the drive (9). 2. Clean the exterior of the steering valve thoroughly. 12.2 1. from the housing (10). 3. 4. contact a service representative concerning issues of warranty. Figure 1-1 STEERING VALVE . Fasten the edges of the port face sides in a vise. Use protective material on the vise jaws to prevent damage to the housing (10. 11. Remove the end cap (4). Remove the threaded bushing (12) over the ball (13) from the housing (10). 8. Remove the ring (19). Take care to keep the pin (20) in the sleeve (15) and spool (14) horizontal. Carefully press the spool (14) out from the control end of the sleeve (15). therefore check that the outer bearing race (16) has come out. Shake out the spring (28) and piston (29) from the housing (10). Remove the pressure relief valve assembly from the housing (10). bearing races (16 and 17). then carefully remove the centering springs (21) from the spool (14) using only your hands. 19. NOTE: The pressure relief valve assembly consists of a plug (25. and ring (19) will be pushed out of the housing (10) together. Remove the set screw (27) from the pressure relief valve port. 16. Loosen and remove the plug (25) and seal washer (26) from the housing (10). 20.SD-116 TF SERIES STEERING VALVE G7. needle bearing (18). Figure 1-1). Figure 1-1 STEERING VALVE .3 14. 22. 17. Remove the dust seal (22) and the O-ring (23) from the housing (10). set screw (27). NOTE: The outer bearing race (16. and the needle thrust bearing (18) from the spool (14) and sleeve (15) assembly. Press the spool (14. bearing races (16 and 17). Be careful not to damage the housing (10). 18. Figure 1-1) can sometimes “stick” in the housing (10). and a piston (29). 21. 15. Figure 1-1) inward and the sleeve (15). Push the pin (20) from the spool (14) and sleeve (15) assembly. seal washer (26). spring (28). 2.4 1. Place the curved centering springs (21) between the flat centering springs (21) that are already installed in the spool (14). Do not wipe dry with cloth or paper towel. Figure 1-1 STEERING VALVE . Insert the pin (20) through the spool (14) and sleeve (15) assembly until the pin is flush on both sides of the sleeve (15). Make sure the ring (19) can rotate smoothly over the centering springs (21). 5. Install the ring (19) over the spool (14) and on the sleeve (15). 4. 2. Figure 1-1) in the centering springs slots of the spool (14). Replace parts as required. ASSEMBLY G7. Align the centering springs (21) within the spring slots of the spool (14). Inspect all mating surfaces for burrs and sharp edges. Do not use grit paper or file or grind these parts. 8. 3. Press the centering springs (21) together and push the centering springs (21) into place in the sleeve (15).SD-116 TF SERIES STEERING VALVE INSPECTION 1. 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. 6. Install the two flat centering springs (21. Clean all metal parts in a cleaning solvent. Align the centering springs (21) and center them in the spool (14) and sleeve (15) assembly. 7. Install the spool (14) and sleeve (15) carefully so that the spring slots line up at the same end. Blow dry all metal parts. Test for free rotation by turning the spool (14) and sleeve (15) assembly with fingertip force at the splined end. leaving the guide from the inner part in the bore. Figure 1-1) must face the splined end of the spool (14). The spool (14) and sleeve (15) assembly will push out the assembly tool guide. 16. 14. 9. and the outer bearing race (16) on the splined end of the spool (14). 13. 11. 10. Press and turn the O-ring (23) into position in the housing (10). Install the inner bearing race (17. keeping the pin (20) nearly horizontal. Install the spool (14) and sleeve (15) assembly splined end in the gerotor end of the housing (10). Place the housing (10) on the work surface with the bore in a horizontal position. Push the spool (14) and sleeve (15) assembly gently into place with slight rotating action. 15. Guide the outer part of the assembly tool into the bore for the spool (14) and sleeve (15) assembly. Make sure the parts do not tilt out of position. 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.SD-116 TF SERIES STEERING VALVE G7. The O-ring (23) is now in position. 12.5 NOTE: The inside chamfer on the inner bearing race (17. 17. Figure 1-1). Hold the outer part of the assembly tool in the bottom of the housing (10) and guide the inner part of the assembly tool into the bottom of the housing (10). needle bearing (18). Figure 1-1 STEERING VALVE . Remove the inner and outer parts of the assembly tool out of the housing (10) bore. 18. 24. 23. Lightly lubricate the new seal (11) with clean hydraulic oil and install the seal (11) in the housing (10). lint free cloth with the bore in a vertical position. 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). 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). Install the check ball (13) in the check valve port of the housing (10). Lightly lubricate the seals (7) with clean hydraulic oil and install the seals (7) on both sides of the gerotor assembly (5). 22. refer to Figure 1-1. 21. 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). making sure the drive (9) is engaged with the pin (20). Place the housing (10. The top of the threaded bushing (12) must lie just below the surface of the housing (10). Figure 1-1 STEERING VALVE . Install the threaded bushing (12) in the check valve port of the housing (10).SD-116 TF SERIES STEERING VALVE G7. Install the drive (9). refer to Figure 15. 20. Figure 1-1) on a clean. Align the splines of the gerotor assembly (5) with those of the drive (9) and install the gerotor assembly (5) on the spacer plate (6). NOTE: The gerotor assembly (5. Use the mounting fork tool to hold the drive (9) in position.6 19. 28. Install the check valve (8) in the housing (10). 27. 26. 25. 38.). 37. seal washer (26). Press the dust seal (22) into housing (10). 32. 36. 31. Torque the plug (25) to 50 ± 10 N·m (36 ± 7 lb-ft. 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). aligning the bolt holes. and a piston (29). Remove the mounting fork tool from the drive (9). 33. spring (28). Install the special screw (2) and washer (3) in the check valve port bolt hole in the end cap (3). Install the screws (1) and washers (3) in the end cap (4). Figure 1-1). 35. Install the piston (29) and spring (28) into the pressure relief valve port. Figure 1-1) on the gerotor assembly (5). Cross tighten the screws (1) and special screw (2) and torque the screws (1) and special screw (2) to 30 ± 6 N·m (22 ± 4. 30. set screw (27). Install the seal washer (26) and plug (25) into the pressure relief valve port. Install the pressure relief valve assembly in the housing (10).4 lb-ft). Figure 1-1 STEERING VALVE .7 29. NOTE: The pressure relief valve assembly consists of a plug (25. 34. Install end cap (4.SD-116 TF SERIES STEERING VALVE G7. 39. ...........2 Disassembly ..................SD-116 TF SERIES STEERING CYLINDER (S/Ns 169494......................4 Steering Cylinders G8................ G8...............1 TABLE OF CONTENTS ....2 Inspection .............................................................................3 Assembly........... G8......................... G8............................ G8.............................................. 169572) TABLE OF CONTENTS............... G8...1 SEAL KIT .... 169572) DISASSEMBLY G8. Wrap the headcap (6) with a soft cloth to prevent the inside diameter of the headcap (6) from touching the piston rod (2). Extend the piston rod (2) until the piston (3) bottoms out on the head (4). Gently tap the piston (3) against the head (4) to drive the piston rod (2) assembly from the tube (1). 7. Figure 1-1 SEAL KIT ..2 1. If the headcap (6) is sruck or moves erratically. Be careful not to damage the tube (1). Place the piston rod (2) assembly on a suitable work surface that will not damage the piston rod (2). If the hoses were removed with the cylinder. 8. contact a service representative concerning issues of warranty. Figure 1-1) in an acceptable repair stand or other holding equipment. Insert a spanner wrench into the holes provided. Remove the headcap (6) from the tube (1) by turning the headcap (6) counterclockwise. remove the hoses from the cylinder. Fasten the tube (1. tap the headcap (6) with a brass or plastic mallet while turning it. (S/Ns 169494. 3. Clean the outside of the cylinder. 2. 4. Loosen and remove the set screw (5) and nylon plug (16) from the headcap (6). 5. 6.NOTICE: SD-116 TF SERIES STEERING CYLINDER Prior to performing repairs on this component. 169572) INSPECTION G8. 12. piston (3). Remove the piston (3). head (4). a new cylinder assembly must be used. Remove and discard the O-ring (12) and backup ring (13) from the outside diameter of the head (4). Figure 1-1) from the piston rod (2). head (4). 10. and headcap (6) from the piston rod (2). (S/Ns 169494.3 1. lip seal (10). Remove and discard the O-ring (8) from the piston rod (2). Remove and discard the wear ring (14) and glyd-ring (15) from the piston (3). Use only lint free cloths for cleaning and drying. Figure 1-1 SEAL KIT . 11. Clean all parts in cleaning solvent. Loosen and remove the locknut (7. 13.SD-116 TF SERIES STEERING CYLINDER 9. Remove and discard the wiper (9). and wear rings (11) from the inside diameter of the head (4). 14. If the piston rod (2). 2. or the tube (1) are damaged in any way. 7.). Wrap the headcap (6) with a soft cloth to prevent the inside diameter of the headcap (6) from touching the piston rod (2). Install the head (4) followed by the piston (3) onto the piston rod (2) noting the proper orientation of each component. Torque the lock nut (7) to 610 to 664 N·m (450 to 490 lb-ft. 2. 6. Install new wear rings (11) in the back groove in the inside diameter of the head (4). 8. Install a new glyd-ring (15) and wear ring (14) in the grooves on the outside diameter of the piston (3). 4. Figure 1-1) in the middle groove in the inside diameter of the head (4). 10. Lubricate the inside and outside diameters of both the piston (3) and head (4) with clean hydraulic oil. 169572) Figure 1-1 SEAL KIT . 12.SD-116 TF SERIES STEERING CYLINDER ASSEMBLY G8. 5. Install a new backup ring (13) in the groove on the outside diameter of the head (4) closest to the headcap (6). Secure the piston (3) onto the piston rod (2) with the lock nut (7).4 1. Install the headcap (6) onto the piston rod (2). Install a new O-ring (12) in the groove on the outside diameter of the head (4) next to the backup ring (13). 3. (S/Ns 169494. Install a new wiper (9) in the front groove in the inside diameter of the head (4). 11. Place the piston rod (2) on a clean work surface. 9. Install a new lip seal (10. 13. Figure 1-1) assembly into the tube (1) until the headcap (6) engages the threads of the tube (1). 16. 169572) G8.5 Figure 1-1 SEAL KIT . then turn the headcap (6) clockwise until it is hand-tight or fully seated.SD-116 TF SERIES STEERING CYLINDER 14. (S/Ns 169494. Install the nylon plug (16) and set screw (5) into the headcap (6). Use a spanner wrench to tighten the headcap (6) 1/8 to 1/4 turn past fully seated. Turn the headcap (6) counterclockwise until the first thread just passes the engagement point. Install the piston rod (2. 15. ..........................1 SEAL KIT .....................3 Assembly...... G9... G9...................................2 Disassembly ................................................... G9..............................1 TABLE OF CONTENTS ..........................3 Steering Cylinders G9..... G9.............................SD-116 TF SERIES STEERING CYLINDER (All Other S/Ns) TABLE OF CONTENTS... G9.....................................................2 Inspection ...... Remove and discard the seal (14) and wear ring (15) from the piston (3). Clean the outside of the cylinder. Remove the piston (3) and head (2) from the cylinder rod (4). 9. 4. Figure 1-1) in an acceptable repair stand or other holding equipment. Figure 1-1 SEAL KIT . contact a service representative concerning warranty issues. Be careful not to damage the tube (1). 3.NOTICE: SD-116 TF SERIES STEERING CYLINDER (All Other S/Ns) Prior to performing repairs on this component. 7. 8. Gently tap the piston (3) against the head (2) to drive the cylinder rod (4) from the tube (1). 5. Extend the cylinder rod (4) until the piston (3) bottoms out on the head (2). Place the cylinder rod (4) assembly on a suitable work surface to prevent damage. 6. DISASSEMBLY G9. If the hoses were removed with the cylinder. 2. remove the hoses from the cylinder. Loosen and remove the locknut (25) from the cylinder rod (4).2 1. Remove and discard the rod seal (11) and the rod wiper seal (13) from the inside diameter of the head. 10. Fasten the tube (1. Remove and discard the O-ring (10) and backup washer (40) from the outside diameter of the head (2). Install the head (2). Figure 1-1 SEAL KIT . 9. 7.3 1. Lubricate the inside and outside diameters of both the piston (3) and head (2) with clean hydraulic oil. a new cylinder assembly must be used. Secure the piston (3) onto the cylinder rod (4) with the locknut (25). Install a new backup washer (40) in the groove on the outside diameter of the head (2). 3. piston (3). followed by the piston (3). Place the cylinder rod (4) on a clean work surface. 4. 8.INSPECTION SD-116 TF SERIES STEERING CYLINDER (All Other S/Ns) 1. ASSEMBLY G9.). Figure 1-1). 2. Torque the locknut (25) to 407 N·m (300 lb-ft. If the cylinder rod (4. Install the cylinder rod (4) in the tube (1). Install a new O-ring (10) in the groove on the outside diameter of the head (2) next to the backup washer (40). Install a new seal (14) and a new wear ring (15) in the groove on the outside diameter of the piston (3). 6. Install a new O-ring (11) and a new rod wiper seal (13) in the inside diameter of the head (2). or tube (1) is damaged in any way. onto the cylinder rod (4). 2. Use only lint-free cloths for cleaning and drying. 5. Clean all parts in cleaning solvent. noting the proper orientation of each component. 10. head (2). ......H2 Starter Alternator H1 Grid Heaters Ignition Switch Fuses ELECTRICAL Grid Heater Relays - - Starter Relay Power Relay Fuel Solenoid Relay Batteries Master Switch BATTERY EFF..............SD-116 TF SERIES Table of Contents Battery............... W/ ALL S/N ... 8 RD .0 H2 1.8 RD B+ TO OPTIONAL REAR LIGHT RELAY. W OOOOOO STARTER MOTOR OO O OO OOOOOOO O O O O O Regulator STATOR STARTER SOLENOID MASTER SWITCH (OPTIONAL) CAP D+ FUSE LINK ALTERNATOR BATTERY .0 5.0 BATTERIES RD RD + RD 5.0 TO OPTIONAL FRONT LIGHT RELAY .0 F1 FUSE 15 A PR GRN RD 1.0 GRID HEATER 2.SD-116 TF SERIES ELECTRICAL POWER RELAY 87A 30 87 86 FUEL SOLENOID RELAY STARTER RELAY 85 87A 30 IGNITION SWITCH RD 87A 30 87 87 86 86 85 85 GRID HEATER OFF IGNITION RD START RD RD IGN RD GRID HEATER RELAYS 1. . 1 1425 23..SD-116 TF SERIES Table of Contents Ignition . 8 1450 24..... 8 VPM HZ Park Brake Switch H3 Fuses Throttle Switch Power Relay Hi/Low Speed Switch Seat Timer Ignition Switch Throttle Solenoid Timer Seat Switch (Under Seat) Horn Park Brake Pressure Switch Vibration Speed Sensor Hydraulic Oil Temperature Switch Rear Speed Sensor IGNITION EFF... 4 1650 2750 Backup Alarm Switch (Behind Hood) Seat Timer Diode (In Harness) ELECTRICAL Park Brake Test Switch Air Filter Restriction Switch Throttle Solenoid Emergency Stop Switch Power Port Backup Alarm 2025 33.. 2 1550 25..... 4 1350 22... 8 1225 20............ 5 1250 20........... 8 1825 30. W/ ALL S/N .H4 1625 27.. RD/WE 86 85 H4 16 .DPE/WE 6 2 4 LOW 3 .DPE/WE IGNITION SWITCH 6 .GY/GN 87A HIGH / LOW SPEED SWITCH 12 .BN/BK 9 ON 3 1 7 IGNITION START B BACK UP ALARM SWITCH TO LIGHT OPTIONS 13 .LGN/BK INIT SEAT TIMER DIODE SEAT TIMER HOLD THROTTLE SOLENOID TO FUEL SOLENOID N/O B THROTTLE SOLENOID TIMER WE SGL RD BK 3 TEST 1 6 5 B A C 16 .LBE 1A 1B OFF 2A 2 2B P 4 B A C 16 .BN RD/BE CLOSES AT 180 F 11 .GY/OE A F4 15A F5 5A F7 10A 87 10 .BK/OE F11 10A TO CAB OPTIONS 36 .DPE/WE 32 .LGN/WE 12 .LGN/WE 18 . ON GAUGES F2 10A 2 HYDRAULIC OIL HIGH TEMP.DBE/YW F6 5A 30 12 .DBE/RD BRAKE TEST SWITCH IGNITION .GY/OE FUSES TO INSTRUMENT CLUSTER SEE GAUGES SD-116 TF SERIES ELECTRICAL TO HORN SWITCH 1 SPARE F12 15A 10 .GY/RD SEAT SWITCH C + N/C 29 .LGN F10 10A 11 .DPE/WE IGN 6 .GY/OE 11 .DBE/RD 4 DRIVE 27 .DBE/RD TO ANTI SPIN CONTROL OPTION 17 .RD/BK 3 BK F8 30A 2 POWER PORT 32 .RD/BK 16 .DPE/WE F1 15A COM A 27 .LBE 23 .OE/GN 5 PR GRN 3 HIGH 1 27 .DBE/RD PARK BRAKE PRESSURE SWITCH 6 5 1 OFF HIGH LOW VIBRATION SPEED SENSOR 21 .LGN/WE F3 10A POWER RELAY BACK UP ALARM AIR FILTER RESTRICTION SWITCH TO I TERM.OE/RD 25 .HORN 34 .RD/DGN THROTTLE SWITCH 2 7 .LBE PARK BRAKE SWITCH 27 . SWITCH F9 10A WE SGL RD BK EMERGENCY STOP REAR SPEED SENSOR 27 .WE BK A B C RD WE BK A B 22 .DPE/WE TO AUTO / MANUAL VIBRATION SELECT SWITCH OPTION 27 .WE 6 . .... 8 145 0 135 0 22.. 8 182 5 30.........SD-116 TF SERIES Table of Contents Start ........ 2 155 0 25. 4 24.......H6 162 5 27...... 5 122 5 125 0 20.... 8 165 0 275 0 202 5 33..... W/ ALL S/N ... 1 142 5 23. 4 20... 8 VPM HZ H5 Park Brake Switch Throttle Switch Fuses Neutral Start Switch Hydraulic Oil Temperature Indicator ELECTRICAL 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) Ignition Switch Power Relay Starter Relay Fuel Solenoid Relay START EFF. PK AIR FILTER RESTRICTION F2 10A F3 10A F4 15A F5 5A POWER RELAY F6 5A 30 F7 10A 87 10 .LBE IGN PARK BRAKE SWITCH 8 .BN FUSES TO INSTRUMENT CLUSTER SEE GAUGES F12 15A HYD.OE/GN 5 PR GRN HIGH 6 4 LOW THROTTLE SWITCH 3 . OIL TEMP.OE/WE OFF 85 86 87 30 87A STARTER RELAY 3 1 OE FUEL SOLENOID RELAY IGN 6 .DBE F1 15A BK B A NEUTRAL START SWITCH STARTER SOLENOID START LIGHT OUT .LGN/BE F8 30A 85 A B 26 .RD/WE 86 TO AUDIBLE ALARM CIRCUIT TO EITHER OPTION CIRCUIT 6 .GY/BK 87A 87 C 28 .OE/RD 30 GRID RELAY OUT PE GN GRID RELAY OUT START IN BN N/A 6 4 26 .OE/WE 59 .SD-116 TF SERIES ELECTRICAL 34 .PK F 7 2 9 .WE/BE A NEUTRAL SWITCH DIODE 85 2 . F11 10A BK B F9 10A TO AUDIBLE ALARM OPTION CIRCUIT F10 1/A HOLD RD BK WE A C FUEL SOLENOID PULL GRID HEATER CONTROL MODULE 71 .LBE AIR FILTER RESTRICTION SWITCH IGNITION SWITCH H6 C D 30 .BK/RD 87A 6 .LBE OFF IGNITION 1A 2A 1B 2B 71 .OE/WE 28 .DGN/OE START E BE RD 26 .YW/BE 5 EMERGENCY STOP 9 ON 3 1 2 7 .GY/BK 86 B 62 . H8 Emergency Stop Switch Brake Test Switch 16 25 27 1 . 13 50 22 5 . VPM HZ Park Brake Switch H7 Seat Switch (Under Seat) Seat Timer Diode (In Harness) Fuses Seat Timer ELECTRICAL Neutral Start Switch Diode (In Harness) Brake Test Diode (In Harness) Brake Latching Relay Pump Return To Normal Solenoid Brake Release Solenoid Park Brake Pressure Switch BRAKE/SHUTDOWN BRAKES APPLIED EFF.. 15 50 25 8 ... W/ ALL S/N .. 16 50 27 50 20 25 33 8 ........ 30 4 .SD-116 TF SERIES Table of Contents Brake/Shutdown Brakes Applied . 18 25 24 2 .. 14 50 14 25 23 8 ... 12 50 20 8 . 12 25 20 4 .. DPE/WE COM A 27 .YW/RD OFF BRAKES APPLIED BRAKE RELEASE SOLENOID 23 .SD-116 TF SERIES ELECTRICAL 21 .YW/BK 20.LGN/YW 19 .RD/DGN PUMP RETURN TO NEUTRAL SOLENOID A A B B 20 .YW/BK 20 .LGN/YW 6 4 30 87A DRIVE 20 .DPE/WE A B 22 .DPE/WE 27 .LGN/BK SEAT TIMER DIODE + N/C N/O INIT SEAT TIMER 62 .DPE/WE 2 PARK BRAKE SWITCH 1A 2A 2 1B 2B 5 EMERGENCY STOP 19 .BN/BK P PARK BRAKE PRESSURE SWITCH TEST 27 .PK/WE 85 3 1 9 ON 3 1 7 BRAKE LATCHING RELAY BRAKE TEST SWITCH 87 B 20 .GY/RD SEAT SWITCH OPERATOR OUT OF SEAT C B 29 .YW/RD A 86 BK 6 49 .WE/BE TO FUEL SOLENOID RUN CONDITION BK B A NEUTRAL START SWITCH BRAKE / SHUTDOWN BRAKES APPLIED .YW/BK 27 .LGN/YW BRAKE TEST DIODE 5 4 81 .YW/BK C B A 27 .DPE/WE H8 NEUTRAL SWITCH DIODE 20 . . 15 50 25 8 .. 18 25 24 2 . 16 50 27 50 20 25 33 8 ....SD-116 TF SERIES Table of Contents Brake/Shutdown Brakes Released . 14 50 14 25 23 8 . VPM HZ Park Brake Switch H9 Seat Switch (Under Seat) Seat Timer Diode (In Harness) Fuses Seat Timer ELECTRICAL Neutral Start Switch Diode (In Harness) Brake Test Diode (In Harness) Brake Latching Relay Pump Return To Normal Solenoid Brake Release Solenoid Park Brake Pressure Switch BRAKE/SHUTDOWN BRAKES RELEASED EFF. 12 50 20 8 ..... W/ ALL S/N . 30 4 . H10 Emergency Stop Switch Brake Test Switch 16 25 27 1 . 12 25 20 4 . 13 50 22 5 .. DPE/WE 27 .LGN/YW 6 4 30 87A DRIVE 20 .YW/BK C B A 27 .LGN/BK SEAT TIMER DIODE + N/C N/O INIT 62 .DPE/WE COM A 27 .BN/BK P PARK BRAKE PRESSURE SWITCH TEST 27 .DPE/WE A B 22 .LGN/YW 85 3 1 PARK BRAKE SWITCH 9 ON 3 1 BRAKE LATCHING RELAY BRAKE TEST SWITCH 4 BRAKE TEST DIODE 81 .GY/RD SEAT SWITCH OPERATOR IN SEAT C B 29 .YW/BK 27 .YW/RD A 86 BK 87 B 20 .LGN/YW 19 .YW/BK 20.DPE/WE H10 NEUTRAL SWITCH DIODE 20 .RD/DGN PUMP RETURN TO NEUTRAL SOLENOID A A B B 20 .YW/BK 20 .DPE/WE 2 7 1A 2A 2 1B 2B 5 EMERGENCY STOP 6 5 49 .SD-116 TF SERIES ELECTRICAL 21 .YW/RD OFF BRAKES RELEASED BRAKE RELEASE SOLENOID 23 .PK/WE 19 .WE/BE TO FUEL SOLENOID RUN CONDITION BK B A SEAT TIMER NEUTRAL START SWITCH BRAKE / SHUTDOWN BRAKES RELEASED . 13 50 22 5 . 14 25 23 8 . 16 50 27 50 20 25 33 8 . 12 25 15 50 25 8 . 24 2 . 20 4 .SD-116 TF SERIES Table of Contents Brake/Shutdown Brakes Released/ Operator Out of Seat. H12 Neutral Start Switch Diode (In Harness) Brake Test Diode (In Harness) 16 25 27 1 .. VPM HZ H11 Park Brake Switch Seat Switch (Under Seat) Seat Timer Diode (In Harness) Fuses ELECTRICAL Emergency Stop Switch Brake Test Switch 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 . 18 25 30 4 .. 14 50 12 50 20 8 .. SD-116 TF SERIES ELECTRICAL 21 - BN/BK P PARK BRAKE PRESSURE SWITCH TEST 27 - DPE/WE 2 1A 2A 2 1B 2B 5 6 9 ON 3 1 5 49 - PK/WE 19 - LGN/YW 19 - LGN/YW 85 3 1 PARK BRAKE SWITCH 7 BRAKE LATCHING RELAY BRAKE TEST SWITCH 4 BRAKE TEST DIODE 81 - YW/RD A 86 BK 87 B 20 - LGN/YW 6 4 30 87A DRIVE 20 - YW/BK 20- YW/RD OFF EMERGENCY STOP BRAKES RELEASED 23 - RD/DGN BRAKE RELEASE SOLENOID 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 SEAT C B 29 - LGN/BK SEAT TIMER DIODE + N/C N/O INIT SEAT TIMER 62 - WE/BE TO FUEL SOLENOID SHUTDOWN CONDITION BK B A NEUTRAL START SWITCH BRAKE / SHUTDOWN BRAKES RELEASED/ OPERATOR OUT OF SEAT SD-116 TF SERIES Table of Contents Brake/Shutdown Brake Test/ Operator In Seat ........... H14 Neutral Start Switch Diode (In Harness) Brake Test Diode (In Harness) 16 25 27 1 . 14 25 23 8 . 14 50 12 50 20 8 . 20 4 . 18 25 30 4 . 24 2 . 13 50 22 5 . 12 25 15 50 25 8 . 16 50 27 50 20 25 33 8 . VPM HZ H13 ELECTRICAL Emergency Stop Switch Brake Test Switch 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 1A 2A 2 1B 2B 5 EMERGENCY STOP 19 - LGN/YW BRAKE TEST DIODE 9 ON 3 1 5 49 - PK/WE 85 4 81 - YW/RD A 86 BK 6 87 B 20 - LGN/YW 6 4 30 87A DRIVE 20 - YW/BK 20- YW/RD OFF BRAKES APPLIED 23 - RD/DGN H14 19 - LGN/YW 3 1 PARK BRAKE SWITCH 7 BRAKE LATCHING RELAY BRAKE TEST SWITCH BRAKE RELEASE SOLENOID 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 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 SEAT TIMER BK B A NEUTRAL START SWITCH BRAKE / SHUTDOWN BRAKES TEST/ OPERATOR IN SEAT SD-116 TF SERIES Table of Contents Anti-Spin Control No Travel ...................... H16 ELECTRICAL Speedometer 1625 27.1 1425 23.8 1450 1350 22.5 1225 1250 20.4 20.8 VPM HZ 24.2 1550 25.8 1825 30.4 1650 2750 2025 33.8 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 SPIN CONTROL MODULE X A1 F2 10A XC B1 X X B2 / BOOT GND HARNESS 4 PIN CONNECTION C1 LGN X X C2 DBE / BK TxD RxD A3 X 6200 C BK X GY / GN DRUM SPEED SENSOR SGL BK + BN .SD-116 TF SERIES ELECTRICAL SPEEDOMETER S CONNECTOR AT ANTI SPIN MODULE I G GY / GN A1 A2 BK A3 B1 RD / WE LBE / BL B2 B3 B A C DBE / RD FUSES D1 D2 D3 WE SGL RD BK FRONT ASC SOLENOID LBE BK / WE E1 E2 BK E3 F1 HARNESS 4 PIN CONNECTIONS RD / WE C3 REAR SPEED SENSOR WE F2 F3 XB F12 15A REFERENCE TO CONNECTOR PIN F11 10A H16 LGN LBE / BK C1 C2 BK / WE F9 10A GY / GN GY / GN X A F10 1/A IGN F3 10A F4 15A F5 5A D3 X HIGH / LOW SPEED SWITCH F6 5A F7 10A 3 F8 30A 1 X E1 HIGH PK / RD 2 LGN / WE D WE X LOW HARNESS 4 PIN CONNECTION MAINTENANCE JUMPER LBE / BK SENSOR POWER BK / WE X F1 PK/RD ANALOG IN 0 ANALOG IN 1 VALVE 0 VALVE 1 ANALOG IN 2 ANALOG IN 3 CAN LOW CAN HIGH DIGITAL 0 DIGITAL OUTPUT DIGITAL 1 DIGITAL 2 REAR ASC SOLENOID ANTI .BE B A C LBE 2000 B A C HARNESS 4 PIN CONNECTIONS BK X C ANTI-SPIN CONTROL NO TRAVEL . 2 1550 25...8 1825 30..SD-116 TF SERIES Table of Contents Anti-Spin Control Travel. W/ ALL S/N .8 1450 1350 22....... H18 ELECTRICAL Speedometer 1625 27..........4 1650 2750 2025 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..1 1425 23..5 1225 1250 20.8 VPM HZ 24..4 20.... SD-116 TF SERIES ELECTRICAL SPEEDOMETER S CONNECTOR AT ANTI SPIN MODULE I G A3 B1 B2 B3 C1 C2 BK / WE B A C DBE / RD RD / WE LBE / BL LGN LBE / BK D2 D3 E1 WE SGL RD BK HARNESS 4 PIN CONNECTIONS RD / WE FRONT ASC SOLENOID LBE BK / WE BK E2 E3 F1 WE F2 F3 XB F12 15A REFERENCE TO CONNECTOR PIN F11 10A F9 10A GY / GN GY / GN X A F10 1/A H18 BK C3 D1 REAR SPEED SENSOR FUSES GY / GN A1 A2 XC ANTI .BE ANALOG IN 0 ANALOG IN 1 B1 X X B2 / BOOT TxD RxD C1 X X C2 A3 X MAINTENANCE JUMPER DRUM SPEED SENSOR LBE / BK SENSOR POWER BK / WE REAR ASC SOLENOID HARNESS 4 PIN CONNECTION LGN DBE / BK BK LBE 2000 B A C HARNESS 4 PIN CONNECTIONS BK X C ANTI-SPIN CONTROL TRAVEL .SPIN CONTROL MODULE X A1 F2 10A IGN F3 10A F4 15A D3 X HIGH / LOW SPEED SWITCH F5 5A F6 5A F7 10A 3 F8 30A LGN / WE 1 X E1 HIGH PK / RD 2 D WE X LOW HARNESS 4 PIN CONNECTION X F1 PK/RD 6200 B A C VALVE 0 VALVE 1 ANALOG IN 2 ANALOG IN 3 CAN LOW DIGITAL OUTPUT CAN HIGH DIGITAL 0 DIGITAL 1 DIGITAL 2 GND C X GY / GN SGL BK + BN . 8 1825 30...4 VPM HZ 1250 20..8 24....1 1425 23...8 1450 1350 22. W/ ALL S/N .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..SD-116 TF SERIES Table of Contents Anti-Spin Control Drum Spin ..2 1550 25....4 1650 2750 2025 33...5 1225 20. H20 ELECTRICAL Speedometer 1625 27...... BE B A C ANALOG IN 0 ANALOG IN 1 VALVE 0 VALVE 1 ANALOG IN 2 ANALOG IN 3 CAN LOW CAN HIGH DIGITAL 0 DIGITAL OUTPUT DIGITAL 1 DIGITAL 2 X B2 HARNESS 4 PIN CONNECTION / BOOT GND C GY / GN 2000 B A C B1 X C1 X X C2 TxD RxD LGN DBE / BK A3 X 6200 DRUM SPEED SENSOR LBE / BK SENSOR POWER BK / WE REAR ASC SOLENOID ANTI .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 LGN LBE / BK RD / WE D1 D2 D3 WE SGL RD BK E1 E2 XB FRONT ASC SOLENOID LBE BK / WE BK WE F2 F3 F12 15A REFERENCE TO CONNECTOR PIN F11 10A F9 10A GY / GN GY / GN X A F10 1/A H20 RD / WE LBE / BL E3 F1 HARNESS 4 PIN CONNECTIONS FUSES BK C3 REAR SPEED SENSOR DBE / RD GY / GN XC X A1 F2 10A IGN F3 10A F4 15A F5 5A D3 X HIGH / LOW SPEED SWITCH F6 5A F7 10A 3 F8 30A 1 X E1 HIGH PK / RD 2 LGN / WE D WE X LOW HARNESS 4 PIN CONNECTION X F1 PK/RD MAINTENANCE JUMPER SGL BK + BN .SPIN CONTROL MODULE BK X LBE HARNESS 4 PIN CONNECTIONS BK X C ANTI-SPIN CONTROL DRUM SPIN . H22 ELECTRICAL Speedometer 1625 27........ 1350 22.2 1550 25.4 20...SD-116 TF SERIES Table of Contents Anti-Spin Control Wheel Spin ...... W/ ALL S/N .5 1225 1250 20...8 VPM HZ 1450 24.8 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..8 1825 30.4 1650 2750 2025 33..1 1425 238 . BE ANALOG IN 0 ANALOG IN 1 B1 X TxD RxD HARNESS 4 PIN CONNECTION C1 X LGN X C2 DBE / BK A3 X MAINTENANCE JUMPER DRUM SPEED SENSOR LBE / BK SENSOR POWER BK / WE REAR ASC SOLENOID ANTI .SD-116 TF SERIES ELECTRICAL SPEEDOMETER S CONNECTOR AT ANTI SPIN MODULE G GY / GN A1 A2 I BK A3 B1 RD / WE LBE / BL B2 B3 B A C DBE / RD D1 D2 D3 WE SGL RD BK FRONT ASC SOLENOID LBE BK / WE E1 E2 E3 F1 HARNESS 4 PIN CONNECTIONS FUSES RD / WE C3 REAR SPEED SENSOR BK WE F2 F3 XB F12 15A REFERENCE TO CONNECTOR PIN F11 10A F9 10A GY / GN GY / GN X A F10 1/A H22 LGN LBE / BK C1 C2 BK / WE XC X A1 F2 10A IGN F3 10A F4 15A F5 5A D3 X HIGH / LOW SPEED SWITCH F6 5A F7 10A 3 F8 30A 1 X E1 HIGH PK / RD 2 LGN / WE D WE X LOW HARNESS 4 PIN CONNECTION X F1 PK/RD 6200 B A C VALVE 0 VALVE 1 ANALOG IN 2 ANALOG IN 3 CAN LOW CAN HIGH DIGITAL 0 DIGITAL OUTPUT DIGITAL 1 DIGITAL 2 2000 B A C X B2 / BOOT GND C GY / GN SGL BK + BN .SPIN CONTROL MODULE BK X LBE HARNESS 4 PIN CONNECTIONS BK X C ANTI-SPIN CONTROL WHEEL SPIN . 8 24 2 . VPM HZ H23 Hi/Low Speed Switch High Speed Drum Motor Solenoid ELECTRICAL 16 25 27 1 .. 16 50 27 50 20 25 33 8 .SD-116 TF SERIES Table of Contents High/Low Speed Low Speed/ Anti-Spin Activated .. 12 25 20 4 . 18 25 30 4 . 14 25 23 8 ... High Speed Axle Motor Solenoid HIGH/LOW SPEED LOW SPEED/ANTI-SPIN ACTIVATED EFF.. 12 50 20 . 15 50 25 8 . H24 14 50 13 50 22 5 . W/ ALL S/N . 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 TO ANTI SPIN CONTROL MODULE BK B HIGH SPEED DRUM MOTOR SOLENOID HIGH / LOW SPEED LOW SPEED/ANTI-SPIN ACTIVATED .SD-116 TF SERIES ELECTRICAL HIGH SPEED AXLE MOTOR SOLENOID ( ON SD-120 ONLY ) 31 . H26 14 50 13 50 22 5 .. 18 25 30 4 ... 12 50 20 ... 15 50 25 8 .8 24 2 .. W/ ALL S/N . 12 25 20 4 ..SD-116 TF SERIES Table of Contents High/Low Speed High Speed/ Anti-Spin Inactive. 16 50 27 50 20 25 33 8 . High Speed Axle Motor Solenoid HIGH/LOW SPEED HIGH SPEED/ANTI-SPIN INACTIVE EFF. VPM HZ H25 Hi/Low Speed Switch High Speed Drum Motor Solenoid ELECTRICAL 16 25 27 1 . 14 25 23 8 .. BK/OE 79 .SD-116 TF SERIES ELECTRICAL HIGH SPEED AXLE MOTOR SOLENOID ( ON SD-120 ONLY ) 31 .BK/OE F3 10A H26 12 .BK/OE A HIGH LOW SPEED SWITCH BK B HIGH 31 .LGN/WE LOW A 31 .PK/RD BK B TO ANTI SPIN CONTROL MODULE HIGH SPEED DRUM MOTOR SOLENOID HIGH / LOW SPEED HIGH SPEED/ANTI-SPIN INACTIVE . 8 1825 30..1 1425 23.4 1650 2750 2025 33..SD-116 TF SERIES Table of Contents Automatic Vibration/Impact Meter Vibration Off ..5 1225 1250 20..4 20.8 Automatic/Manual Vibration Switch H27 Fuses High/Low Amplitude Switch Low Vibration Solenoid High Vibration Solenoid Automatic Vibration & Impact Meter Control Module ELECTRICAL Impact Meter Vibration Speed Sensor Rear Speed Sensor AUTOMATIC VIBRATION/ IMPACT METER VIBRATION OFF EFF... H28 VPM Meter Vibration On/Off Switch Speedometer 1625 27....8 1350 22...... W/ ALL S/N ..2 1550 25..8 VPM HZ 1450 24. LBE / RD YW IGN SENSOR POWER 44 .DBE / RD BK WE SGL RD BK MACHINE NOT IN MOTION REAR SPEED SENSOR ANALOG IN 0 ANALOG IN 1 VALVE 0 VALVE 1 ANALOG IN 2 ANALOG IN 3 CAN LOW DIGITAL OUTPUT CAN HIGH DIGITAL 0 / BOOT DIGITAL 1 DIGITAL 2 TxD RxD GND 67.VIBRATION OFF . 1 16.BK / WE B A C 16.LGN H28 2 3 16.WE / OE 1 55.1 V 5 WATT RESISTOR 500 OHM 3 WATT 43.YW / WE 1 2 3 LOW BK 4 38.LGN 68.DBE / RD IMPACT METER 4 LOW VIBRATION SOLENOID ZENER DIODE 500 OHM 5.SD-116 TF SERIES ELECTRICAL VIBRATION ON/OFF AUTO/MANUAL VIBRATION SELECT SWITCH F5 5A AUTO.DBE / BK SPEEDOMETER S G VPM METER S I S I G G BK I Zd1 F10 1/A 36.DBE / RD 39.DGN/YW B A C 45.DBE / BK BK AUTO VIBRATION & IMPACT METER CONTROL MODULE AUTOMATIC VIBRATION / IMPACT METER .LPE 2 HIGH VIBRATION SOLENOID HIGH / LOW AMPLITUDE SWITCH 3 40-YW / BN 2 3 MANUAL 1 HIGH 89.BK / WE BK WE SGL RD BK VIBRATION SPEED SENSOR 45. 2 1550 25.1 1425 23.4 20..8 Automatic/Manual Vibration Switch H29 Fuses High/Low Amplitude Switch Low Vibration Solenoid High Vibration Solenoid Automatic Vibration & Impact Meter Control Module ELECTRICAL Impact Meter Vibration Speed Sensor Rear Speed Sensor AUTOMATIC VIBRATION/ IMPACT METER MANUAL/LOW AMPLITUDE EFF.SD-116 TF SERIES Table of Contents Automatic Vibration/Impact Meter Manual/Low Amplitude.5 1225 1250 20...8 VPM HZ 1450 24..8 1825 30.4 1650 2750 2025 33. W/ ALL S/N .8 1350 22. H30 VPM Meter Vibration On/Off Switch Speedometer 1625 27. 1 V 5 WATT RESISTOR 500 OHM 3 WATT 43.MANUAL/LOW AMPLITUDE . 1 16.LPE 2 HIGH / LOW AMPLITUDE SWITCH 3 40-YW / BN 2 3 MANUAL 1 HIGH HIGH VIBRATION SOLENOID 89.LBE / RD YW IGN SENSOR POWER 44 .BK / WE BK WE SGL RD BK VIBRATION SPEED SENSOR B A C 16.LGN H30 2 16.BK / WE WE SGL RD BK ANALOG IN 0 ANALOG IN 1 MACHINE IN MOTION REAR SPEED SENSOR / BOOT GND 67.LGN TxD RxD 68.DBE / RD 4 LOW VIBRATION SOLENOID ZENER DIODE 500 OHM 5.DBE / RD BK VALVE 0 VALVE 1 ANALOG IN 2 ANALOG IN 3 CAN LOW CAN HIGH DIGITAL 0 DIGITAL OUTPUT DIGITAL 1 DIGITAL 2 45.DGN/YW B A C 45.SD-116 TF SERIES ELECTRICAL AUTO/MANUAL VIBRATION VIBRATION SELECT SWITCH ON/OFF F5 5A AUTO.DBE / BK BK AUTO VIBRATION & IMPACT METER CONTROL MODULE AUTOMATIC VIBRATION / IMPACT METER .DBE / BK SPEEDOMETER S G IMPACT METER VPM METER S I S I G G 3 BK I Zd1 F10 1/A 36.WE / OE 1 55.DBE / RD 39.YW / WE 1 2 LOW 3 BK 4 38. 1 1425 23.8 1825 30.8 VPM HZ 1450 24.SD-116 TF SERIES Table of Contents Automatic Vibration/Impact Meter Manual/High Amplitude. W/ ALL S/N .8 Automatic/Manual Vibration Switch H31 Fuses High/Low Amplitude Switch Low Vibration Solenoid High Vibration Solenoid Automatic Vibration & Impact Meter Control Module ELECTRICAL Impact Meter Vibration Speed Sensor Rear Speed Sensor AUTOMATIC VIBRATION/ IMPACT METER MANUAL/HIGH AMPLITUDE EFF..4 20.5 1225 1250 20.. H32 VPM Meter Vibration On/Off Switch Speedometer 1625 27.8 1350 22.2 1550 25..4 1650 2750 2025 33. DBE / RD VIBRATION ON/OFF 39.LGN H32 4 LOW VIBRATION SOLENOID ZENER DIODE 500 OHM 5.DGN/YW B A C 45.BK / WE 16. 1 16.DBE / BK BK AUTO VIBRATION & IMPACT METER CONTROL MODULE AUTOMATIC VIBRATION / IMPACT METER .DBE / BK SPEEDOMETER S G S I BK S I G 2 3 16.1 V 5 WATT RESISTOR 500 OHM 3 WATT 43.LBE / RD YW IGN SENSOR POWER 44 .YW / WE 1 2 3 LOW BK 4 38.LGN 68.SD-116 TF SERIES ELECTRICAL AUTO/MANUAL VIBRATION SELECT SWITCH F5 5A AUTO.WE / OE 1 55.DBE / RD VALVE 0 VALVE 1 CAN HIGH DIGITAL 0 VIBRATION SPEED SENSOR WE SGL RD BK ANALOG IN 0 ANALOG IN 1 MACHINE IN MOTION BK REAR SPEED SENSOR GND / BOOT TxD RxD 67.LPE 2 HIGH / LOW AMPLITUDE SWITCH 3 40-YW / BN 2 3 MANUAL 1 HIGH HIGH VIBRATION SOLENOID 89.MANUAL/HIGH AMPLITUDE .BK / WE BK WE SGL RD BK B A C ANALOG IN 2 ANALOG IN 3 CAN LOW DIGITAL OUTPUT DIGITAL 1 DIGITAL 2 45.DBE / RD VPM METER G I Zd1 F10 1/A 36. W/ ALL S/N .8 VPM HZ 1450 24.8 1350 22..8 1825 30..4 1650 2750 2025 33.4 20.2 1550 25.SD-116 TF SERIES Table of Contents Automatic Vibration/Impact Meter Automatic/Low Amplitude..5 1225 1250 20.8 Automatic/Manual Vibration Switch H33 Fuses High/Low Amplitude Switch Low Vibration Solenoid High Vibration Solenoid Automatic Vibration & Impact Meter Control Module ELECTRICAL Impact Meter Vibration Speed Sensor Rear Speed Sensor AUTOMATIC VIBRATION/ IMPACT METER AUTOMATIC/LOW AMPLITUDE EFF.1 1425 23. H34 VPM Meter Vibration On/Off Switch Speedometer 1625 27. WE / OE 1 55.LPE 2 HIGH / LOW AMPLITUDE SWITCH 3 40-YW / BN 2 3 MANUAL 1 HIGH HIGH VIBRATION SOLENOID 89.DBE / BK BK AUTO VIBRATION & IMPACT METER CONTROL MODULE AUTOMATIC VIBRATION / IMPACT METER .DBE / RD VIBRATION ON/OFF 39.LBE / RD YW IGN SENSOR POWER 44 .LGN H34 2 3 16.1 V 5 WATT RESISTOR 500 OHM 3 WATT 43.AUTOMATIC/ LOW AMPLITUDE .YW / WE 1 2 3 LOW BK 4 38.DBE / BK SPEEDOMETER S G VPM METER S I S I G G BK I Zd1 F10 1/A 36.DBE / RD IMPACT METER 4 LOW VIBRATION SOLENOID ZENER DIODE 500 OHM 5.BK / WE WE SGL RD BK ANALOG IN 0 ANALOG IN 1 MACHINE IN MOTION BK REAR SPEED SENSOR / BOOT GND 67.BK / WE BK WE SGL RD BK VIBRATION SPEED SENSOR B A C 16.DGN/YW B A C 45.DBE / RD VALVE 0 VALVE 1 ANALOG IN 2 ANALOG IN 3 CAN LOW CAN HIGH DIGITAL 0 DIGITAL OUTPUT DIGITAL 1 DIGITAL 2 45. 1 16.LGN TxD RxD 68.SD-116 TF SERIES ELECTRICAL AUTO/MANUAL VIBRATION SELECT SWITCH F5 5A AUTO. 8 1350 22..8 Automatic/Manual Vibration Switch H35 Fuses High/Low Amplitude Switch Low Vibration Solenoid High Vibration Solenoid Automatic Vibration & Impact Meter Control Module ELECTRICAL Impact Meter Vibration Speed Sensor Rear Speed Sensor AUTOMATIC VIBRATION/ IMPACT METER AUTOMATIC/HIGH AMPLITUDE EFF.8 VPM HZ 1450 24. W/ ALL S/N . H36 VPM Meter Vibration On/Off Switch Speedometer 1625 27.8 1825 30.4 20.SD-116 TF SERIES Table of Contents Automatic Vibration/Impact Meter Automatic/High Amplitude.5 1225 1250 20..2 1550 25.4 1650 2750 2025 33.1 1425 23. DBE / RD VIBRATION ON/OFF 39.DBE / BK SPEEDOMETER S G VPM METER S I S I G G 3 BK I Zd1 F10 1/A 36.DBE / RD IMPACT METER 4 LOW VIBRATION SOLENOID ZENER DIODE 500 OHM 5. 1 16.BK / WE BK WE SGL RD BK VIBRATION SPEED SENSOR B A C 16.DGN/YW B A C 45.LGN H36 2 16.BK / WE WE SGL RD BK ANALOG IN 0 ANALOG IN 1 MACHINE IN MOTION REAR SPEED SENSOR / BOOT GND 67.SD-116 TF SERIES ELECTRICAL AUTO/MANUAL VIBRATION SELECT SWITCH F5 5A AUTO.AUTOMATIC/ HIGH AMPLITUDE .WE / OE 1 55.LPE 2 HIGH / LOW AMPLITUDE SWITCH 3 40-YW / BN 2 3 MANUAL 1 HIGH HIGH VIBRATION SOLENOID 89.LBE / RD YW IGN SENSOR POWER 44 .DBE / RD BK VALVE 0 VALVE 1 ANALOG IN 2 ANALOG IN 3 CAN LOW CAN HIGH DIGITAL 0 DIGITAL OUTPUT DIGITAL 1 DIGITAL 2 45.LGN TxD RxD 68.YW / WE 1 2 3 LOW BK 4 38.DBE / BK BK AUTO VIBRATION & IMPACT METER CONTROL MODULE AUTOMATIC VIBRATION / IMPACT METER .1 V 5 WATT RESISTOR 500 OHM 3 WATT 43. ....8 1825 30...4 20.4 1650 2750 2025 33... H38 VPM Meter Vibration On/Off Switch Speedometer 1625 27...1 1425 23..2 1550 25...SD-116 TF SERIES Table of Contents Automatic/Variable/ Impact Meter .8 VPM HZ 1450 24.. W/ ALL S/N .5 1225 1250 20.8 Automatic/Manual Vibration Switch H37 Fuses High/Low Amplitude Switch Low Vibration Solenoid High Vibration Solenoid Automatic Vibration & Impact Meter Control Module ELECTRICAL Impact Meter Vibration Speed Sensor Rear Speed Sensor AUTOMATIC/VARIABLE/ IMPACT METER EFF..8 1350 22. LBE / BK 16. & IMPACT METER CONTROL MODULE 3 SENSOR POWER CAN HIGH DIGITAL 0 BK 2 IGN SENSOR POWER BK H38 Zd1 ZENER DIODE 500 OHM 5.RD / BE BK 63.DBE / RD 54.LGN 15 16 BK VARIABLE FREQUENCY SWITCH 11 HIGH 54.S S I G G SD-116 TF SERIES ELECTRICAL IMPACT METER VPM METER SPEEDOMETER S I I G 200 OHM EACH F10 1/A AUTO/MANUAL VIBRATION SELECT SWITCH 45 .DBE / RD 16.WE / BK 2 3 BK 4 WE SGL RD BK RESISTOR 500 OHM 3 WATT 1 IGN B A C 45.GY PROGRAM PORT VARIABLE VIBRATION CONTROL MODULE 44.LBE / RD HIGH / LOW AMPLITUDE SWITCH VIBRATION ON/OFF 2 39-LPE 2 1 MANUAL F5 5A 3 40.LBE / BK 55.GY / WE 4 LOW VIBRATION SOLENOID / BOOT GND 60.PK / WE TxD RxD 61.YW / BN 1 13 14 12 200 OHM SPEED 4 SPEED 5 SPEED 2 200 OHM SPEED 3 43. 3 43.YW / BN ANALOG IN 0 ANALOG IN 1 VALVE 0 VALVE 1 ANALOG IN 2 ANALOG IN 3 CAN LOW CAN HIGH DIGITAL 0 DIGITAL OUTPUT DIGITAL 1 DIGITAL 2 BK 42.WE / BK C 38 .BE / WE 44.BK / WE AUTO.DBE / RD REAR SPEED SENSOR 41.WE / OE B A HIGH VIBRATION SOLENOID 16 .DBE / BK LOW 48.DPE 1 48.1 V 5 WATT GND BK / BOOT TxD RxD 40.DGN / YW ANALOG IN 0 VALVE 0 ANALOG IN 1 ANALOG IN 2 VALVE 1 DIGITAL OUTPUT B A C WE SGL RD BK VIBRATION SPEED SENSOR 90-YW ANALOG IN 3 CAN LOW DIGITAL 1 DIGITAL 2 AUTO VIB.DGN / YW PROGRAM PORT AUTOMATIC/ VARIABLE / IMPACT METER .LBE / RD TO VIB SPEED SENSOR SIGNAL B TERMINAL SPEED 1 36.LGN / OE 64. ..H40 ELECTRICAL Grid Heaters 1 62 5 2 7.. 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 .1 1 45 0 2 4...... 5 1 25 0 2 0.8 1 22 5 2 0...... 2 1 42 5 2 3......... 8 1 82 5 3 0.4 1 35 0 2 2.SD-116 TF SERIES Table of Contents Grid Heater.... 8 1 65 0 2 75 0 2 02 5 3 3...4 1 55 0 2 5... BN / RD BK GRID HEATER INDICATOR B+ W A STATOR 92.PK 86 A C A C B B RD BK WE FUEL SOLENOID PULL 85 50.RD 37.LGN WE BK D+ ALTERNATOR F9 10A GRID HEATER GRID HEATER .RD / BK B BK CAP O O O OO OOOOOOO O O O O O A TEMPERATURE SENSOR 34.WE / BN INIT FUEL SOLENOID RELAY HOLD 87A 30 BK 87 71.SD-116 TF SERIES ELECTRICAL SEAT TIMER COM + ENGINE RUN CONDITION N/C N/O 47.LGN / RD BK IGN LIGHT OUT GRID RELAY OUT GRID RELAY OUT START IN H40 N/A BE A RD OE B C PE D GN BN RD RD 37 . GND A YW GRID HEATER RELAYS 53.BN /RD E F 51.0 TEMP.RD GRID HEATER CONTROL MODULE GRID HEATER 52.BN Regulator B RD OOOOOO BK RD 5. ........ 8 1450 24....... 1 ELECTRICAL VPM Meter 2025 33. 5 1225 20.. 8 1350 22.... 2 1550 25.. 4 1250 20. 8 1825 30. 4 1650 2750 Engine Oil Pressure Sender Hydraulic Oil Temperature Gauge 1625 27..SD-116 TF SERIES Table of Contents Gauges ... 8 VPM HZ Voltmeter Impact Meter Speedometer H41 Fuses Vibration Speed Sensor Hydraulic Oil Temperature Sender Rear Speed Sensor GAUGES EFF.. W/ ALL S/N .......H42 Engine Oil Pressure Gauge 1425 23....... 0E 36 . TERM.0E IMPACT 73 .DGN/BK WE SGL RD BK BK ENGINE OIL PRESSURE SENDER VIBRATION SPEED SENSOR TO AUTOVIB. TERM.BK/WE F10 10A TO AUTOVIB.DGN/YW 82 .SD-116 TF SERIES ELECTRICAL FROM WORK LIGHT SWITCH TERM.LGN 36 .0E 36 .LBE/RD 36 .YW/GN H42 TO AUTOVIB. & IMPACT METER CONTROL MODULE. E1 P B A C 83 .0E OIL PRESSURE 73 .LGN 36 . 3 HYDRAULIC OIL TEMPERATURE VOLTMETER 73 .LGN 44 . E1 T B A C WE SGL RD BK REAR SPEED SENSOR BK HYDRAULIC OIL TEMPERATURE SENDER GAUGES . & IMPACT METER CONTROL MODULE.0E 36 .LGN 43 .LGN SPEEDOMETER 73 . & IMPACT METER CONTROL MODULE.0E 73 . TERM. B1 45 .LGN VPM METER 73 . D3 TO ANTISPIN CONTROL MODULE. .2 1550 25...8 1225 20..8 VPM HZ ELECTRICAL Coolant Level Hydraulic Oil Temperature Indicator (In Indicator (In Instrument Cluster) Instrument Cluster) Coolant Temperature Engine Coolant Sender Engine Oil Temperature Gauge Air Filter Pressure Sender Tachometer Restriction Switch 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 .....4 1650 2750 2025 33.1 1425 23.....8 Alternator Charge Indicator (In Instrument Cluster) 1825 30.8 24.SD-116 TF SERIES Table of Contents Instrument Cluster .H44 H43 Grid Heater Indicator (In Instrument Cluster) 1625 27..5 1250 20....4 1450 1350 22. WE/RD FROM SIGNAL OPTION 37 .TN 30 .GY FROM LIGHT SWITCH 34 .OE 78 .BN 15 .LGN/BK COOLANT LEVEL INDICATOR 73 .DGN 34 .DBE/WE 77 .YW 4 .BN F9 10A LAMP RESISTOR 68 OHM \ 5 WATT P FROM ALTERNATOR D+ TERM ENGINE OIL PRESSURE SENDER T AIR FILTER RESTRICTION SWITCH FROM FUEL GAUGE SENDER 5 .SD-116 TF SERIES ELECTRICAL ALTERNATOR CHARGE INDICATOR I ENGINE COOLANT TEMERATURE GAUGE LOW OIL PRESSURE INDICATOR FUEL LEVEL GAUGE TACHOMETER I RPM T I G T G DIODE AIR FILTER RESTRICTION INDICATOR G BACK LIGHT BACK LIGHT BACK LIGHT GRID HEATER INDICATOR H44 14 .OE/BE FROM ALTERNATOR W TERM COOLANT TEMPERATURE SENDER INSTRUMENT CLUSTER .BN/RD FROM B TERM ON GRID HEATER CONTROL MODULE 85 .LGN/BE HYDRAULIC OIL TEMPERATURE INDICATOR 35 . ..........8 1225 20..8 1350 22..4 1450 24....1 1425 23..SD-116 TF SERIES Table of Contents Fuses ...8 VPM HZ Power Port Seat Switch Park Brake (Under Seat) Switch H45 Automatic/Manual Vibration Switch Fuel Throttle Solenoid Impact Meter Fuses Horn Anti-Spin Control Module Ignition Switch Hydraulic Oil Temperature Switch FUSES EFF..H46 Instrument Cluster Work Lights Engine Oil Pressure Gauge Beacon Light Air Filter Backup Alarm ELECTRICAL Voltmeter VPM Meter Coolant Level Sensorr Speedometer 1625 27..4 1650 2750 2025 33...5 1250 20....2 1550 25..8 1825 30.... W/ ALL S/N .......... OIL PRESSURE.SD-116 TF SERIES ELECTRICAL AMPERE RATING CIRCUIT F1 15 AMP KEY SWITCH. HYDRAULIC OIL TEMPERATURE & COOLANT LEVEL CIRCUITS F3 10 AMP TWO SPEED CIRCUIT & BACK UP ALARM F4 15 AMP WORK LIGHTS. E-STOP. AIR FILTER. IGNITION. BEACON & TURN SIGNAL / HAZARD LIGHTS F5 5 AMP AUTO / MANUAL VIBRATION & IMPACT METER F6 5 AMP ANTI-SPIN CONTROL F7 10 AMP POWER PORT F8 30 AMP THROTTLE SOLENOID PULL-IN CIRCUIT F9 10 AMP INSTRUMENT CLUSTER F10 10 AMP VOLTMETER. FUEL & THROTTLE SOLENOID HOLD CIRCUITS. SEAT SWITCH AND PARK BRAKE F2 10 AMP HORN. VPM & IMPACT METER GAUGES F11 10 AMP CAB OPTIONS F12 10 AMP STRIKE OFF BLADE OPTION FUSE NO H46 FUSES . SPEEDOMETER. ....4 ROPS/FOPS J1................................................................... J1........................ J1..................... J1.............................................................2 Safety ..................................4 Installation ................... J1.......... J1........................................2 Removal .............................................................1 032503AA TABLE OF CONTENTS ............2 Tools Required ..............1 ROPS/FOPS......3 Inspection ...... J1....................... J1.....SD-116 TF SERIES / ROPS/FOPS REPLACEMENT TABLE OF CONTENTS............. which should include safety practices pertaining to your specific location and situation. examine them closely to ensure they are free from defects. and sufficient capacity for lifting weight specified on ID tag located on the ROPS/FOPS SAFETY J1. Take note of the lifting height to ensure that the ROPS/FOPS will clear the unit. 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). and check for overhead power lines or other obstructions.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. When attaching chains or straps. These safety practices include the use of safety glasses and adherence to common safety procedures.2 Appropriate safety practices should be observed at all times. Figure 1-1 ROLLOVER PROTECTIVE STRUCTURE (ROPS) . Refer to the AEM Safety Manual for safety instructions. SD-116 TF SERIES/ ROPS/FOPS REPLACEMENT REMOVAL NOTE To ensure the safe removal and installation of your ROPS/ FOPS. 1. and flatwashers (3). Lift the ROPS/FOPS (1) clear of the frame with the suitable lifting device and move to desired location. hex nuts (4). Figure 1-1 ROLLOVER PROTECTIVE STRUCTURE (ROPS) . WARNING: All assisting personnel should stay clear of pinch points and avoid standing under the suspended ROPS/FOPS at all times. Remove the plastic plugs (10) covering the ROPS attaching hardware. 5. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Figure 1-1). 3. take out the slack so the straps or chains are fully supporting the ROPS/FOPS (1). 2. Check for overhead obstructions. Attach the straps or chains of the suitable lifting device to the ROPS/FOPS (1. refer to and view the service video which is available from your distributor. Once the lifting device is attached. Remove the capscrews (2). Check above the unit for obstructions. J1. 4.3 WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. ). 4. If cracks are found. and flatwashers (3) and secure the ROPS/FOPS. Remove the lifting device from the ROPS/FOPS (1). Replace as necessary. Figure 1-1) for signs of fatigue or cracks. 7. INSTALLATION 1. Apply Loctite #271 to capscrews (2). 2. 2.SD-116 TF SERIES/ ROPS/FOPS REPLACEMENT INSPECTION 1. hex nuts (4). Install the plastic plugs (10). 5. the machine should be placed out of service and the ROPS/FOPS and all mounting hardware replaced. Attach a suitable lifting device with straps or chains to the ROPS/FOPS. J1.4 WARNING: All assisting personnel should stay clear of pinch points and avoid standing under the suspended ROPS/FOPS at all times. 3. Torque the capscrews (2) to 637 N·m (470 lbs-ft. Check the ROPS/FOPS (1. 6. Install the capscrews (2). Check overhead for obstructions and lift the ROPS/FOPS (1) slowly over the unit and lower it into position. Check all mounting hardware for damage and wear. Figure 1-1 ROLLOVER PROTECTIVE STRUCTURE (ROPS) . ................. J2..........................7 Assembly...........7 J2.....................4 Cleaning and Inspection......................................................................1 032503AA TABLE OF CONTENTS .... J2................ J2........ J2..................................................................2 Removal and Disassembly..... J2....................2 Tools Required .............2 Safety .....SD-116 TF SERIES / SWIVEL BEARING REPLACEMENT TABLE OF CONTENTS..............1 SWIVEL BEARING ... J2............................................................. J2.. Read and understand all unit mounted safety labels before starting. fundamental safety rules and precautions. Refer to the AEM Safety Manual for safety instructions. fueling. such as a 3. Auto-Crane that is in perfect condition SAFETY J2.2 Accidents are caused by failure to follow simple. maintaining. using common sense. WARNING: Unexpected machine motion or moving parts can cut or crush. or maintain this compactor. operating. 032503AA Figure 1-1 TOOLS REQUIRED AND SAFETY . No unauthorized person should be allowed to operate. fueling. or servicing this unit. or servicing the compactor.SD-116 TF SERIES / SWIVEL BEARING REPLACEMENT TOOLS REQUIRED: • Safety glasses • Basic sockets and wrenches • Torque wrench • Loctite number 271 • Feeler gauges • Petroleum jelly • Sledge hammer • Heat resistant gloves • Non-residue type solvent • Straps or chains • Anti-seize • Lifting device. WARNING: Improper maintenance can be hazardous. Most accidents can be avoided by paying attention. service.000 lb. Study the Operator’s Manual and Service Manual before starting. maintaining. and following the instructions. Never use aggressive detergents. fuel. check the de-energized parts for the presence of power. Use lint free cleaning rags. 032503AA Figure 1-1 TOOLS REQUIRED AND SAFETY . Do not work on a hydraulic system while the engine is running or pressure is still in the system. or preservatives before carrying out maintenance or repair. or examining the compactor with the engine running. J2. NOTE: Clean the machine. Avoid ingestion. and safety shoes. Before starting any work. Exercise extreme caution when working around pressurized hydraulic systems. grease. Ensure all pressure is relieved from the system before performing maintenance. When handling oil.SD-116 TF SERIES / SWIVEL BEARING REPLACEMENT WARNING: Oil under pressure can cause serious cuts or injury. Do not perform any work on the equipment that is unauthorized. Ground or short circuit them in addition to insulating adjacent live parts and elements. of any traces of oil. and breathing fumes. grease or fuel could be hazardous to health if used incorrectly. Wear protective gear such as safety glasses. skin contact.3 Keep hands and fingers from between small parts. observe the product related safety regulations. or other chemical substances. cleaning. heavy gloves. Avoid whenever possible servicing. especially connections. Substances such as oil. SD-116 TF SERIES / SWIVEL BEARING REPLACEMENT WARNING: When draining fluids. WARNING: Exercise extreme caution when working around pressurized hydraulic systems. Improper support of the frame could cause death or severe injury. Ensure all pressure is relieved from the system before disconnecting hydraulic lines and performing maintenance. Park the machine on a level surface with ample clearance for working. REMOVAL AND DISASSEMBLY J2. Block Drum Frame Figure 1-2 JACK AND BLOCK PLACEMENT . Do not work on a hydraulic system while the engine is running or pressure is still in the system. Tag and disconnect the hydraulic lines to the propulsion. Tag and disconnect any electrical harnesses connected between the two frames. Block the tires of the machine to prevent the machine from moving. Always ensure waste fluids are disposed of in an environmentally safe manner. 1. and blade systems that are routed between the drum frame and rear frame. Block the drum frame in such a manner that it can be moved back when the articulation joint is unbolted. Cap or plug all lines and openings. 4. 2. Refer to Figure 1-2. vibration.4 WARNING: Crushing hazard. ensure that adequate sealable containers are available and that every care is taken to prevent spillage. 3. 5. Ensure that adequate supports are used prior to working in or around the articulation joint area. washer (7) and nut (6) from the swivel and drum frame.5 WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Move the drum frame clear of the swivel. 9. Remove and discard the bearings (4) and dust seals (24 and 25) from the drum frame (2). Remove the hitch pin (16) and remove the lock pin (9). Refer to the Drum and Drum Drive Teardown and Rebuild Procedure J3. Do not work on a hydraulic system while the engine is running or pressure is still in the system. Remove the pin (5). J2. 7. Ensure all pressure is relieved from the system before disconnecting hydraulic lines and performing maintenance. Remove the lock plate (26). 13. 10. Figure 1-3 DRUM FRAME AND SWIVEL BEARINGS . Check for overhead obstructions.SD-116 TF SERIES SWIVEL BEARING REPLACEMENT WARNING: Exercise extreme caution when working around pressurized hydraulic systems. Remove the drum assembly (1. Figure 1-3) and scraper from the drum frame (2). Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. 8. 12. Attach an adequate lifting/supporting device to the drum frame (2). 11. Loosen the stop nut (6) on the drum frame oscillating pin (5). 14. 6. Remove the capscrews (27) and washers (28) from the lock plate (26) on the drum frame and swivel horizontal oscillating pin (5). Figure 1-3) and cylinder pivot pin (11) from the steering cylinder rod end. Remove and discard the bushings (10) from the top of the frame swivel (3). Figure 1-4). J2. 18. Remove the roll pin (12. NOTE: Steer cylinder barrel ends to frame attaching hardware shown in this illustration.6 Figure 1-4 REAR FRAME AND STEER CYLINDERS . Support the rod end of the steer cylinder (6). Remove the steer cylinder rod end from the swivel (3). 17. Cap and plug all lines and openings. Repeat steps 15 through 19 for the other steer cylinder. 20. Tag and disconnect the hydraulic lines to the steering cylinder (6. Refer to Figure 1-3 for rod end attaching hardware.SD-116 TF SERIES SWIVEL BEARING REPLACEMENT 15. 16. 19. Remove the stop nut (6) and washer (7) from the pin (5). 25. 23. Remove and discard the bearings (7) and dust seals (9 and 10. Figure 15). Figure 1-5 DRUM FRAME AND SWIVEL BEARINGS . remove the swivel (3). ASSEMBLY AND INSTALLATION 1. 21. Attach an adequate lifting device to the swivel (3.7 WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents.SD-116 TF SERIES SWIVEL BEARING REPLACEMENT J2. Ensure all parts are cleaned in a type solvent. Remove the lock plate (26). Figure 15). Remove the capscrews (27) and washers (28) from the lock plate (26) on vertical swivel oscillating pin (5. 2. Figure 1-5) in the swivel (3) and secure temporarily with the washer (7) and stop nut (6). Figure 1-4) from the top and bottom of the rear frame swivel mounting sleeve. CLEANING AND INSPECTION 1. 22. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. 27. 24. Discard all gaskets and seals. 3. Do not torque the pin at this time. 26. Remove the pin (5) from the swivel (3) and rear frame. Inspect all fasteners for damage. Install the drum frame oscillating pin (5. Check for overhead obstructions. Using the lifting device. NOTE: Bearings are to be cooled to -18°C (0°F) for 2 to 4 hours before installation.SD-116 TF SERIES SWIVEL BEARING REPLACEMENT 2. Figure 1-6). 5. 4. 3. Apply a coat of grease to the new bearings (7. 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. Lower the temperature of the bearings. Install the new bearings (7) into the top and bottom of the rear frame swivel mounting sleeve. J2.8 Figure 1-6 REAR FRAME AND STEER CYLINDERS . Refer to Figure 1-5 for rod end attaching hardware. Attach an adequate lifting device to the swivel (3. Check for overhead obstructions. 16. 11. 9. Install the new bushings (10) into the top of the swivel (13). Install the washers (28) and capscrews (27) into the lock plate (26). 17. Install the lock plate (26). 6.9 WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Torque the capscrews (27) to 61 N·m (45 lb-ft. Install the new O-ring (41). 10. 8. Figure 17). Apply a light coat of Never-Seize to the large diameter of the vertical swivel oscillating pin (5). Using the adequate lifting device. 14. Install the vertical swivel oscillating pin (5) into the swivel (3) and rear frame mounting sleeve. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. 12. Apply Loctite #271 to the capscrews (27).SD-116 TF SERIES SWIVEL BEARING REPLACEMENT J2. Figure 1-7 DRUM FRAME AND SWIVEL BEARINGS . install the swivel (3) to the rear frame swivel mount. 18. 7. being careful not to damage the drum frame horizontal oscillating pin temporarily installed in the swivel. 15. Install the washer (7) and stop nut (6) onto the oscillating pin (5).). Apply a coat of grease to the new bushings (10). Torque the pin (5) to 340 N·m (250 lb-ft.). 13. Install the steer cylinder pivot pin (11. 29. Install the bearings (4) into the drum frame (2). Lower the temperature of the bearings (4). Attach an adequate lifting device to the drum frame (2). 26. 28. Connect the steer cylinder (6. NOTE: Bearings are to be cooled to -18°C (0°F) for 2 to 4 hours before installation. 30. unplug and connect the hydraulic lines to the steer cylinders as tagged during disassembly. Figure 1-7) and connect the steer cylinder to the frame swivel (3). Install the roll pin (12). Install the dust seals (24 and 25) onto the drum frame (2). Figure 1-6) rod end to the swivel (3). Apply a light coat of Never-Seize to the large diameter of the pin (5). 23. 24. Figure 1-7 DRUM FRAME AND SWIVEL BEARINGS . Apply a coat of grease to the new bearings (4). Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Keep the lifting device attached to the drum frame.SD-116 TF SERIES SWIVEL BEARING REPLACEMENT J2. Remove the temporarily installed swivel horizontal oscillating pin (5) from the swivel (3). Check for overhead obstructions. Repeat steps 19 and 20 for the other steer cylinder. align the drum frame (2) with the swivel (3). 22. 20. WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents.10 19. 25. Using the lifting device. 27. Uncap. 21. 44. Install the washer (7) and stop nut (6) onto the pin (5). steer cylinder pins. 41. It is recommended that after the first 50 to 100 hours of operation.SD-116 TF SERIES SWIVEL BEARING REPLACEMENT NOTICE: J2. 33. vibration. Install the washers (28) and capscrews (27) into the lock plate (26). 35. Refer to the Operation and Maintenance Manual for maintenance instructions. Connect the hydraulic lines to the propulsion. 36. Apply Loctite #271 to the capscrews (27). Figure 1-7). 42. 34.).). Torque the pin (5) to 340 N·m (250 lbs-ft. 37. Torque the capscrews (27) to 61 N·m (45 lb-ft. 40. 43. 31. Operate the machine and check for proper operation and leaks.11 During installation of the horizontal swivel oscillating pin (5. Connect the electrical harness between the two frames. Install the drum assembly (1) and scraper into the drum frame (2). Figure 1-7) into the drum frame (2) and swivel (3). Install the horizontal swivel oscillating pin (5. and blade systems. Refer to the Drum and Drum Drive Teardown and Rebuild Procedure J3. Figure 1-7 DRUM FRAME AND SWIVEL BEARINGS . 38. 39. Lubricate the articulation joint and pins. Install the lock plate (26). and ensure the weight of the drum frame (2) is off of the pin so as not to cause damage to the pin. 32. the articulation joint fasteners be checked for proper torque. steer cylinder bearings and swivel pins. Ensure the pin (5) is centered in the drum frame (2). ..........1 DRUM AND DRUM DRIVE.................11 Vibration Side Assembly ................................................................................................................... J3....10 Cleaning and Inspection ............9 Vibration Side Disassembly .............SD-116 TF SERIES DRUM AND DRUM DRIVE TABLE OF CONTENTS ...J3.......................17 Assembly and Installation ............................... J3... J3.............................................2 Safety .............................. J3........2 Tools Required ... J3... J3......................7 Drum Drive Side Disassembly ....................................... J3................. J3.J3.....................1 J3.....11 Carrier Assembly..........................2 Removal and Disassembly.... J3..............14 Drive Side Assembly and Installation .............................15 Drum Drive Assembly and Installation .............. J3........ J3...............................19 DRUM AND DRUM DRIVE 032503AA TABLE OF CONTENTS ...8 Carrier Disassembly.................................................... J3.............4 Drum Drive Motor Removal and Disassembly ............ J3...................... SD-116 TF SERIES DRUM AND DRUM DRIVE TOOLS REQUIRED: • Safety glasses • Basic sockets and wrenches • Blue Loctite • Feeler gauges • Sledge hammer • Heat resistant gloves • Non-residue type solvent • Acetylene torch • Straps or chains • Loctite primer-T • Anti-seize • Petroleum jelly • Loctite number 271 red and blue • Torque wrench • Lifting device. 032503AA Figure 1-1 TOOLS REQUIRED AND SAFETY . WARNING: Unexpected machine motion or moving parts can cut or crush. Auto-Crane that is in perfect condition SAFETY J3.2 Accidents are caused by failure to follow simple.000 lb. operating. maintaining. or servicing this unit. WARNING: Improper maintenance can be hazardous. using common sense. fueling. Study the Operator’s Manual and Service Manual before starting. such as a 3. service. No unauthorized person should be allowed to operate. Most accidents can be avoided by paying attention. or servicing the compactor. fundamental safety rules and precautions. and following the instructions. maintaining. Refer to the AEM Safety Manual for safety instructions. fueling. or maintain this compactor. Read and understand all unit mounted safety labels before starting. heavy gloves. NOTE: Take extra care when working around or on the hydraulic system to ensure its complete cleanliness. or examining the compactor with the engine running. of any traces of oil. Do not perform any work on the equipment that is unauthorized. Never use aggressive detergents. Use lint free cleaning rags. NOTE: Clean the machine. especially connections. Before starting any work. Avoid ingestion. Do not work on a hydraulic system while the engine is running or pressure is still in the system. or other chemical substances. grease. Exercise extreme caution when working around pressurized hydraulic systems. check the de-energized parts for the presence of power. 032503AA Figure 1-1 TOOLS REQUIRED AND SAFETY .3 Keep hands and fingers from between small parts. Ground or short circuit them in addition to insulating adjacent live parts and elements. J3.SD-116 TF SERIES DRUM AND DRUM DRIVE WARNING: Oil under pressure can cause serious cuts or injury. observe the product related safety regulations. Wear protective gear such as safety glasses. and breathing fumes. When handling oil. Avoid whenever possible servicing. or preservatives before carrying out maintenance or repair. and safety shoes. cleaning. fuel. grease or fuel could be hazardous to health if used incorrectly. Substances such as oil. Ensure all pressure is relieved from the system before performing maintenance. skin contact. 4 1. Adjust the jack up or down until the measurements are roughly equal. measure from the inner drum shell to the top and bottom of the frame rail. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. 2. Block Drum Frame WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. 4. Check for overhead obstructions. ensure that adequate sealable containers are available and that every care is taken to prevent spillage. (Figure 1-2). REMOVAL AND DISASSEMBLY J3. positions A and B. This will relieve any load on the shock mounts. 3. This should include space to allow for rolling the drum assembly out from the frame of the compactor. Park the machine on a level surface with ample clearance for working. Repeat the previous procedure on the other side of the drum. Attach an adequate lifting/supporting device to the scraper. 5. Install the articulation lock pin and chock the tires securely to prevent movement when removing the drum assembly. Figure 1-2 JACK AND BLOCK PLACEMENT . To allow for easier removal of the drum mounting hardware. Always ensure waste fluids are disposed of in an environmentally safe manner. 6. Jack at the center articulation joint to raise the frame.SD-116 TF SERIES DRUM AND DRUM DRIVE WARNING: When draining fluids. 5 WARNING: Exercise extreme caution when working around pressurized hydraulic systems. Ensure all pressure is relieved from the system before disconnecting hydraulic lines and performing maintenance. 9. 11. Remove the capscrews (37) and flatwashers (36) securing the vibration motor (27) to the carrier assembly (23). Figure 1-3 DRUM. 13. and nuts (23) from the scraper and drum frame (2). DRUM FRAME AND SCRAPER . NOTE’ Steps 11 and 12 are usually done after drum assembly is removed from drum frame. Do not work on a hydraulic system while the engine is running or pressure is still in the system. Cap or plug all lines and openings. Figure 1-3). J3.SD-116 TF SERIES DRUM AND DRUM DRIVE 7. Figure 1-6) (left side of the drum). Tag and wire the shims (19 and 20) together so that they can be reinstalled at the same locations. flatwashers (21). Tag and disconnect the hydraulic lines and the electrical line to the drum drive motor (1. Figure 1-5). Using the lifting device. 8. shims (19 and 20). 10. remove the scraper from the drum frame (2). Remove the vibration motor (27) and O-ring (28) from the carrier assembly (23). 12. Remove the capscrews (42. Tag and disconnect the hydraulic lines to the vibration motor (27. Remove the capscrews (22. Carefully roll the drum assembly (1) out of the drum frame (2) and block into position for further maintenance. 16. Figure 1-4).6 Figure 1-4 DRUM.SD-116 TF SERIES DRUM AND DRUM DRIVE 14. Tag and wire the shims (19 and 20) together so that they can be reinstalled at the same location. securing the drum assembly (1) to the drum frame (2). DRUM FRAME AND SCRAPER . shims (19 and 20) and hex nuts (23). J3. flatwashers (21). 15. Use an adequate lifting/supporting device to support drive motor (1. Separate the drum drive motor (1) from the drive plate (2) and mounting plate (3). 4. If maintenance of the drum drive motor (1) is required. 7. Figure 1-5 DRUM DRIVE . 8. 1. Remove the nuts (35. 9. Remove the capscrews (30. Remove the capscrews (7. Using the lifting device. Remove the capscrews (5).SD-116 TF SERIES DRUM AND DRUM DRIVE DRUM DRIVE REMOVAL AND DISASSEMBLY J3. Figure 1-5) and flatwashers (4) from the drive plate (2) and drive motor (1). 2. refer to the Drum Drive Motor service information for this model. 5.7 WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. and hex nuts (6) from the mounting plate (3) and drive motor (1). Figure 1-5) and drive plate (2). 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. Figure 1-6) and flatwashers (29) securing the shock mounts (16) to the drum (1). flatwashers (4). Figure 1-6) flatwashers (34) and washers (39) securing the drive plate assembly (33) to the shock mounts (16). drive plate (2) and mounting plate (3) from the drum. Remove the shock mounts(16) from the drum (1). 3. remove the drive motor (1). 3. Remove and discard the O-ring (20) from the bearing housing drive (2). J3. remove the bearing housing drive (2) from the drum (1). 9. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. 6. Remove the capscrews (12. WARNING: Safety glasses must be worn when removing the retaining rings. 5. 2.SD-116 TF SERIES DRUM AND DRUM DRIVE DRUM DRIVE SIDE DISASSEMBLY 1.8 WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Using the lifting device. Remove the retaining ring (19) from the eccentric (5). Check for overhead obstructions. Remove the cover (11) from the bearing housing drive (2). Remove and discard the O-ring (9). 4. 8. Figure 1-6) from the cover (11). Remove the retaining rings (7) and remove the bearings (6) from the bearing housing drive (2). Figure 1-6 DRUM ASSEMBLY . 7. Remove the bolts (10) and flatwashers (8) securing the bearing housing drive (2) to the drum (1). Attach an adequate lifting/supporting device to the bearing housing drive (2). WARNING: Safety glasses must be worn when removing the retaining ring. 5. J3. Remove the nuts (12).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. 1. 2. Check for overhead obstructions. Attach an adequate lifting/supporting device to the shock mounting plate (10. 7. Figure 1-7 CARRIER ASSEMBLY . Check for overhead obstructions. flatwashers (11) and washers (9) securing the shock mount plate (10) to the shock mounts (6). 4. Remove and discard the oil seal (5) from the carrier plate (1). remove the shock mount plate (10). 6. Using the lifting device. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired.9 WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Remove the capscrews (8) and the flatwashers (7) securing the shock mounts (6) to the carrier plate (1). Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Attach an adequate lifting device to the carrier plate (1). Figure 1-7). Using the lifting device. 3. remove the carrier plate (1) from the drum. remove the bearing housing spindle (3) from the drum (1). If maintenance of the eccentric assembly is required. 8. 6. 11. Remove the eccentric (5) from the drum (1). Attach an adequate lifting/supporting device to the bearing housing spindle (3. 9. Remove the retaining ring (18) from the spindle (3). WARNING: Safety glasses must be worn when removing the retaining rings. refer to the Eccentric Assembly service information for this model. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. J3. 5.10 WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. 4. Figure 1-8 DRUM ASSEMBLY . 10. Using the lifting device. Remove the wear sleeve (14). 12. Figure 1-8) and splined shaft (26) from the drum (1). 3. Remove and discard the V-ring seal (17). Remove the coupling (24. Figure 1-8). Remove the bolts (10) and flatwashers (8) from the bearing housing spindle (3). Check for overhead obstructions. 7. Remove the bearing (15). Remove the spacer (4) and bearing (15). Remove and discard the O-ring (20) from the bearing housing spindle (3). 2.SD-116 TF SERIES DRUM AND DRUM DRIVE VIBRATION SIDE DISASSEMBLY 1. Install the new bearing (15) and the spacer (4) onto the bearing housing spindle (3). NOTE: Bearings are to be cooled to -18°C (0° F) for 2 to 4 hours before installation. Replace as necessary. or other damage. 5. wear. or other damage. Apply a coat of grease to the new bearings (15). Check shocks for cracks.SD-116 TF SERIES DRUM AND DRUM DRIVE CLEANING AND INSPECTION 1. 7. 3. Contact with hot bearings will cause severe burns. Lower the temperature of the new bearings (15). Install the new V-ring seal (17) onto the bearing housing spindle (3). Replace as necessary. 4. 4. 6. VIBRATION SIDE ASSEMBLY J3. Figure 1-8 DRUM ASSEMBLY . Clean the inside of the drum. Inspect all threaded holes. Heat the bearings (15) to 107° C (225° F) for 15 to 30 minutes before installation. Clean all metal parts in a nonresidue type solvent. 2. Check all mounting hardware for damage or wear. Figure 1-8) onto the bearing housing spindle (3). 6. Check the carrier plate for cracks. Check the bearings for wear. WARNING: Wear protective heat resistant gloves when handling heated parts. spalling. 7. 3. Replace as necessary. wear or other damage. Install the wear sleeve (14. 5. Apply petroleum jelly to the new V-ring seal (17).11 1. 2. J3. Figure 1-8) and the retaining ring (18) onto the bearing housing spindle (3). 9. Install the new O-ring (20) into the bearing housing spindle (3). 8. WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. 12. 16. Check for overhead obstructions. 14. Using the lifting device. 15. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired.SD-116 TF SERIES DRUM AND DRUM DRIVE WARNING: Safety glasses must be worn when installing the retaining rings.). install the eccentric assembly (5) into the drum from the drive side of the drum and into the bearing housing spindle (3). 10. 13. Check for overhead obstructions. Using the lifting device. Torque the bolts (10) to 373 N·m (275 lb-ft.12 WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Figure 1-8 DRUM ASSEMBLY . 11. install the bearing housing spindle (3) into the drum (1). Attach an adequate lifting/supporting device to the bearing housing spindle (3 Figure 1-8). Install the bolts (10) and flatwashers (8) into the bearing housing spindle (3). Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Apply petroleum jelly to the new O-ring (20). Apply Loctite #271 (red) to the bolts(10). Install a new bearing (15. Check the eccentric oil. 19. 20. J3. Install the splined shaft (26) and coupling (24) into the drum (1).13 Figure 1-8 DRUM ASSEMBLY . Coat the contact areas of both ends of the splined shaft (26) with Dow Corning Moly-Kote grease prior to installation into the coupling (24) and eccentric (5).SD-116 TF SERIES DRUM AND DRUM DRIVE 17. 18. Refer to the Operation and Maintenance Manual for this model. Figure 1-8) until the bearing housing drive (2) is installed. Support the eccentric assembly (5. Attach an adequate lifting device to the carrier assembly. 7. Check for overhead obstructions. Attach an adequate lifting device to the shock mount plate (10).).). 2. Torque the capscrews (8) to 149 N·m (110 lb-ft. Check for overhead obstructions. Install the shock mount plate (10) to the shocks (6). Install new oil seal (5. J3. 6. 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. Install the washers (9). 3. Apply Loctite #271 to the capscrews (8). 4. Figure 1-9 CARRIER ASSEMBLY . Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. 9. Figure 1-9) into the carrier plate (1). flatwashers (11) and nuts (12) in to the shock mount plate (10). 10. Torque the nuts to 373 N·m (275 lb-ft.14 WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Install the shock mounts (6) onto the carrier plate (1). Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. 8. Install the capscrews (8) and flatwashers (7) onto the shock mounts (6) 5. WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Install the carrier plate assembly into the drum and onto the bearing housing spindle. 11.SD-116 TF SERIES DRUM AND DRUM DRIVE CARRIER ASSEMBLY 1. 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. 11. Install the retaining ring (19) onto the eccentric (5). Figure 1-10 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 (blue) 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.). J3.17 WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Check for overhead obstructions. 5. Using an adequate lifting/supporting device, position the drive motor (1) onto the drive plate (2). 6. Apply loctite #271 to the capscrews (7). 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 drum (1). 11. Install the capscrews (30) and flatwashers (29) into 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. 13. Attach an adequate lifting/supporting device to the drive motor (1, Figure 1-12), drive plate (2) and mounting plate (3). Figure 1-12 DRUM DRIVE SD-116 TF SERIES DRUM AND DRUM DRIVE 14. Apply Loctite #271 (red) to the nuts (35, Figure 1-13). 15. Using the lifting device, install the drive plate (2), drive motor (1) and mounting plate (3) to the shock mounts (16). 16. Install the nuts (35), flatwashers (34) and washers (39) into the drum drive plate (2). 17. Torque the nuts (35) to 373 N·m (275 lb-ft.). 18. Check the drum drive and carrier oil level. Refer to the Operation and Maintenance Manual for these models for maintenance instructions. J3.18 Figure 1-13 DRUM ASEMBLY Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired.0 in.4 mm (1. Check for overhead obstructions. 1. 1. Figure 1-14 DRUM ALIGNMENT . WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. 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. Use a lifting device that is in perfect condition and with sufficient capacity for lifting components being serviced or repaired. Attach an adequate lifting device to the scraper.19 WARNING: Use care when attaching and securing the lifting device to avoid risk of accidents. Ensure the gap is consistent between the siderails along the entire length of the siderail.) greater than measurement D. Figure 1-14). Measurement A should be no more than 25. Check for overhead obstructions. Measure the scraper bar length.SD-116 TF SERIES DRUM AND DRUM DRIVE ASSEMBLY AND INSTALLATION J3. NOTE: Locate smooth drum scraper or tooth scraper with a 20 mm (0.79 gap between drum shell and closest edge of scraper. Carefully roll the drum assembly into position in the drum frame. Measure the distance between the frame sides at positions A and D (Figure 1-14). Figure 1-15). 3. Align scraper into the drum frame (2. 2. 4. 5. Attach an adequate lifting device to the drum assembly (1. 16. flat washers (21) and nuts (23). but not exceed the distance between the drum frame siderails. Take clearance measurements B and C (Fgure 1-14) on both ends of the drum. Measure to determine the shim thickness on each end at the drum mounting location E. Install scraper shims (19 and 20). then add the smallest thickness 1. Figure 1-15 ). Install required shims (19 and 20. 14. flatwashers (21). 11. 9. Install capscrews (22. NOTE: Scraper shim packs should result in the scraper total length to nearly match. Measure between the edge of the drum shell and the drum frame.5 mm (0. 8. Install the capscrews (42). 7.SD-116 TF SERIES DRUM AND DRUM DRIVE J3. and nuts (23) into the scraper and drum frame. Compare this to the thickness of the shim packs removed at disassembly.). Align the drum mounting holes by rocking the drum forward and backward until the mounting capscrews can be inserted temporarily on each side. 15. Apply Loctite #271 to the capscrews (22). Figure 1-15) at each end of the drum.06 in.) shim to each side of mounting bracket. Alternately torque the capscrews (22) to 1780 N·m (1310 lb-ft.20 6. AND SCRAPER . 10. 12. Figure 1-15 DRUM. Shift the drum until these measurements are equal. Preload the drum assembly by shimming the vibration side only. 13. Apply Loctite to the capscrews (42). Add or subtract shims equally to both sides as necessary to meet the required thickness. DRUM FRAME. Fill gap on both sides of mounting bracket. ). Figure 1-12). Install the vibration motor (27.SD-116 TF SERIES DRUM AND DRUM DRIVE J3. Connect the hydraulic lines to the drum drive motor (1. 19. Figure 1-16) and new O-ring (28) into the drum. and ensure there are no oil leaks. Figure 1-16). Connect the hydraulic lines to the vibration motor (27). Figure 1-16) and carrier assembly (23). Operate the compactor and check for proper operation. 22. Torque the cappscrews (42. Figure 1-16 DRUM ASSEMBLY . Apply petroleum jelly to new O-ring (28. Lubricate the drum assembly prior to operation. 27. 26. 25. Refer to the Operations and Maintenance Manual for these models for maintenance instructions. Check the system hydraulic oil. 20. Torque the capscrews (37) to 107 N·m (79 lb-ft. Install the capscrews (37) and flatwashers (36) into the vibration motor (27.). 21. Figure 1-15) to 1780 N·m (1313 lb-ft. 23. 24.21 17. 18. Apply Loctite #271 (red) to the capscrews (37). ........... J4.......................................2 Safety ..................... J4.................2 Tools Required ...................3 Eccentric Assembly J4............................1 ECCENTRIC ASSEMBLY...........................SD-116 TF SERIES / ECCENTRIC ASSEMBLY TABLE OF CONTENTS..... J4.............1 032503AA TABLE OF CONTENTS ........................................2 Cleaning and Inspection......................................... . J4............................................................ J4.2 Disassembly .................... J4.............. J4..........3 Assembly....... Remove the spline coupling (6) from the non-drive side journal (4). 3. Refer to the AEM Safety Manual for safety instructions. J4. and following the instructions. Remove the roll pin (10) from the non-drive journal (4) and eccentric shaft (2). Figure 1-1) and flatwasher (7) from the spline coupling (6). 4. using common sense. Auto-Crane that is in perfect condition SAFETY Accidents are caused by failure to follow simple. Pull the eccentric shaft (2) from the non-drive side journal (4). 5. such as a 3. Figure 1-1 ECCENTRIC ASSEMBLY .000 lb.SD-116 TF SERIES / ECCENTRIC ASSEMBLY TOOLS REQUIRED: • Safety glasses • Basic sockets and wrenches • Torque wrench • Loctite number 271 (red) • Non-residue type solvent • Grease • Hammer Punch • • Lifting device.2 DISASSEMBLY 1. Remove and discard the oillite bearing (5) from the nondrive side journal (4). Remove the capscrews (8) and flatwashers (7) from the non-drive side journal (4). fundamental safety rules and precautions. Remove the capscrew (9. 2. 6. Most accidents can be avoided by paying attention. oil.3 1. Install the new oillite bearing (5) onto the eccentric shaft (3). Inspect all threaded holes for debris or foreign material. 2. Polish the drive side journal end of housing. Figure 1-1 ECCENTRIC SHAFT ASSEMBLY . Check all mounting hardware for damage and wear. Remove the capscrews (8. 10. ASSEMBLY 1.SD-116 TF SERIES / ECCENTRIC ASSEMBLY 7. Thoroughly clean threaded holes of cosmoline. 4. Remove and discard the oillite bearing (5) from the eccentric shaft (3). Clean all parts in a non-residue type solvent. dirt. 6. Install the drive side journal (1) onto the end of eccentric housing (2). metal chips. Figure 1-1) and flatwashers (7) from the drive side journal (1). Remove the drive side journal (1) from the eccentric shaft housing (2). CLEANING AND INSPECTION J4. Remove the eccentric shaft (3) from the eccentric shaft housing (2). 2. Install the eccentric shaft (3) in the shaft housing (2). 3. 3. 4. and any other contaminants that could interfere with the curing of Loctite. 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. 8. 9. Polish the journal end of housing. 5. Replace as necessary. Install the capscrews (8) and flatwashers (7) into the hub non-drive side journal (4). 12.). 15. 8. 13. Install the non-drive side journal (4) onto eccentric housing (2). Install the spline coupling (6) to the non-drive side journal (4) and secure with the capscrews (9) and flatwashers (7). 11. Install the capscrews (8. 10. Apply enough Loctite #271 (red) to both the capscrews (9) and the hole threads to completely fill the thread engagement length once the capscrews (9) are installed.SD-116 TF SERIES / ECCENTRIC ASSEMBLY J4. Figure 1-1 ECCENTRIC SHAFT ASSEMBLY . Torque the capscrews (8) to 61 N·m (45 lb-ft). 16. Torque the capscrews (8) to 61 N·m (45 lb-ft).4 7. Figure 1-1) and flatwashers (7) in the drive side journal (1). Install the new bearing (5) into the non-drive side journal (4). 14. Apply Loctite #271 (red) to the capscrews (8). Torque the capscrews (9) to 61 N·m (45 lb-ft. 9. K1 SYMPTOMS ENGINE Won't crank or cranks slowly Hard to start or will not start Stalling Surge Noise (excessive) Smoke ELECTRICAL SYSTEMS No Lights No Gauges 8 1 1 4 4 3 3 2 3 3 4 2 2 2 7 5 7 5 6 4 1 7 1 2 1 4 6 4 8 8 6 6 1 1 10 1 Starting motor operating but not cranking engine 6 3 7 2 5 2 2 TROUBLESHOOTING NOTE: Possible causes for each symptom are numbered in order of most likely occurance. 3 3 5 3 Valves incorrectly adjusted Valve lash excessive Starting Circuit connections loose or corroded 5 Solenoid or Starting motor malfunction Starting aid needed No voltage to Starter Solenoid Multiple seal washers under injector nozzle Malfunctioning engine shut-down Malfunctioning injectors Lugging engine Low/No fuel Intake air/exhaust leaks Intake air system restricted Injection pump malfunction Injection pump timing incorrect Injector nozzle malfunction Incorrect starting procedure Idle speed too low Fuel supply restricted Fuses Gear train noise Engine cranking speed too low Engine drive units engaged Engine running too cold Fuel contaminated Fuel filter plugged Electical circuits Air cleaner/filter plugged Air in fuel system Battery Battery charge low Crankshaft rotation restricted Drive belt squeal AFC malfunction/injection pump overfueled POSSIBLE CAUSES ELECTRICAL 9 . K2 8 5 11 4 Charge pump (Vibration) 3 4 7 5 4 3 6 2 2 2 3 3 4 6 4 4 3 5 4 3 3 6 2 1 10 2 6 3 9 3 4 5 3 4 4 8 9 7 12 11 2 6 2 1 2 6 4 5 4 9 2 1 1 5 6 1 6 5 8 1 3 7 3 2 1 1 4 5 2 7 5 1 1 1 1 1 3 12 2 3 TROUBLESHOOTING NOTE: Possible causes for each symptom are numbered in order of most likely occurance. 13 10 1 1 8 5 Traction control valve (Optional) System relief pressure System relief/check valves System pressure check Steering pump Loop flushing valve Settings on console Servo pressure differential Replace Transmission RPM Servo Control pressure Replace Control Valve Pump multi-function valve Linkage and lever Inspect Control orifice Inspect chrg relief valve/pump Inlet filter Hydraulic oil level in reservoir Heat Exchanger Electical circuit EDC Electrical displmt cntrl (DX/F) Eccentric oil level Eccentric bearings Drive coupling Cylinder by-pass Control Valve Control Cable Contaminated System Charge Pressure Broken Cylinder Bad pump Air in system Bypass valve SYMPTOMS VIBRATION Not working One direction only Frequency low System operating "HOT" Neutral difficult to find Wrong Mode STEERING No Steering Hard to Steer Off and On again Wander or Drift Steering Slip (Intermittant) PROPULSION No Propulsion One Direction Sluggish Neutral difficult to find System operating "HOT" POSSIBLE CAUSES HYDRAULICS 10 9 2 8 7 5 2 1 3 2 2 3 10 6 7 4 . ..................K3.4 Fault Code Troubleshooting Chart ...................2 Microprocessor LED Functions .....K3............4 Fault Codes ....K3......K3.......................................................K3.....K3.....SD-116 TF SERIES / VIBRATION CONTROL SYSTEM TABLE OF CONTENTS.........6 K3.........2 Troubleshooting...........................6 CHARTS Vibration Control Components .......................K3..............................1 032503AA TABLE OF CONTENTS ..........2 Major Components ..................1 VIBRATION CONTROL SYSTEM ......3 Troubleshooting Chart..........................................................................K3. .......K3.................... 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. Figure 1-2) contains four LED indicator lights located vertically on the front of the case.2 • A speed sensor located at the vibration motor. The microprocessor (1. The system maintains the selected VPM during natural fluctuations in machine performance. • The electronic displacement control located on the vibration pump. Figure 1-1 INSTRUMENT PANEL SELECTOR SWITCH . This is achieved by supplying a signal from a speed sensor at the eccentric motor to a microprocessor. Figure 1-1). This microprocessor then regulates the output of the vibration pump to maintain the selected VPM. Figure 1-2) labeled "SX C. K3. Loop Vibration Control" located in the battery compartment. • A five-position selector switch located on the instrument panel (1. There are five VPM set points for the high amplitude range and five VPM set points for the low amplitude range. Refer to the Microprocessor LED Function Chart. MAJOR COMPONENTS Vibration Control Components • A microprocessor (1. SD-116 TF SERIES / VIBRATION CONTROL SYSTEM Microprocessor LED Functions K3.3 Power Indicates power is being supplied to the microprocessor. System Indicates the microprocessor is functioning normally. Mode Will blink amber when power is being supplied to microprocessor. • A blink rate of about 10 times per second indicates no application is loaded or an application is loaded with faults. • A blink rate of once per second indicates an application is loaded with no faults. This would be the normal or required condition. Status Will display a red four-blink code only if a fault exists. This code will be a series of short and long blinks. • Short blink lasts approximately 0.5 seconds • Long blink lasts approximately 1 second When a fault occurs, The status LED will display a four-blink code then pause for approximately 2 seconds and then display the fault code again. It is possible for more than one fault to exist at the same time; therefore several series of codes may need to be observed. 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 Correction Is status LED displaying a In order for the fault red four-blink fault code? codes to be illuminated, the ignition switch must remain in the “on position” from the time the fault occurs. 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 CODES 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 Figure 1-2 MICROPROCESSOR . Note: When this fault occurs. the “signal from speed sensor is out of range” (LLLS) fault may also be displayed. check resistance between terminals A & B at each of the five VPM settings.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.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. Under this condition the speed of the vibration will not change if the selector switch is repositioned. K3. 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. There should be 19 ohm resistance between A-B and 16. Some changes or variations in VPM may be noticed.5 ohm resistance between C-D. Under this condition the current from the fivespeed selector switch will be sent directly to the control on the pump. Figure 1-2 MICROPROCESSOR . The microprocessor will not attempt to “fine tune” the VPM setting. the wiring and connections between the EDC and the microprocessor. but will default to “open loop”.8 NOTE: This fault will not shutdown vibration. K3. • Check the resistance across the coil at the EDC. To adjust speed sensor.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. loosen locking nut and turn sensor in until it bottoms out. SLLS • Coil at EDC on vibration • Check the integrity of is open or shorted. then back sensor out 3/4 of a turn and tighten locknut. a. 9 Figure 1-2 MICROPROCESSOR . Under these conditions it’s possible that the LLLS fault could be displayed even though the sensor is functioning correctly. K3.SD-116 TF SERIES / VIBRATION CONTROL SYSTEM Fault Code Troubleshooting Chart (Continued) Code Symptom Check NOTE: When this fault occurs. the “signal from speed sensor is out of range” (LLLS) fault may also be displayed. .... 43..4 Fault Code Troubleshooting Chart .............. ......4 Fault Codes ......K4.......................................................K4..........................3 Troubleshooting Chart.................K4....6 CHARTS Traction Enhancement Components ..SD-116 TF SERIES / TRACTION ENHANCEMENT SYSTEM TABLE OF CONTENTS..............K4............K4..............................................1 TRACTION ENHANCEMENT SYSTEM....................................2 Major Components ...2 Microprocessor LED Functions .......7 K4...K4........K4..........2 Troubleshooting.K4...............................................1 032503AA TABLE OF CONTENTS ....................... MAJOR COMPONENTS Traction Enhancement Components K4. • A traction control valve is located on the inside of the main frame on the right hand side opposite the battery compartment. 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. one located on the drum drive motor and one located on the axle drive motor. Figure 1-2) labeled “SX Traction Control. • A resistor pack is located in the drum speed sensor harness just inside the swivel area.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. 032503AA • A remote loop-flushing valve is located on the inside of the main frame on the left-hand side.” is located in the battery compartment. 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. which continuously compares the speed of one motor to the other. • Two speed sensors. Note: The loop-flushing valve in the axle drive motor is disabled on units equipped with the traction enhancement system.2 • A microprocessor (1. Figure 1-1 TRACTION ENHANCEMENT SYSTEM . The speed of each motor is transmitted to a microprocessor. Microprocessor LED Functions Power Indicates power is being supplied to the microprocessor. therefore several series of codes may need to be observed. 1 second When a fault occurs. • A blink rate of about 10 times per second indicates no application is loaded or an application is loaded with faults. K4. Refer to the Microprocessor LED Function Chart. System Indicates the microprocessor is functioning normally.5 seconds • Long blink lasts approximately. Figure 1-2) contains four LED indicator lights located vertically on the front of the case. This code will be a series of short and long blinks. • Short blink lasts approximately. The status LED will display a four-blink code then pause for approximately 2 seconds and then display the fault code again.SD-116 TF SERIES / TRACTION ENHANCEMENT SYSTEM The microprocessor (1. 0.3 Figure 1-2 MICROPROCESSOR . It is possible for more than one fault to exist at the same time. This would be the normal or required condition. Status Will display a red four-blink code only if a fault exists. • A blink rate of once per second indicates an application is loaded with no faults. Mode Will blink amber when power is being supplied to microprocessor. which is located in the harness next to the microprocessor. NOTE: The traction enhancement system only functions in the compaction or low travel speed setting. installed? Figure 1-2 MICROPROCESSOR . Unplug all micro controllers prior to welding. ensure the articulation locking device is installed and the wheels and drum are chocked. Troubleshooting Chart K4. 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. WARNING: If it is required for the engine to be operating to perform any testing or repair.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.4 Step 1 Check Establish that power is being supplied to the microprocessor. Figure 1-2 MICROPROCESSOR . NOTE: Do not turn the ignition switch to the off position. the ignition switch must remain in the “on position” from the time the fault occurs.SD-116 TF SERIES / TRACTION ENHANCEMENT SYSTEM Troubleshooting Chart (Continued) Step K4. as this will reset the microprocessor. Observe the status LED on the traction control microprocessor with the engine running or shut down the engine with the emergency stop switch.5 Check Correction 2 Is the system LED on the microprocessor illuminated? If system LED is not illuminated and the POWER LED is illuminated. stop the machine travel and apply park brake. To accomplish this. an internal problem exists in the microprocessor and it will require replacement 3 Is status LED displaying a In order for the fault red four-blink fault code? codes to be illuminated. 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. For this fault to occur the condition described above must exist for a minimum of 30 seconds. Figure 1-2 MICROPROCESSOR . • LLLS = Rear (axle) speed sensor out of range.SD-116 TF SERIES / TRACTION ENHANCEMENT SYSTEM FAULT CODES The following is a list of possible fault codes (S = short and L = long) • SSLS = Current supplied to front valve coil on the traction valve is out of range.6 • SLLS = Front (drum) speed sensor signal out of range. • LSLS = Current supplied to rear valve coil on the traction valve is out of range. K4. When this fault occurs a blink code will be displayed on microprocessor and the system will continue to try to perform anti-spin. This fault would indicate either a short in the wiring/coil or an open circuit. For this fault to occur the condition described above must exist for a minimum of 30 seconds. 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). 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). • Check continuity of the wire that runs from the front valve coil to ground frame. Figure 1-2 MICROPROCESSOR . microprocessor to the rear valve coil at the traction valve.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. • Check continuity of the wire that runs from the front valve coil to ground/frame. • Check the resistance across the coil to determine condition of coil. Resistance should be approximately. 6.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 K4.7 Check • Check continuity of the wire that runs from the B1 terminal at the microprocessor to the front valve coil at the traction valve. (Cont) coil. A reading of 1900 to 2100 Ohms of resistance would be typical. Check continuity of the signal wire between the sensor and the microprocessor.8 • Check the integrity of the wiring at the front drive-motor speed sensor. Figure 1-2 MICROPROCESSOR . K4. 6.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. It should be noted that there is a resistor pack located in this circuit.0 ohms) SLLS • Front (drum) speed sensor signal out of range. With the key switch in the run position confirm that system voltage is present at the “A” or B+ terminal of the sensor connector. (Resistance should be approximately. b. a. • If the problem persists the speed sensor may be damaged or out of adjustment.9 Check c. Restart the machine and test the operation of traction system. • After the wiring and connectors have been inspected reset the microprocessor by cycling the ignition switch to the off position. Figure 1-2 MICROPROCESSOR . Check continuity between the “C” or “B-“ terminal of the sensor connector and ground/ frame. (Cont) K4.SD-116 TF SERIES / TRACTION ENHANCEMENT SYSTEM Fault Code Troubleshooting Chart (Continued) Code Symptom SLLS • Front (drum) speed (Cont) sensor signal out of range. The unit must be propelled for at least 30 seconds at 1 mph in one direction for a fault (if present) to be displayed. K4. Figure 1-3) out of range.SD-116 TF SERIES / TRACTION ENHANCEMENT SYSTEM Fault Code Troubleshooting Chart (Continued) Code Symptom SLLS • Front (drum) speed (Cont) sensor signal out of range. When installing the speed sensor in the drum drive motor. To determine if the sensor is out of adjustment. (Cont) Check a. • Check the integrity of the wiring and connectors between the speed sensor on axle drive motor and microprocessor. b. Figure 1-3 REAR AXLE SPEED SENSOR . the sensor would have to be removed and reinstalled with a new clearance tab applied and then the unit test run. If upon inspection it is found that there is evidence of scratching or scuffing on the end of the sensor.10 c. the following procedure applies: LLLS • Rear (axle) speed sensor (1. it is very likely that it has been damaged and it should be replaced. With the key switch in the run position confirm that system voltage is present at the “A” terminal of the sensor connector. b.11 c. Figure 1-3) out of range. Check continuity between the “C” terminal of the sensor connector and ground/frame.SD-116 TF SERIES / TRACTION ENHANCEMENT SYSTEM Fault Code Troubleshooting Chart (Continued) Code Symptom LLLS • Rear (axle) speed (Cont) sensor (1. (Cont) Check a. Figure 1-3 REAR AXLE SPEED SENSOR . Check continuity of the signal wire between terminal ‘B” at the sensor connector and terminal “E1” at the microprocessor. • After verifying the integrity of wiring and connectors. reset microprocessor by cycling ignition switch to the off position and then restarting the machine. K4. • If after resetting microprocessor the traction system fails to operate correctly. verify the axle drive motor speed sensor is properly adjusted. a. Figure 1-3 REAR AXLE SPEED SENSOR . Turn speed sensor in until it bottoms out. Figure 1-3) out of range.12 Check • The unit must be propelled for at least 30 seconds at 1 mph in one direction for a fault (if present) to requester. 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. Loosen the locking nut on speed sensor. (Cont) K4. replace the speed sensor.SD-116 TF SERIES / TRACTION ENHANCEMENT SYSTEM Fault Code Troubleshooting Chart (Continued) Code Symptom LLLS • Rear (axle) speed (Cont) sensor (1. K4. Extra speed sensor clearance tabs are available under part number 13284203. Orient the notch located at the connector end of the sensor so that it points toward the center of the motor. Its purpose is to ensure that the proper clearance is maintained between sensor and motor block.13 Figure 1-3 REAR AXLE SPEED SENSOR . Once the sensor has been bottomed out and the notch is correctly positioned. the sensor may be secured in place.SD-116 TF SERIES / TRACTION ENHANCEMENT SYSTEM NOTE: There is a paper tab on the inboard end of speed sensor. With paper tab in place install the sensor into the motor until it bottoms out. This will result in the connector being positioned in the manner displayed in Figure 1-3. This tab must remain on the sensor when installing. If an existing speed sensor is removed for inspection a new clearance tab would have to be applied before that sensor could be reinstalled. Non-Compensating. Three Position Directional Control Valve Lines Passing Servo Line to Tank (Below Fluid Level) Drain Line Fixed Restriction Plug or Plugged Connection Two Position Multiple Flow Path Valve (Arrows show direction of flow) . Rotary Hydraulic Motor Push Button Level Cooler Variable Displacement. Bidirectional Hydraulic Pump Double Acting Cylinder Needle Valve Variable Displacement. Rotary Hydraulic Motor Miscellaneous Symbols Pressure Gauge Pumps Fixed Displacement. Three Position Directional Control Valve Open Center. Rotary Hydraulic Motor L1 Pilot Pressure Fixed Displacement. Bidirectional. Three Position Directional Control Valve Tandem Center. Three Position Directional Control Valve Solenoid Working Hydraulic Line Pressure Relief Valve Line to Tank (Above Fluid Level) Pilot Line Float Center. Bidirectional.Hydraulic Symbol Quick Reference Chart Operation Methods Manual Motors & Cylinders Fixed Displacement. Bidirectional Hydraulic Pump Pressure Switch Filter or Strainer Component Enclosure Line Hydraulic Lines Spring Lines Joining Closed Center. Unidirectional. Unidirectional Hydraulic Pump Valves Check Valve Manual Shut Off Valve Pedal Or Treadle Temperature Gauge Fixed Displacement. 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 Dr Blue/White DBE/WE Yellow/Brown YW/BN Black/Orange BK/OE Dr Green/Orange DGN/OE White/Orange WE/OE White/Blue WE/BE Dr Blue/Yellow DBE/YW Dr Blue/Black DBE/BK Lt Green/Black LGN/BK White/Green WE/GN Dr Green/Red DGN/RD Gray/Red GY/RD Dr Blue/Red DBE/RD Yellow/Red YW/RD Purple/Red PE/RD Pink/Red PK/RD Orange/Red OE/RD Brown/Red BN/RD White/Red WE/RD Black/Red BK/RD White/Brown WE/BN White/Yellow WE/YW Tan/White TN/WE Lt Green/White LGN/WE Lt Blue/White LBE/WE Gray/White GY/WE Dr Blue/White DBE/WE Yellow/White YW/WE Red/White RD/WE Purple/White PE/WE Pink/White PK/WE Orange/White OE/WE White/Black WE/BK Brown/White BN/WE Black/White BK/WE Dk Green DGN Lt Green LGN Lt Blue LBE Gray GY Dk Blue DBE Yellow YW Red RD Purple PE Pink PK Orange OE White WE Brown BN Black BK . L3 D13238902 MACHINE HYDRAULIC SCHEMATIC SD-116 TF SERIES HYDRAULIC . L4 D13238902 MACHINE HYDRAULIC SCHEMATIC SD-116 TF SERIES HYDRAULIC . 4 MACHINE ELECTRICAL SCHEMATIC SD-116 TF SERIES ELECTRICAL .L5 D59292995 Rev. 4 MACHINE ELECTRICAL SCHEMATIC SD-116 TF SERIES ELECTRICAL .L6 D59292995 Rev. L7 D59292995 Rev. 4 MACHINE ELECTRICAL SCHEMATIC SD-116 TF SERIES ELECTRICAL . The warranty statement is provided within the manual kit shipped with the machine. . Ref. No. Shippensburg CST English . VOE21A1004254 CPN 43929439 Printed in USA 2007-12 Volvo.