Volvo EN SD100 SD105 TF PDF

VOLVO CONSTRUCTION EQUIPMENT
ROAD MACHINERY
MORE CARE. BUILT IN.

SD-100/105 TF SERIES
Table of Contents............................................... A1
Features of This Manual.................................... B1
Safety Information ............................................. C1
Illustrated Hose Schematic
TABLE OF CONTENTS
Option Without Traction Control .............. D1
Option With Traction Control .................... D2
HYDRAULIC
Propulsion / Braking
Schematics ................................................. E1
Overview
Standard Parallel................................ E2
Optional)............................................. E3
Neutral - Brakes Applied
Standard Parallel)............................... E4
Optional ............................................. E5 Save time and money by contacting your authorized
INGERSOLL-RAND representative for information
Forward - Brakes Released
A1 Standard Parallel..... ........................... E6
regarding Authorized Rebuilt Components.
Optional .............................................. E7
Reverse - Brakes Released
Standard Parallel..... ........................... E8
Optional .............................................. E9
Forward - Brakes Released R
Optional - Tire Spin........................... E10
Optional - Drum Spin .........................E11
Optional - Tire Spin........................... E12 authorized
rebuilt
Component Teardown & Rebuild
Propulsion Pump.................................. E13
components
Axle ...................................................... E14
Axle Motor............................................ E15
Drum Drive Motor................................. E16
Loop Flush Valve ................................. E17
EFF. W/ ALL S/N
January 2003
Vibration
Schematics .................................................F1
Overview.................................................F2
Neutral, No Vibration ..............................F3
Clockwise, High Amplitude .....................F4
TABLE OF CONTENTS
Counterclockwise, Low Amplitude..........F5
Component Teardown & Rebuild
Vibration Pump .......................................F6
Vibration Motor .......................................F7
Steering
Schematics ................................................ G1
Overview................................................ G2
Neutral ................................................... G3
Steer Right............................................. G4
Steer Left ............................................... G5 Save time and money by contacting your authorized
Component Teardown & Rebuild INGERSOLL-RAND representative for information
Steering Pump ...................................... G6 regarding Authorized Rebuilt Components.

A2 Steering Valve........................................ G7
Steering Cylinder
(S/Ns 169494,169572)...........................G8
Steering Cylinder(All other S/Ns)........... G9
R
authorized
rebuilt
components
EFF. W/ ALL S/N
January 2003
ELECTRICAL Automatic/Variable/Impact Meter ....................H37
Schematics..................................................H1 Grid Heater .......................................................H39
Battery ................................................... H1 Gauges .............................................................H41
Ignition ................................................... H3 Instrument Cluster.............................................H43
Start ....................................................... H5 Fuses ................................................................H45
Brake/Shutdown - Brakes Applied ......... H7
TABLE OF CONTENTS
Brake/Shutdown - Brakes Released ...... H9 MACHINE
Brake/Shutdown - Brakes Released/ Component Teardown & Rebuild
Operator Out of Seat ........................ H11 ROPS/FOPS Replacement.................................. J1
Brake/Shutdown - Brakes Test/ Swivel Bearing Replacement ............................... J2
Operator In Seat ............................... H13
Drum and Drum Drive .......................................... J3
Anti-Spin Control/No Travel ................. H15
Eccentric Assembly.............................................. J4
Anti-Spin Control/Travel ...................... H17
Anti-Spin Control/Drum Spin ................ H19
Anti-Spin Control/Wheel Spin............... H21 TROUBLESHOOTING
High/Low Speed - Hydraulic ............................................................. K1
Low Speed/Anti-Spin Activated ........ H23 Electrical ............................................................. K2
A3 High/Low Speed - Vibration Control System .................................... K3
High Speed/Anti-Spin Inactive .......... H25 Traction Enhancement system............................ K4
Automatic Vibration/Impact Meter -
Vibration Off...................................... H27 REFERENCE CHARTS AND SCHEMATICS
Automatic Vibration/Impact Meter - Hydraulic Symbol Quick Reference Chart................L1
Manual, Low Amplitude .................... H29 Electrical Schematic Wire Color Code
Automatic Vibration/Impact Meter - Reference Chart ................................................L2
Manual, High Amplitude ................... H31 Hydraulic Schematic.................................................L3
Automatic Vibration/Impact Meter - Electrical Schematic .................................................L5
Automatic, Low Amplitude ................ H33
Automatic Vibration/Impact Meter -
Automatic, High Amplitude ............... H35
EFF. W/ ALL S/N
January 2003
SD-100/105 TF SERIES PROPULSION PUMP
atics &
m
TABLE OF CONTENTS...............................................E13.1 REMOTE CHARGE PRESSURE FILTRATION.................................... E13.8
Disassembly..........................................................................................E13.8
LIP SEAL AND SHAFT................................................ E13.2 Inspection..............................................................................................E13.8
Disassembly.................................................................E13.2 Assembly...............................................................................................E13.8
S c he
Inspection.................................................................... E13.2
MANUAL DISPLACEMENT CONTROL................................................E13.9
Assembly..................................................................... E13.3
Disassembly..........................................................................................E13.9
FEATURES OF THIS MANUAL

MULTI-FUNCTION VALVE CARTRIDGES..................E13.4 Assembly.............................................................................................. E13.9
Disassembly................................................................ E13.4
Inspection.................................................................... E13.4
CHARGE RELIEF VALVE............................................................E13.5 SDSD-70/77TF
100/105TF SERIES PROPULSION PUMP
ting
Assembly..................................................................... E13.4
Disassemb ly................................................................... E13.5
CHARGE RELIEF VALVE............................................E13.5
Inspection.......................................................................E13.5
Disassembly................................................................ E13.5
DISASSEMBLY
DISASSEMBLY
NOTE:
Assembly........................................................................E13.5 To maintain original adjustment, mark the plug (7), the locknut
Inspection.................................................................... E13.5 (8), and the housing (2).
E13.1 Assembly..................................................................... E13.5 1. Loosen the locknut (8) and remove the plug (7) by
CHARGE PUMP.......................................................... E13.6 unscrewing the plug (7) from the housing (2), refer to
Figure 1-3.
Disassembly................................................................
Save time and money by contac ting your author ized E13.6
repr esentative for infor mation 2. Remove and diskard the O-ring (6) from the plug (7).
Inspection....................................................................
regar ding Authorized Rebuilt Components. E13.6
Assembly..................................................................... E13.7 Propulsion Pump
INSPECTION
3. Remove the spring (5) and charge relief valve (4) from the
plug (7).
INSPECTION
1. Inspect the charge relief valve (4) and mating seat in the
oo
R end cap for damage or foreign material.
ASSEMBLY
authorized CAUTION:
Do not interchange parts with another valve.
rebuilt
Tr
1. Install the charge relief valve (4) and spring (5) onto the
h
plug (7).
components 2. Install a new O-ring (6) onto plug (7).
oubles
3. Install the plug (7) with its locknut (8) aligning the marks
E13.5 made at disassembly and torque the locknut (8) to 52 N·m
(38 lb-ft).
TABLE OF CONTENTS 4. Check and adjust the charge pressure as required.
CHARGE RELIEF VALVES
Figure 1-3.
CHARGE
CHARGERELIEF
RELIEFVALVES
VALVES
• Hose routing diagram w/ components labeled.

• Hydraulic symbol quick reference chart.
• Wire color code reference chart.
• Settings and specifications.
B1 • Troubleshooting chart w/ symptoms & prioritized possible causes.
• Each page is specific to
one functional
HYDRAULIC TANK
SUCTION S TRAINER
PROPULSION
subsystem.
DUM P / BRAKE / 2 S PEED MANIFOLD
• Operational status is
AXLE MOTOR
LOOP M1
FLUSH
VALVE
1 40 F CR ACK ING
1 65 F O PEN A
THERMAL
BYPASS
VALVE
2 5 PSI
M2 L2
identified by color.
CHARGE FILTER
PROPULSION PUMP
E8 M6 M3 D E
M1
A
DRUM MOTOR
• Standard symbols are
used.
M1
M5
M4
HI / LO
• Colors are standard

R BR AK
BR AKEE
B
M2 L22
L
M2
L1 S
throughout manual.
REVERSE - BRAKES RELEASED
dashed lines
indicate STANDARD PARALLEL
low pressure
S e p te mb er 2 0 0 2
EFF. W/ ALL S/N
January 2003
ILLUSTRATED HOSE SCHEMATIC

OPTION WITHOUT TRACTION CONTROL
Hydraulic Tank Steering
Suction Filter Valve
Propulsion Pump
Vibration Pump
Steering Pump Right

Steering Cylinder
D1 Charge Filter Left

Oil Cooler Steering Cylinder
Thermal
Bypass Valve
Brake
Valve
Axle
Suction Filter Drum Drive Motor
Vibration Motor
Axle Motor
EFF. W/ ALL S/N
January 2003
ILLUSTRATED HOSE SCHEMATIC

OPTION WITH TRACTION CONTROL
Hydraulic Tank Steering

Suction Filter Valve
Propulsion Pump
Vibration Pump
Steering Pump Right

Steering Cylinder
D2
Left
Oil Cooler Steering Cylinder
Charge Filter
Traction Control Valve
Brake
Valve
Axle
Suction Filter Drum Drive Motor
Thermal
Vibration Motor
Axle Motor Bypass Valve
EFF. W/ ALL S/N
January 2003
Table of Contents
Overview
PROPULSION / BRAKING
Standard Parallel .............................. E2
Optional............................................. E3
Neutral - Brakes Applied Hydraulic Tank Brake Valve
Standard Parallel ............................. E4 Oil Cooler
Loop
Optional............................................. E5 Flush
Valve
Forward - Brakes Released Propulsion Pump
Standard Parallel ............................. E6
Optional............................................. E7 Traction
Control
Reverse - Brakes Released Axle
Thermal
Bypass Valve
Standard Parallel ............................. E8 Valve
E1 Optional............................................. E9
Axle Drive
Motor
Charge
Filter
Forward - Brakes Released
Tire Spin (Optional) ....................... E10
Drum Spin (Optional .......................E11
Tire Spin (Optional) ........................ E12 Drum Drive Motor
Settings and Specifications - Propulsion* 100D 105DX 105F

Engine RPM (Hi/Low) 2457/950 X X X
Flow at Input Speed 219.3 l/m 57.9 g/m X X X
System Relief Pressure (psi/bar) 6500/448 X X X
Charge Relief Pressure (psi) 350 X X X
* For specific application settings, contact your authorized Ingersoll-Rand
service personnel. EFF. W/ ALL S/N
January 2003
HYDRAULIC TANK
SUCTION STRAINER
PROPULSION
DUMP / BRAKE / 2 SPEED MANIFOLD
AXLE MOTOR
OIL LOOP M1
COOLER FLUSH
VALVE
140 F CRACKING
165 F OPEN A
25 PSI
THERMAL
BYPASS B
VALVE
M2 L2
PROPULSION PUMP CHARGE FILTER
E2 M6 M3 D E
M1
DRUM MOTOR
A M1
M5
M4
HI / LO
R BRAKE
BRAKE
B
M2 L2
M2
L1 S
OVERVIEW
STANDARD PARALLEL
January 2003
HYDRAULIC TANK
PROPULSION
SUCTION STRAINER
AXLE MOTOR
OIL LOOP M1
COOLER FLUSH
VALVE
140 F CRACKING
165 F OPEN A
25 PSI
THERMAL
BYPASS B
VALVE
M2 L2
TRACTION ENHANCEMENT VALVE
PROPULSION PUMP CHARGE FILTER
E3 M6 M3 D E
M1
DRUM MOTOR
A M1
M5
M4
HI / LO
R BRAKE
B
M2
M2
L1 S
OVERVIEW
OPTIONAL
January 2003
HYDRAULIC TANK
SUCTION STRAINER
PROPULSION
AXLE MOTOR
OIL LOOP M1
COOLER FLUSH
VALVE
140 F CRACKING
165 F OPEN A
25 PSI
THERMAL
BYPASS B
VALVE
M2 L2
CHARGE FILTER
PROPULSION PUMP
M6 M3 D E
E4 M1
DRUM MOTOR
A M1
M5
M4
HI / LO
R BRAKE
BRAKE
B
M2 L2
M2
L1 S
NEUTRAL - BRAKES APPLIED

dashed lines
indicate
low pressure STANDARD PARALLEL
January 2003
HYDRAULIC TANK
SUCTION STRAINER
PROPULSION
AXLE MOTOR
M1
OIL LOOP
COOLER FLUSH
140 F CRACKING VALVE
165 F OPEN A
25 PSI
THERMAL
BYPASS B
VALVE
M2 L2
CHARGE FILTER TRACTION ENHANCEMENT VALVE

PROPULSION PUMP
M6 M3 D E
E5 M1
DRUM MOTOR
A M1
M5
M4
HI / LO
R BRAKE
B
M2 L2
M2
L1 S
NEUTRAL - BRAKES APPLIED

dashed lines
indicate
low pressure OPTIONAL
January 2003
HYDRAULIC TANK
SUCTION STRAINER
PROPULSION
AXLE MOTOR
LOOP M1
OIL FLUSH
COOLER VALVE
140 F CRACKING
165 F OPEN A
25 psi
THERMAL
BYPASS B
VALVE
M2 L2
CHARGE FILTER
PROPULSION PUMP
M6 M3 D E
E6
M1
DRUM MOTOR
A M1
M5
M4
HI / LO
R BRAKE
BRAKE
B
M2 L2
M2
L1 S
dashed lines
FORWARD - BRAKES RELEASED
indicate
January 2003
HYDRAULIC TANK
SUCTION STRAINER
PROPULSION
AXLE MOTOR
M1
LOOP
FLUSH
140 F CRACKING
VALVE
165 F OPEN A
25 PSI
THERMAL
BYPASS B
VALVE
M2 L2
PROPULSION PUMP
M6 M3 D E
E7 M1
DRUM MOTOR
A M1
M5
M4
HI / LO
R BRAKE
B
M2 L2
M2
L1 S

dashed lines
indicate
low pressure
OPTIONAL
January 2003
HYDRAULIC TANK
SUCTION STRAINER PROPULSION
AXLE MOTOR
LOOP M1
FLUSH
VALVE
140 F CRACKING
165 F OPEN A
25 PSI
THERMAL
BYPASS B
VALVE
M2 L2
CHARGE FILTER
PROPULSION PUMP
E8 M6 M3 D E
M1
DRUM MOTOR
A M1
M5
M4
HI / LO
R BRAKE
B
M2 L2
M2
L1 S
dashed lines
indicate
January 2003
HYDRAULIC TANK
SUCTION STRAINER
PROPULSION
LOOP AXLE MOTOR

M1
OIL FLUSH
COOLER VALVE
140 F CRACKING
165 F OPEN A
25 PSI
THERMAL
BYPASS B
VALVE
M2 L2
PROPULSION PUMP CHARGE FILTER TRACTION ENHANCEMENT VALVE
M6 M3 D E
E9 M1
DRUM MOTOR
A M1
M5
M4
HI / LO
R BRAKE
B
M2 L2
M2
L1 S
dashed lines
indicate
low pressure OPTIONAL
January 2003
HYDRAULIC TANK
SUCTION STRAINER
PROPULSION
AXLE MOTOR
LOOP M1
FLUSH
VALVE
140 F CRACKING
165 F OPEN A
25 PSI
THERMAL
BYPASS B
VALVE
M2 L2
TRACTION ENHANCEMENT VALVE
CHARGE FILTER
PROPULSION PUMP
M6 M3 D E
E10 M1
DRUM MOTOR
A M1
M5
M4
HI / LO
R BRAKE
B
M2 L2
M2
L1 S
dashed lines
indicate
low pressure TIRE SPIN (OPTIONAL)
January 2003
HYDRAULIC TANK
SUCTION STRAINER PROPULSION
AXLE MOTOR
LOOP M1
OIL FLUSH
COOLER VALVE
140 F CRACKING
165 F OPEN A
25 PSI
THERMAL
BYPASS B
VALVE
M2 L2
PROPULSION PUMP
M6 M3 D E
E11 M1
A
DRUM MOTOR
M1
M5
M4
HI / LO
R
BRAKE
B
M2 L2
M2
L1 S
dashed lines
indicate
low pressure DRUM SPIN (OPTIONAL)
January 2003
HYDRAULIC TANK
SUCTION STRAINER
PROPULSION
AXLE MOTOR
M1
OIL LOOP
COOLER FLUSH
140 F CRACKING VALVE
165 F OPEN A
25 PSI
THERMAL
BYPASS B
VALVE
M2 L2
PROPULSION PUMP
M6 M3 D E
E12 M1
DRUM MOTOR
A M1
M5
M4
HI / LO
R BRAKE
B
M2 L2
M2
L1 S
dashed lines
indicate
low pressure TIRE SPIN (OPTIONAL)
January 2003
TABLE OF CONTENTS ...........................................E13.1
LIP SEAL AND SHAFT............................................E13.2

Disassembly .......................................................E13.2
Inspection ...........................................................E13.2
Assembly............................................................E13.3
MULTI-FUNCTION VALVE CARTIDGES.................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
TABLE OF CONTENTS
September 2002
NOTICE:
Prior to performing repairs on this component, contact an
Ingersoll-Rand service representative concerning issues of
warranty.
DISASSEMBLY
1. Position the motor with the shaft end facing up.
2. Remove screws (1) securing the retainer plate (2), refer to
Figure 1-1.
3. Remove the retainer plate (2) and seal carrier (3) from the
housing (4).
4. Remove the O-ring (5) from the seal carrier (3).
5. Press out the lip seal (6) from the seal carrier (3).
6. If necessary, remove the shaft (9) and bearing assembly
(8) from the housing (4).
E13.2 7. Remove the retaining ring (7) that secures the 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

September 2002
ASSEMBLY
1. If necessary, install the original bearing assembly (8) or a
new bearing assembly (8) on a new shaft (9), refer to
Figure 1-1.
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.
E13.3
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

September 2002
DISASSEMBLY
1. Remove the multi-function valve cartridges (1) from the
end cap (2), refer to Figure 1-2.
2. Remove and discard the O-rings (3) from the multi-function
valve cartridges (1).
INSPECTION
1. Inspect the multi-function valve cartridge for damage to
parts.
ASSEMBLY
CAUTION:
If the pressure limiter housing is disassembled for cleaning,
the pressure setting must be readjusted after reassembly.
1. Lightly lubricate the new O-rings (3) with clean petroleum
jelly.
E13.4 2. Install new O-rings (3) onto the multi-function valve
cartridges (1).
3. Install the multi-function valve cartridges (1) in the end cap
(2).
4. Torque the multi-function valve cartridges (1) to 89 N·m (66
lb-ft).
Figure 1-2
MULTI-FUNCTION VALVE CARTRIDGES

September 2002
DISASSEMBLY
NOTE:
To maintain original adjustment, mark the plug (7), the locknut
(8), and the housing (2).
1. Loosen the locknut (8) and remove the plug (7) by
unscrewing the plug (7) from the housing (2), refer to
Figure 1-3.
2. Remove and discard the O-ring (6) from the plug (7).
plug (7).
INSPECTION
end cap for damage or foreign material.
ASSEMBLY
E13.5 CAUTION:
plug (7).
2. Install a new O-ring (6) onto plug (7).
made at disassembly and torque the locknut (8) to 52 N·m
(38 lb-ft).
4. Check and adjust the charge pressure as required.
Figure 1-3
CHARGE RELIEF VALVE

September 2002
DISASSEMBLY
1. Remove the screws (1), flange cover (2) and O-ring (3).
discard the O-ring (3), refer to Figure 1-4.
2. Remove the screws (4), washers (5), and flange adapter
(6) from the end cap (17).
CAUTION:
Do not allow the force of the cylinder block spring and
swashplate leveler springs to separate the flange adapter from
the charge pump housing.
3. Remove the screws (7), retaining plate (8) and O-ring (9).
discard the O-ring (9).
4. Remove the charge pump cover (10), bushing (11), and
coupling (12). Note the orientation of the gerotor assembly
(15).
5. Remove the charge pump shaft (13) and key (14) from the
end cap (17).
E13.6
6. Remove the charge pump gerotor assembly (15) and
alignment pin (16).
INSPECTION
1. Surfaces need to be clean and free of any foreign material
or paint prior to assembly.
2. Inspect for abnormal wear or damage.
Figure 1-4
CHARGE PUMP
September 2002
ASSEMBLY
NOTE:
Be sure to install the charge pump in the proper orientation.
1. Apply a small amount of petroleum jelly to the charge pump
gerotor assembly (15) inside diameter and outside diameter,
refer to Figure 1-4.
2. Install the charge pump gerotor assembly (15) and alignment
pin (16).
3. Install the charge pump shaft (13) and key (14) into the end
cap (17). The internally splined end of the shaft must engage
the main pump shaft.
4. Install the coupling (12), bushing (11), and charge pump
cover (10).
CAUTION:
In order to avoid loss of charge pressure, always install the
charge pump cover (10) with the drain hole located on the same
E13.7 side of the end cap (17) as the charge inlet port.
5. Install the retaining plate (8) and secure the retaining plate
(8) with screws (7).
6. Torque the screws (7) to 13.5 N·m (10 lb-ft).
7. Install a new O-ring (9) around the charge pump cover (10).
8. Install the flange adapter (6), washers (5), and screws (4)
onto the end cap (17).
10. Install a new O-ring (3), flange cover (2), and screws (1) onto
the flange adapter (6).
Figure 1-4
CHARGE PUMP
September 2002
DISASSEMBLY
1. Loosen the swivel locknut (19), refer to Figure 1-5.
2. Remove the filter manifold (17) from the end cap (21).
3. Remove and discard the O-ring (20) from the filter manifold
(17).
INSPECTION
1. Inspect the filter manifold (17) and tube (18) for blockage or
foreign material.
ASSEMBLY
1. Install a new O-ring (20) onto the filter manifold (17).
2. Rotate the filter manifold (17) so the threads engage with the
threads in the end cap (21), continue to rotate clockwise 6 or
7 turns.
3. Place filter manifold (17) in desired position.
E13.8
CAUTION:
Failure to install the filter manifold to a sufficient depth in the
housing will result in insufficient engagement of the tube in the
housing. This may allow oil to bypass the filter and enter the
charge system.
4. Torque the swivel locknut (19) to 122 N·m (90 lb-ft).
5. Install a new filter canister per manufacturer’s instructions.
Figure 1-5
REMOTE CHARGE
PRESSURE FILTRATION
September 2002
DISASSEMBLY
1. Clean external surfaces prior to removal.
2. Remove the screws (1) that secure the manual displacement
control (2) to the housing (8), refer to Figure 1-5.
3. Remove the manual displacement control (2) with neutral
start switch (9), the orifice check valve (3), the spring (4), the
spring retainer (5), and the gasket (6) from the housing (8).
CAUTION:
Protect exposed surfaces and cavities from damage and foreign
material.
ASSEMBLY
1. Install a new gasket (6) on the housing (8).
2. Install the orifice check valve (3), the spring (4), and the
spring retainer (5) into the manual displacement control (2).
3. All at once, install the manual displacement control (2) with
E13.9
neutral start switch (9) and engage the pin on the control
linkage into the mating hole in the link attached to the
swashplate.
4. Check for proper engagement of the control linkage pin by
moving the control handle (7) off center creating center
torque. If there is a lack of centering torque, repeat step 3.
5. Align the new gasket (6) with the housing (8) and install the
screws (2).
7. Readjust the neutral start switch (9) per manufacturer’s
instructions.
NOTICE:
The neutral start switch (9) “neutral” must be readjusted after Figure 1-6
reassembling the manual displacement control module.
MANUAL DISPLACEMENT
CONTROL
September 2002
SD-100/105 TF SERIES AXLE
TABLE OF CONTENTS. ..........................................E14.1
BRAKES ..................................................................E14.2
Disassembly .......................................................E14.2
Assembly............................................................E14.4
PLANETARY REDUCTION AND AXLE SHAFT .....E14.6
Disassembly .......................................................E14.6
Assembly............................................................E14.8
PINION ..................................................................E14.10
Disassembly .....................................................E14.10
Assembly.......................................................... E14.11
DIFFERENTIAL UNIT............................................E14.15 Axle
Disassembly .....................................................E14.15
Assembly..........................................................E14.17
E14.1
Save time and money by contacting your authorized
authorized
rebuilt
components TABLE OF CONTENTS
September 2002
DISASSEMBLY
1. Remove the lower plug from the axle arm (24) and drain the
oil.
2. Attach a suitable lifting device to the axle arm to be removed.
3. Loosen and remove the screws (12) and nuts (13) securing
the axle arm to the axle cylinder.
4. Remove the arm (24) from the cylinder, together with the
brakes and axle shaft. Using the sling for support, stand the
arm on end with the open end facing up.
5. Loosen the screws (19) on the cylinder in an alternate
manner and remove them.
6. Move the cylinder outward (5) while supporting the Belleville
washers (1).
7. Remove the screws (7) from the counterwasher (18). Note
down their order of assembly.
E14.2 8. Remove the counterwasher (18) from the cylinder (5).
9. Slowly introduce low-pressure compressed air through the
connection member for the negative brake, in order to
remove the piston (3).
CAUTION:
Hold the piston (84) back, as it may be suddenly ejected and
damaged.
10. Remove and discard the O-rings (2 and 4) from the piston
(3).
11. Remove the braking disks (8 and 17) from the cylinder (5).
Note dow their direction of assembly.
NOTE:
If the disks are not to be replaced, avoid changing their position.
Figure 1-1
BRAKES
September 2002
12. Remove the screw (13) and safety (14) from the arm (24).
13. Remove the pinion (16) complete with O-ring from the arm
(24). Discard the O-ring
14. Unscrew and extract the brake disk clearance adjustment
crown wheel (9).
E14.3
Figure 1-1
BRAKES
September 2002
ASSEMBLY
1. Lubricate the threaded portion of the crown wheel (9).
2. Screw down the crown wheel into the arm (24) as far as it will
go.
3. Lubricate and install the pinion (16) in the slot provided on
the arm, inserting the pinion teeth into the crown wheel (9)
teeth.
4. Lightly lubricate the first steel braking disk (17), then install it
into the axle arm (24).
NOTE:
Check the wear on all braking disks. The thickness of a new
braking disk is 4.9 mm (0.19 in.). If the thickness of an existing
braking disk is less than 4.5 mm (0.18 in), replace the disk.
5. Lubricate the first friction disk (8) and install it on the axle
shaft.
E14.4 6. Complete the assembly, alternating steel disks and friction
disks.
7. Remove the breather (22) from the cylinder (5).
8. Grease the breather (22) with TECNOLUBE.
9. Install new O-rings (2 and 4) onto the piston (3).
10. Lubricate the piston (3) and the O-rings (2 and 4), and install
the unit into the cylinder (5). The piston relief must face
downwards.
11. Grease the diameters of the piston (3) with TECNOLUBE.
NOTE:
Use a plastic hammer and lightly hammer all around the edge of
the piston (3) in an alternate sequence to install the piston (3)
into the cylinder (5).
12. Insert the intermediate disk (18) into the piston (3). Figure 1-1
13. Install the intermediate disk screws (7) on the intermediate
disk (18). Torque the screws to 23 ± 26 N-m (17 ± 19 lb-ft). BRAKES
September 2002
14. Install the breather (22) on the cylinder (5).
15. Check the integrity and position of the cylinder O-ring (6) and
arm O-ring.
16. Position the Belleville washers (1) and engage the cylinder
(5). Check the sense of direction of the washers (1) and the
relative centering.
17. Lubricate a new O-ring (6) and position the cylinder on the
arm studs without fastening.
18. Preload the spring and fasten the screws (19) in two stages
using the criss-cross method.
19. Lock the cylinder (5) by torquing the cylinder screws (19) to
82 ± 91 N-m (60 ± 68 lb-ft).
20. Install the complete arm.
21. Temporarily lock the arm with nuts (11) previously lubricated
with Loctite 242. Fasten lighly to make the unit touch the
main body.
E14.5 22. Check to ensure the axle arms are level.
23. Lubricate the screws (12) with Loctite 242.
24. Lock the arms in their final position with the criss-cross
method. Torque the screws (12) to 283 ± 312 N-m (209 ±
230 lb-ft).
25. Connect an external pump to the union piece “P” of the
negative brake and apply pressure of 5-30 bar (218-435 psi).
26. Rotate the adjustment pinion (13) counterclockwise to
eliminate all existing clearance between the braking disks.
Rotate up to a torque of 8-10 N-m (6-7 lb-ft).
27. Rotate the pinion (13) clockwise to obtain the accurate
clearance. Each turn of the pinion produces a clearance of
0.25 mm (0.01 inch).
Figure 1-1
28. Release the pressure, fit the catch (15), and lock with a
screw coated with Loctite 242. Torque the screw to 20-30
N-m (15-22 lb-ft). BRAKES
September 2002
DISASSEMBLY
1. Remove the locking screws (21) of the planetary cover (18).
2. Use two screwdrivers or levers inserted in the slots provided,
pry the planetary cover (18) away from the wheel hub (3).
3. Remove the cover (18).
4. Remove the axle half shaft (28).
5. Unfasten the nuts (11) and remove them.
6. Remove the safety flange (10).
7. Use an extractor and apply a counterpressure to the screws
(9) to disengage the crown wheel (12) from the hub (4).
8. Remove the crown (12).
9. Sling the hub (4) and connect it to a hoist.
10. Use a hammer to shift the hub (4) and the external bearing
(31).
11. Remove the hub (4) complete with external bearing (31).
E14.6
12. Remove the internal bearing (2) and the hub (4).
13. Use an extractor to remove the snap ring (29). Note down
the direction of assembly of the snap ring.
14. Remove the safety spring rings (15) of the planetary gears
(14).
15. Remove the planetary gears (14). Note down the direction of
assembly of the planetary gears.
Figure 1-2
PLANETARY REDUCTION
AND AXLE SHAFT
September 2002
16. If necessary, use an extractor to remove the shim washer
(29) from the planetary carrier.
17. Remove and discard the snap ring (1) from the hub (4). Note
down the direction of assembly.
18. Remove the internal bearing (10).
19. Use a pin-driver to remove the external thrust blocks of the
bearings.
NOTE:
Hammer in an alternate sequence to prevent crawling and
deformation of the thrust blocks.
20. Use a pin-driver to remove the internal thrust blocks of the
bearings.
NOTE:
Hammer in an alternate sequence to prevent crawling and
deformation of the thrust blocks.
E14.7
Figure 1-2
PLANETARY REDUCTION
AND AXLE SHAFT
September 2002
ASSEMBLY
1. Position the wheel hub (4) under a press. Lubricate the seat
of the external bearing and press the thrust block of the
bearing (2) into the hub (4).
2. Install the bearing (2) onto the hub (4).
3. Apply an appropriate sealant to the outer surface of a new
snap ring (1).
4. Position the snap ring (1) into the hub (4). Check the
orientation of the snap ring.
5. Press the snap ring (1) down into its seat.
6. Turn the hub upside down. Lubricate the seat of the bearing
(31) and press the thrust block of the bearing (31) into the
hub (4).
7. If the shim washer had previously been removed, apply a
sealant for removable seals to the outer surface of the shim
washer (17) and use a driver to fit the shim washer into the
E14.8 planetary gear cover (18).
8. Install the planetary gear (14) onto the planetary gear cover
(4).
NOTICE
The jointed portion of the internal ring of the bearings must face
the bottom of the pin.
9. Lock the planetary gears (14) into position with the snap
rings (15).
10. Lubricate and install the snap rings into the axle arm, paying
particular attention to the direction of assembly of the rings.
11. Grease the snap ring (1) and the hub (4) of the arm. Install
the wheel hub (4) onto the arm.
12. Install the external bearing (31). Move the bearing to the limit
Figure 1-2
stop by hammering lightly all around the edge.
13. Use a driver with adequate diameter to install and fasten the PLANETARY REDUCTION
crown wheel (12) to the hub of the arm.
AND AXLE SHAFT
September 2002
14. Install the security flange (10).
15. Grease the surface of the safety flange (10) that touches the
crown wheel (12) with Tecno Lube /101.
16. Coat the nuts (10) with Loctite 242 and use a criss-cross
method to torque them in two stages. For the first stage,
torque the nuts (10) to 120 N-m (89 lb-ft). In the second
stage, torque the nuts (10) to 255-285 N-m (188-210 lb-ft).
NOTE:
Check the continuous rolling torque on the hub. The torque
should be 10-30 N-m (7-22 lb-ft).
17. Install the axle shaft (28); ensure that it is properly inserted
into the braking disks and differential unit.
NOTE:
Check the condition and position of the O-ring.
18. Install the planetary gear cover (18) onto the wheel hub (4).
Torque the screws to 40-50 N-m (29-37 lb-ft).
E14.9
Figure 1-2
PLANETARY REDUCTION
AND AXLE SHAFT
September 2002
DISASSEMBLY
1. Remove the axle arms from the central body (15).
2. Remove the screws (22) from the cover (1).
3. Disjoin the cover (1) from the central body (15).
4. Remove and discard the O-rings (21 and 23) from the cover
(1).
5. Remove the bushing (2) and circlip (20) from the snap ring
(19).
6. Use a special wrench to rotate the pinion (16) so as to
release and remove the pinion lock nut (19).
7. Use a puller to extract the pinion (16) complete with the
bearing (18), distance piece (17), and shims (3 and 4).
NOTE:
The thrust blocks of the bearings remain in the central body.
8. Remove the pinion (16), shims (3 and 4), and distance piece
E14.10 (17). Refer to and maintain the positions marked during
disassembly.
9. Remove the thrust block (2) of the bearings.
10. Insert a drift in the appropriate holes.
11. Remove the thrust block of the bearing (5) as well as the
shim washers (14).
12. Remove the snap ring (11) from the central body (15).
13. Remove the cap (12) from the central body (15).
Figure 1-3
PINION
September 2002
ASSEMBLY
NOTE
Before inserting the thrust block of the bearing (5) into the
central body (15), it is necessary to calculate the thickness of
any shims (3) that may also need to be inserted.
1. Use a faceplate to reset a centesimal comparator on a
calibrated block whose known thickness is 36 mm (1.42 in.).
Preload the comparator by about 3 mm (0.12 in.).
2. Bring the bearing (5) complete with the thrust block under
the comparator. Press the thrust block centrally and perform
several measurements of the thickness of the thrust block by
rotating the thrust block. To obtain the adjusted thickness
(D), add the obtained value to 36 mm (1.42 in.).
3. Check the nominal dimension as marked on the side of the
pinion (16). To obtain the actual center distance (I), add the
positive or negative variation (indicated as Y on the bottom
E14.11 of the pinion) to the nominal dimension.
Equation: I = Pinion nominal dimension - Y
NOTE
The marking on the bottom of the pinion uses an X(Y) format
whereby X represents the match part number and Y represents
the variation value in millimeters.
4. To obtain the thickness (S) of the shim (3) to be inserted,
subtract the sum of the actual center distance (I) and the
thickness of the thrust block (D) from 170.2 mm (6.7 in.).
Equation: S = 170.2 mm/6.7 in - (I + D)
Figure 1-3
PINION
September 2002
5. Use special tool T5 to partially insert the thrust block of the
bearing (5) with the shim (3) .
Tool T5 Tool T6
Tool T5
E14.12
Figure 1-3
PINION
September 2002
6. Connect the tension rod to the press and move the thrust
block of the bearing (18) into its seat. Disconnect the press
and remove the tension rod.
NOTE:
Before starting the next stage, make sure that the thrust block
has been completely inserted into its seat.
7. Introduce the special tool T6 (refer to previous page)
complete with bearings (5 and 18) into the main body (15).
Fasten by hand until a rolling torque is definitely obtained.
8. Introduce the tracer of a depth comparator into either side
hole of tool T6. Reset the comparator with a preload of about
3 mm.
9. Remove the comparator and take the tool and bearing kits
out of the main body. Reinstall every part, applying a
distance piece (17) between the bearings (5 and 18). Tighten
the entire pack by hand.
E14.13 10. Introduce a depth comparator to the special tool and
measure the deviation (H) from the previous reset.
11. To obtain the thickness (S1) of the pack of shims (4) for
insertion between the bearing (5) and distance piece (17),
add the deviation (H) to a set value of 0.12-0.15 (X).
Equation: S1 = H + X
NOTE
Round off the obtained thickness value (S1) to the higher 5/100.
12. Heat the bearing (5) to 100°C (212°F) and install it in the
pinion (16). Once the bearing (5) has cooled down, lightly
lubricate the bearing with SAE85W90 oil.
13. Make sure that the bearing is well set. Refer to and maintain
the positions marked during disassembly.
14. Install the pinion (16), the pack of shims (4), and the distance Figure 1-3
piece (17) in the main body (15). Place the finer shims in
between the thicker ones.
PINION
September 2002
15. Heat the bearing (18) to 100°C (212°F) and install it in the
pinion (16). Once the bearing has cooled down, lightly
lubricate the bearing with SAE85W90 oil.
16. Apply Loctite 242 to the thread of the ring nut (19) and install
the nut (19) onto the pinion (16).
17. Apply a wrench to the ring nut (19) and a bar-hold to the
pinion (16).
18. Lock the wrench and rotate the pinion (16) to a minimum
torque of 600 N-m (442 lb-ft).
19. Apply the bar-hold to the pinion (16) and use a torque meter
to measure the torque of the pinion (16). The torque should
be between 120 and 170 N-cm (10 and 15 lb-in).
NOTICE:
If the torque exceeds the maximum value of 170 N-cm (15 lb-in),
then the thickness of the shims (3 and 4) between the bearing
(18) and the distance piece (17) must be increased.
E14.14 If the torque does not reach the set value, increase the torque
setting of the ring nut (19) in different stages to obtain a
maximum value of 800 N-m (590 lb-ft).
If the torque does not reach the minimum value of 120 N-cm (10
lb-in), then the size of the shim (3) must be decreased.
When calculating the increase or decrease in the size of the shim
(3), bear in mind that a variation of 0.01 mm (0.00039 in) in the
thickness of a shim corresponds to a variation of 60 N-cm (5 lb-
in) in the torque of the pinion (16).
20. Install the bushing (2) and circlip (20) on the ring nut (19).
21. Install new O-rings (21 and 23) on the cover (1)
22. Install the cover (1) on the central body (15).
23. Install the screws (22) on the cover (1).
24. Install the cap (12) on the central body (15). Figure 1-3
25. Install the snap ring (11) on the central body (15).
PINION
September 2002
DISASSEMBLY
1. Remove the axle arms together with the brakes and axle
shafts from the central body (27); lay the arm down vertically.
2. Remove and discard the external cover O-rings (19 and 30).
3. Unfasten the screws in an alternate manner and remove
them.
4. Remove the screw (18).
5. Uniformly heat the ring nut (22) up to a temperature of 80°C
(176°F).
6. If it is necessary to remove or adjust the ring nut (22), mark
the position of the ring nut. Remove the screws (18) and ring
nut checks.
7. Loosen the safety studs and remove two of them.
8. Disjoin the cover (20) crown side.
9. Remove the covers (20 and 29) and studs.
E14.15 10. Remove the internal cover O-rings (21 and 28).
11. Extract the whole differential unit from the central body (27).
12. Remove the snap ring (8) from the central body (27).
13. Remove the cap (9) from the central body (27).
14. If the bearings need replacing, remove the bearings (12 and
17) from the differential carrier (13).
Figure 1-4
DIFFERENTIAL UNIT
September 2002
15. Remove and discard the O-ring (21) from the crown (23).
16. Remove the fitting screws (16) from the crown (23).
17. Remove the crown (23) from the lower differential unit half
box (15).
18. Remove the screws (24) jointing the differential unit half
boxes (13 and 15).
19. Use a plastic hammer to disassemble the upper differential
half box (13).
NOTE
Note down the coupling marks.
20. Extract the no-spin unit (14).
21. Unfasten the wing nut of the stay. Disassemble the no-spin
unit (14) in order to remove the distance piece that prevents
the axial sliding of the axial shafts.
E14.16
Figure 1-4
DIFFERENTIAL UNIT
September 2002
ASSEMBLY
1. Assemble the no-spin unit (14), inserting the distance piece
and using the stay.
2. Install the no-spin unit (14) into the lower differential unit half
box (15). Center the upper differential half box (13) and
fasten with screws (24).
NOTICE
Make sure that the connection marks coincide.
3. Coat the screws (24) with Loctite 270. Use the criss-cross
method to torque the screws (24) to form the differential box.
Torque the screws to 37 ± 41 N-m (27 ± 30 lb-ft).
4. Position the crown (23) on the lower differential half box (15).
5. Lock the crown (23) to the lower differential half box (15) with
screws (16) coated with Loctite 242. Torque the screws to
128-142 N-m (94-105 lb-ft).
E14.17 NOTICE
Use only new screws.
Use the alternate and criss-cross method to fasten the screws.
6. Position the differential unit under a press. Use a driver with
an adequate diameter to install the first bearing (17).
7. Turn the unit upside down and install the second bearing
(12).
NOTICE
Position a shim with adequate diameter in order to engage the
internal ring of the bearing without engaging the cage.
8. If the bearings have been replaced, insert the thrust blocks
into the intermediate covers (21 and 29).
9. Install new O-rings (21 and 28) in the cover.
NOTE Figure 1-4
Ensure that the cover is fitted with the oil discharge in the lower
position.
DIFFERENTIAL UNIT
September 2002
10. Torque the intermediate cover (20) with the journals set at
129 ± 143 N-m (95 ± 105 lb-ft).
11. Fasten the two safety studs into the main body (27) and
install the intermediate cover (20).
12. Lock the intermediate cover (20) into place with two service
screws (M16 x 50) locked to the same torque. Torque the
screws to 30-45 N-m (22-33 lb-ft).
13. Fasten the ring nut (22) on the crown side until the clearances
between the pinion and crown are zero. Then loosen by 1/4
turn.
14. If the ring nuts have been removed, preload the bearings with
the ring nut (22) on the non-gear ring side in order to increase
the torque of the pinion.
NOTICE
In the case of used bearings, check the thrust torque.
In the case of new bearings, check the continuous torque.
E14.18
Figure 1-4
DIFFERENTIAL UNIT
September 2002
15. Apply a torque meter to the pinion nut and check that the
torque increases by 20-40 N-cm (2-3 lb-in) as a result of a
differential bearing preload.
Example: pinion torque: 120-130 N-cm (11-12 lb-in)
Pinion + differential torque: 140-170 N-cm (12-15 lb-in)
16. Introduce a comparator with a long tracer through the hole
provided for the cap. Position the comparator on the side of a
tooth of the crown (23) approximately 5 mm (0.12 inch) from
the outer rim. Preload by about 1 mm (0.04 inch) and preset
the comparator to zero.
17. When holding the pinion in position, move the crown (23)
manually in both directions to check the clearance between
the pinion and the crown. The standard clearance is between
0.13 and 0.20 mm (0.005 and 0.008 inch).
18. If the torque and/or pinion-crown clearance is not within the
tolerance values and the ring nuts (22 and 25) have not been
E14.19 removed, mark the position of the ring nuts (22 and 25) and
remove the safety stops (18).
19. To increase the clearance between the pinion and crown,
loosen the ring nut (22) on the crown side and tighten the ring
nut (25) on the non-crown side by the same measure.
To decrease the clearance between the pinion and crown,
tighten the ring nut (22) on the crown side and loosen the ring
nut (25) on the crown ring side by the same measure.
20. Use a special wrench to rotate the ring nuts.
Figure 1-4
DIFFERENTIAL UNIT
September 2002
21. Engage the screw (26) in the slot next to the holes provided
for the check screws.
22. Coat the screws (26) with Loctite 42 and torque to 24-26
N-m (18-19 lb-ft).
23. After applying repositionable jointing compound for seals to
the rims, fit the cap (9) on the central body (27) .
24. Install the snap ring (8) on the central body (27).
25. Lubricate a new O-ring (19) and position the cylinder on the
studs and fastening.
26. Lock the cylinder, torquing the screws to 82-91 N-m (60-67
lb-ft).
27. Install the complete arm. Torque to 283 ± 312 N-m (209 ±
230 lb-ft). Tighten using the criss-cross method.
E14.20
Figure 1-4
DIFFERENTIAL UNIT
September 2002
SD-100/105 TF SERIES AXLE MOTOR
NOTICE:
warranty.
DISASSEMBLY
1. Position the motor with the shaft end facing up.
2. Remove the screws (1) securing the retainer plate (2), refer
to Figure 1-1.
3. Remove the retainer plate (2) and the seal carrier (3) from
the housing (4).
4. Remove and discard the O-ring (5) from the seal carrier (3).
5. Press out and discard the lip seal (6) from the seal carrier
(3).
6. If necessary, remove the shaft (9) and the bearing assembly
(8) from the housing (4).
E15.2 WARNING:
Safety glasses must be worn when removing the retaining ring
(7).
7. Remove and discard the retaining ring (7) that secures the
bearing assembly (8) on the shaft (9).
8. Remove the bearing assembly (8) from the shaft (9).
INSPECTION
1. Inspect the seal carrier (3) for any damage or nicks.
necessary.
3. Inspect the bearing assembly (8) for damage. Use a new Figure 1-1
bearing assembly (8) as required.
LIP SEAL AND SHAFT

September 2002
ASSEMBLY
1. If necessary, install the original bearing assembly (8) or a
new bearing assembly (8) on the shaft (9), refer to Figure 1-
1.
WARNING:
Safety glasses must be worn when installing the retaining ring
(7).
2. Secure the bearing assembly (8) on the shaft (9) with a new
retaining ring (7).
3. Install the shaft (9) and the bearing assembly (8) into the
housing (4).
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
E15.3 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 new O-ring (5) and the inside diameter of the
new lip seal (6) with clean petroleum jelly.
8. Install the seal carrier (3) and retainer plate (2) into the
housing (4) bore and secure with the screws (1).
9. Torque the screws (1) to 9.5 N·m (7 lb-ft).
Figure 1-1
LIP SEAL AND SHAFT

September 2002
DISASSEMBLY
1. Remove the plugs (1) from both sides of the valve orifice,
2. Remove and discard the O-rings (4) from each plug (1).
3. Remove the springs (2), the spring guides (3), and the
flushing valve shuttle spool (5) from the valve orifice in the
housing (6).
4. Note the orientation of the spring guides (3). Remove the
springs (2) and the spring guides (3) from the flushing valve
shuttle spool (5).
INSPECTION
1. Inspect the parts for damage or foreign material.
ASSEMBLY
1. Install the flushing valve shuttle spool (5) into the valve
E15.4 orifice of housing (6).
2. Install the spring guides (3) with the shoulders facing out and
the springs (2) on each side of the flushing valve shuttle
spool (5).
3. Install the new O-rings (4) on each plug (1).
4. Install the plugs (1) into both sides of the valve orifice and
torque the plugs (1) to 41 N·m (30 lb-ft).
Figure 1-2
LOOP FLUSHING VALVE

September 2002
DISASSEMBLY
NOTE:
To maintain original adjustment, mark the plug (10), the locknut
(7), and the housing (6).
1. Loosen the locknut (7) from the housing (6).
2. Remove the plug (10) by unscrewing it from the locknut (7),
3. Remove and discard the O-ring (8) from the locknut (10).
5. Remove the spring (11) and the charge relief valve (9) from
the locknut (7).
INSPECTION
1. Inspect the charge relief valve (9) and mating seat in the end
cap for damage or foreign material.
E15.5
ASSEMBLY
CAUTION:
1. Install the charge relief valve (9) and the spring (11) onto the
locknut (7).
2. Install a new O-ring (8) onto the locknut (7).
3. Install a new O-ring (12) onto the plug (10).
(38 lb-ft).
Figure 1-3
CHARGE RELIEF VALVE

September 2002
TABLE OF CONTENTS...........................................E15.1
LIP SEAL AND SHAFT............................................E15.2

Disassembly .......................................................E15.2
Inspection ...........................................................E15.2
Assembly............................................................E15.3
LOOP FLUSHING VALVE .......................................E15.4
Disassembly .......................................................E15.4
Inspection ...........................................................E15.4
Assembly............................................................E15.4
CHARGE RELIEF VALVE........................................E15.5
Disassembly .......................................................E15.5
Axle Drive Motor
Inspection ...........................................................E15.5
Assembly............................................................E15.5
E15.1
authorized
rebuilt
components TABLE OF CONTENTS
September 2002
SD-100/105 TF SERIES DRUM DRIVE MOTOR
DISTRIBUTION VALVE ...........................................E16.2

Disassembly .......................................................E16.2
Inspection ...........................................................E16.2
Assembly............................................................E16.3
CYLINDER BLOCK AND CAM................................E16.4
Disassembly .......................................................E16.4
Assembly............................................................E16.5
CYLINDER BLOCK .................................................E16.6
Disassembly .......................................................E16.6
Inspection ...........................................................E16.6
Assembly............................................................E16.7
E16.1 BEARING HOUSING...............................................E16.8
Disassembly .......................................................E16.8
Inspection ...........................................................E16.8
Assembly............................................................E16.9
Drum Drive Motor
TABLE OF CONTENTS
September 2002
NOTICE:
warranty.
DISASSEMBLY
1. Remove the screws (6) securing the back plate (5) to the
distribution cover (1), refer to Figure 1-1.
2. Remove and discard the O-ring (18) from the distribution
cover (1).
3. Mark the position of the distribution cover (1) in relation to the
cam (2) and the bearing support (3).
4. Remove the screws (7 and 8) from the distribution cover (1).
5. Remove the bearing support (3) from the distribution cover
(1).
6. Remove the cam (2) and cylinder block (4) from the
E16.2 distribution cover (1). Remove and discard the O-rings (14)
from the bearing support (3) and distribution cover (1).
7. Mark the position of the valving (9) in relation to the
distribution cover (1).
8. Remove the valving (9) from the distribution cover (1).
9. Remove the springs (10) from the valving (9), then remove
the O-rings and back-up rings (11) from the valving (9).
INSPECTION
1. Check the condition of the valving surface on its faces in
contact with the cylinder block and the seal facings.
Figure 1-1
DISTRIBUTION VALVE
September 2002
ASSEMBLY
1. Apply a light coat of petroleum jelly or grease to the O-rings
and back-up rings (11), refer to Figure 1-1.
2. Install the O-rings and back-up rings (11) onto the valving
(9).
3. Apply grease into the spring (10) housings.
4. Install the springs (10) into the valving (9).
5. Apply a light coat of petroleum jelly or grease to the faces of
the O-rings and back-up rings (11).
6. Install the valving (9) into the distribution cover (1).
7. Apply a light coat of petroleum jelly or grease to the contact
surfaces of the cylinder block (4) and the valving (9).
(14).
9. Install the new O-rings (14) on the bearing support (3) and
E16.3 distribution cover (1).
10. Install the bearing support (3), cam (2) and cylinder block (4)
onto the distribution cover (1).
11. Align the marks on the bearing support (3), cam (2), and
12. Install the screws (7 and 8) into the distribution cover (1).
13. Torque the screws (7 and 8) to 350 N·m (258 lb-ft).
14. Apply a light coat of petroleum jelly or grease to the new O-
ring (18).
15. Install the new O-ring (18) on the distribution cover (1).
16. Install the back plate (5) onto the distribution cover and
secure it in place with the screws (6).
17. Torque the screws (6) to 350 N·m (258 lb-ft). Figure 1-1
DISTRIBUTION VALVE
September 2002
DISASSEMBLY
1. Mark the position of the bearing support (3) in relation to the
cam (2) and the distribution cover (1), refer to Figure 1-1.
3. Remove the bearing support (3) from the distribution cover
(1).
5. Remove and discard the O-rings (14) from the bearing
support (3) and distribution cover (1).
6. If the valving (9) remains attached to the cylinder block (4),
mark the position of the valving (9) in relation to the
7. Remove the valving (9) from the cylinder block (4).
8. Remove the springs (10) from the valving (9).
E16.4 9. If the valving (9) remains in the distribution cover (1),
removal of the valving (9) and springs (10) is not necessary.
Figure 1-1
CYLINDER BLOCK AND CAM

September 2002
ASSEMBLY
1. Apply grease into the spring (10) housings, refer to Figure 1-
1.
(14).
7. Install the O-rings (14) on the distribution cover (1) and
bearing support (3).
8. Install the bearing support (3), cam (2) and cylinder block (4)
E16.5 9. Install the screws (7 and 8) into the distribution cover (1).
Figure 1-1
CYLINDER BLOCK AND CAM

September 2002
DISASSEMBLY
3. Remove the bearing support from the distribution cover (1).
support (3) and distribution cover (1).
9. If the valving (9) remains in the distribution cover (1),
E16.6 removal of the valving (9) and springs (10) is not necessary.
10. Remove the clips (12) from the cylinder block (4).
11. Remove the pistons (13) from the cylinder block (4).
INSPECTION
1. Inspect the surface condition of the bores in the cylinder
block (4) for seizing or abnormal wear.
Figure 1-1
CYLINDER BLOCK
September 2002
ASSEMBLY
1. Apply a light coat of petroleum jelly or grease to the pistons
(13), refer to Figure 1-1.
2. Install the pistons (13) into the cylinder block (4).
3. Install the clips (12) into the cylinder block (4).
(14).
E16.7 bearing support (3).
11. Install the bearing support (3), cam (2) and cylinder block
Figure 1-1
CYLINDER BLOCK
September 2002
DISASSEMBLY
3. Remove the bearing support from the distribution cover (1).
support (3) and distribution block (1).
9. If the valving (9) remains in the distribution cover (1),
E16.8 removal of the valving (9) and springs (10) is not necessary.
10. Remove the thrust ring (15), O-rings (16, 20, and 21), shaft
seal (17), and seal kit (22) from the bearing support (3).
INSPECTION
1. Inspect the condition of the valving seal face surfaces for
their level and wear.
Figure 1-1
BEARING HOUSING
September 2002
ASSEMBLY
surfaces of the thrust ring (15), O-ring (16) and shaft seal
2. Install the thrust ring (15), O-rings (16, 20, and 21), shaft seal
(17), and seal kit (22) into the bearing support (3).
and back-up rings (11).
4. Install the O-rings and back-up rings (11) onto the valving (9).
E16.9 surfaces of the cylinder block (8) and the valving (9).
(14).
bearing support (3).
12. Install the bearing support (3), cam (2) and cylinder block
13. Align the marks on the bearing support (3), cam (2), and
Figure 1-1
BEARING HOUSING
September 2002
SD-100/105 TF SERIES LOOP FLUSH VALVE
LOOP FLUSHING VALVE .......................................E17.2

Disassembly .......................................................E17.2
Inspection ...........................................................E17.2
Assembly............................................................E17.2
Loop
CHARGE RELIEF VALVE........................................E17.3 Flush
Valve
Disassembly .......................................................E17.3
Inspection ...........................................................E17.3
Assembly............................................................E17.3

E17.1 regarding Authorized Rebuilt Components.
authorized
rebuilt
components
TABLE OF CONTENTS
September 2002
NOTICE:
warranty.
DISASSEMBLY
1. Remove the plugs (1) from both sides of the valve housing
2. Remove and discard the O-rings (2) from each plug (1).
3. Remove the springs (3), spring guides (4), and flushing valve
shuttle spool (5) from the valve housing (6).
NOTE:
Note the orientation of the spring guides (3).
INSPECTION
1. Inspect the parts for damage or foreign material.
E17.2
ASSEMBLY
1. Install the shuttle spool (5) into the valve housing (6).
2. Install the spring guides (4) with the shoulders facing out and
springs (3) on each side of the shuttle spool (5).
3. Install new O-rings (2) on each plug (1).
4. Install plugs (1) into both sides of the valve housing (6) and
torque the plugs (1) to 41 N·m (30 lb-ft).
Figure 1-1
LOOP FLUSHING VALVE

September 2002
DISASSEMBLY
NOTE:
To maintain original adjustment, mark the plug (10), locknut (7),
and the housing (6).
1. Loosen the locknut (7) and remove the plug (10) by
unscrewing the plug (10) from the housing (6), refer to
Figure 1-2.
plug (10).
INSPECTION
valve housing for damage or foreign material.
ASSEMBLY
E17.3 NOTICE
plug (10).
2. Install a new O-ring (8) onto plug (10).
(38 lb-ft).
Figure 1-2
CHARGE RELIEF VALVE

September 2002
Settings and Specifications - Vibration* 100D 105DX 105F
Table of Contents Engine RPM (Hi/Low) 2457/950 X X X
Flow at Input Speed 90.5 l/m 23.9 g/m X X X
Overview ........................................... F2 System Relief Pressure (psi/bar) 5000/345 X X X
Neutral - No Vibration ......... F3 Charge Relief Pressure (psi) 285 X X X
Clockwise - High AmplitudeF4 * For specific application settings, contact your authorized Ingersoll-Rand
service personnel.
Counterclockwise -
Low Amplitude ................ F5
VIBRATION
Hydraulic Tank Vibration
Motor
Oil Cooler
F1
Suction Filter
Thermal Bypass Valve
Vibration Pump
EFF. W/ ALL S/N
September 2002
HYDRAULIC TANK
SUCTION STRAINER
VIBRATION
SUCTION
FILTER
OIL
COOLER
140 F CRACKING
165 F OPEN
THERMAL
BYPASS
VALVE
25 PSI
VIBRATION PUMP
M3
F2 M4
A
VIBRATION MOTOR
M1 M1
M5
B
M2
M2 L2
L1 S
OVERVIEW
September 2002
HYDRAULIC TANK
SUCTION STRAINER
VIBRATION
SUCTION
FILTER
L E G E N D
OIL
COOLER
BYPASS
THERMAL
BYPASS
VALVE
25 PSI dashed lines
indicate
low pressure
VIBRATION PUMP
M3
F3 M4
A VIBRATION MOTOR
M1 M1
M5
B
M2
M2 L2
L1 S
NEUTRAL - NO VIBRATION
September 2002
HYDRAULIC TANK
SUCTION STRAINER
VIBRATION
SUCTION
FILTER L E G E N D
OIL
COOLER
140 F CRACKING
THERMAL
BYPASS
VALVE
25 PSI
dashed lines
VIBRATION PUMP indicate
low pressure
M3
F4 M4
A
VIBRATION MOTOR
M1 M1
M5
M2
M2 L2
L1 S
CLOCKWISE - HIGH AMPLITUDE
September 2002
HYDRAULIC TANK SD-100/105 TF SERIES
SUCTION STRAINER
VIBRATION
SUCTION
FILTER
L E G E N D
OIL
COOLER
165 F OPEN
THERMAL
BYPASS
VALVE
25 PSI
VIBRATION PUMP dashed lines

indicate
low pressure
M3
F5 M4
A
VIBRATION MOTOR
M1 M1
M5
B
M2
M2 L2
L1 S
COUNTERCLOCKWISE -
LOW AMPLITUDE
September 2002
SD-100/105 TF SERIES VIBRATION PUMP
TABLE OF CONTENTS .............................................F6.1 FORWARD - NEUTRAL - REVERSE
CONTROL (SD-100/105D Only)................................F6.9
LIP SEAL ...................................................................F6.2 Disassembly .........................................................F6.9
Disassembly .........................................................F6.2 Inspection .............................................................F6.9
Inspection .............................................................F6.2 Assembly............................................................F6.10
Assembly..............................................................F6.2
BYPASS VALVE.........................................................F6.3
Disassembly .........................................................F6.3
Inspection .............................................................F6.3
Assembly..............................................................F6.3
CHARGE CHECK AND
HIGH PRESSURE RELIEF VALVE ...........................F6.4
Disassembly .........................................................F6.4
Inspection .............................................................F6.4
F6.1 Assembly..............................................................F6.4
Vibration Pump
CHARGE RELIEF VALVE..........................................F6.5

Disassembly .........................................................F6.5
Inspection .............................................................F6.5
Assembly..............................................................F6.5
FILTER ADAPTER.....................................................F6.6
Disassembly .........................................................F6.6
Assembly..............................................................F6.6
ELECTRICAL DISPLACEMENT
CONTROL (SD-100/105DX/F Only) ..........................F6.7
Disassembly .........................................................F6.7
Inspection .............................................................F6.7
Assembly..............................................................F6.8
TABLE OF CONTENTS
September 2002
NOTICE:
warranty.
DISASSEMBLY
1. Remove the retaining ring (1) from the housing (2), refer to
Figure 1-1.
2. Carefully remove the lip seal (3) from the housing (2) bore. A
slide type hammer may be used to remove the lip seal (3).
INSPECTION
necessary.
ASSEMBLY
F6.2
CAUTION:
To prevent damage to the lip seal (3), wrap the spline or key end
of the shaft (4) with thin plastic.
2. Slide the new lip seal (3) over the shaft (4) and press it into
the housing (2) bore.
3. Install the retaining ring (1).
Figure 1-1
LIP SEAL
September 2002
DISASSEMBLY
1. Remove the bypass valve (5) from the housing (2), refer to
Figure 1-2.
2. Remove and discard the O-ring (6) and backup ring (7) from
the bypass valve (5).
INSPECTION
1. Inspect the bypass valve (5) and mating seat for damage or
foreign material. Use new parts as required.
ASSEMBLY
1. Install a new backup ring (7) and O-ring (6) onto the bypass
valve (5).
2. Lubricate the new O-ring (6) with clean hydraulic fluid and
install the bypass valve (5) into the housing (2).
3. Torque the bypass valve (5) to 9.5 to 13.6 N·m (7 to 10 lb-ft).
F6.3
Figure 1-2
BYPASS VALVE
September 2002
DISASSEMBLY
1. Remove the charge check and high pressure relief valve
plug (8), refer to Figure 1-3.
2. Remove and discard the O-ring (9) from the charge check
and high pressure relief valve plug (8).
3. Remove the spring (10) and poppet or valve cartridge (11)
from the housing (2).
INSPECTION
1. Inspect the poppet or valve cartridge (11) and mating seat in
the housing (2) for damage or foreign material. If the seat in
the housing (2) is damaged, a new vibration pump must be
used and the original must be returned to Ingersoll-Rand for
warranty repair or replacement.
NOTE:
Always replace ball type check valves with the poppet type.
F6.4
ASSEMBLY
1. Install a new O-ring (9) on the charge check and high
pressure relief valve plug (8).
2. Install a new poppet or valve cartridge (11), new spring (10),
and charge check and high pressure relief valve plug (8) into
the housing (2).
3. Torque the charge check and high pressure relief valve plug
(8) to 41 to 95 N·m (30 to 70 lb-ft).
CAUTION:
The high pressure relief valves are factory set and should not be
tampered with except for replacing the entire poppet or valve
cartridge. Disassembly may change the setting and cause
system malfunctions or premature failure. Figure 1-3
CHARGE CHECK AND HIGH

PRESSURE RELIEF VALVE
September 2002
DISASSEMBLY
1. Remove the charge relief valve plug (12), refer to Figure 1-4.
2. Remove and discard the O-ring (13) from the charge relief
valve plug (12).
3. Remove and discard the shims (14) from the charge relief
valve plug (12).
4. Remove the spring (15) and poppet (16) from the housing
(2).
INSPECTION
1. Inspect the poppet and mating seat in the end cap for
damage or foreign material. Use new parts as required.
ASSEMBLY
1. Install a new O-ring (13) on the charge relief valve plug (12).
2. Install new shims (14) in the inside diameter of the charge
F6.5 relief valve plug (12).
3. Install a new poppet (16), new spring (15), and charge relief
valve plug (12) with shims (14) into the housing (2).
4. Torque the charge relief valve plug (12) to 41 to 95 N·m (30
to 70 lb-ft).
Figure 1-4
CHARGE RELIEF VALVE

September 2002
DISASSEMBLY
1. Remove the screws (1) from the housing (19), refer to Figure
1-5.
2. Remove the filter adapter (2) and gasket (3) from the housing
(19).
ASSEMBLY
1. Install a new gasket (3) and filter adapter (2) onto the
housing (19).
2. Install the screws (1) to secure the filter adapter (2) onto the
housing (19).
3. Torque the screws (1) to 22 to 28 N·m (16 to 21 lb-ft).
F6.6
Figure 1-5
FILTER ADAPTER
September 2002
(SD-100/105DX/F Only)
NOTICE:
The removal of any portion of the electrical displacement control
mechanism may result in the loss of neutral, which will require
readjustment.
DISASSEMBLY
1. Remove the screws (4 and 5), refer to Figure 1-6.
2. Carefully lift the electrical displacement control (6) off the
housing (19).
3. Remove the O-rings (11 and 12) from the control (6).
4. Remove the screws (14) from the servo piston covers (15
and 17) on each side of the housing (19).
5. Remove the servo piston covers (15 and 17).
6. Remove and discard the gaskets (16).
INSPECTION
F6.7 1. Clean all parts in a suitable solvent and allow to air dry.
2. Clean all sealing surfaces.
3. Inspect all machined surface for burrs and sharp edges.
Remove any burrs or sharp edges as required.
Figure 1-6
ELECTRICAL DISPLACEMENT CONTROL

September 2002
(SD-100/105DX/F Only)
ASSEMBLY
1. Install a new gasket (16) for each servo piston cover (15 and
17).
2. Install the servo piston covers (15 and 17) and secure each
with screws (14).
4. Install new O-rings (11 and 12) on the control (6).
5. Carefully install the spool of the electrical displacement
control (6) on the housing (19).
6. Install the screws (4 and 5), torque the screws to 13 to 14
N·m (10 to 11 lb-ft).
7. Perform pump neutral adjustment.
NOTICE:
After installing the servo piston cover (15), the pump neutral
adjustment MUST be performed before the machine is put back
F6.8 into service.
Performance of the pump neutral adjustment may adjust the
position of the displacement limiter.
Figure 1-6
ELECTRICAL DISPLACEMENT CONTROL

September 2002
DISASSEMBLY
(SD-100/105D Only)
1. Remove the screws (4), refer to Figure 1-7.
2. Remove the control (6) from the gasket (7).
3. Remove the screws (5) from the gasket (7).
4. Remove the gasket (7) from the housing (19). Discard the
gasket.
5. Remove and discard the O-rings (8 and 9) from the gasket
(7).
6. Remove the screws (14) from each side of the housing (19).
7. Remove the servo piston covers (15 and 17).
8. Remove and discard the gaskets (16).
INSPECTION
1. Clean all parts in a suitable solvent and allow to air dry.
2. Clean all sealing surfaces.
F6.9 3. Inspect all machined surfaces for burrs and sharp edges.
Remove any burrs or sharp edges as required.
Figure 1-7
FORWARD - NEUTRAL -
REVERSE CONTROL
September 2002
SD-100-105 TF SERIES VIBRATION PUMP
(SD-100/105D Only)
ASSEMBLY
1. Install a new gasket (16) for each servo piston cover (15 and
17).
2. Install the servo piston covers (15 and 17) and secure each
with screws (14).
4. Install new O-rings (8 and 9) onto a new gasket (7).
5. Install the gasket (7) onto the housing (19)
6. Install the screws (5) onto the gasket (7).
7. Torque the screws (5) to 8 to 11 N-m (11 to 15 lb-ft).
8. Install the control (6) onto the gasket (7).
9. Install the screws (4), torque the screws to 13 to 14 N·m (10
to 11 lb-ft).
10. Perform pump neutral adjustment.
NOTICE:
F6.10 After installing the servo piston cover (15), the pump neutral
adjustment MUST be performed before the machine is put back
into service.
Figure 1-7
FORWARD - NEUTRAL -
REVERSE CONTROL
September 2002
SD-100/105 TF SERIES VIBRATION MOTOR
TABLE OF CONTENTS............................................. F7.1
SHAFT SEAL............................................................. F7.2

Disassembly ......................................................... F7.2
Inspection ............................................................. F7.2
Assembly.............................................................. F7.3 Vibration Motor

F7.1
authorized
rebuilt
components
TABLE OF CONTENTS
September 2002
NOTICE:
warranty.
DISASSEMBLY
1. Remove the retaining ring (6) located on the shaft end of the
motor (8), refer to Figure 1-1.
2. Remove the support washer (10) and lip seal (7) from the
motor housing (8).
3. Remove the second retaining ring (6) from the motor housing
4. Remove the O-rings and ball bearing from the motor
housing. Discard the O-rings.
5. If necessary, remove the shaft from inside the motor
housing.
6. Turn the vibration motor over with the motor shaft end facing
F7.2 down. Locate and loosen the screws that connect the end
cap gasket (9) to the motor housing (8).
7. Remove the end cap (9) from the motor housing (8).
8. Remove the end gasket (2) from the end cap (9) and
discard.
9. Remove the needle bearing (1) from the end cap motor.
INSPECTION
1. Inspect parts for damage or wear, use new parts as required.
Figure 1-1
SHAFT SEAL
September 2002
ASSEMBLY
1. Place a new needle bearing (1) and a new gasket (2) on the
motor end cap (9), refer to Figure 1-1.
2. Place the motor end cap (9) on the motor shaft (8). Make
sure that the screw hole are line up perfectly on both the end
cap (9) and the motor shaft (8).
3. Using the screws provided, fasten the end cap motor (9) to
the motor shaft (8).
4. Lubicate the new O-rings (4) with petroleum jelly and in them
along with the ball bearing (5) on the motor shaft .
5. Place the first retaining ring (6) on the motor shaft.
6. Lightly lubricate the outside of the diameter of the new lip
seal (7) with Loctite High Performance Sealant #59231.
7. Install the new lip seal (7) into the shaft end of the motor
housing (8).
F7.3 8. Install the support washer (10) and retaining ring (6).
Figure 1-1
SHAFT SEAL
September 2002
Table of Contents Settings and Specifications - Steering* 100D 105DX 105F

Engine RPM (Hi/Low) 2457/950 X X X
Overview .......................................... G2 Flow at Input Speed 24.2 l/m 6.4 g/m X X X
Neutral.................................. G3 System Relief Pressure (psi/bar) 2610/180 X X X
Steer Right........................... G4 * For specific application settings, contact your authorized Ingersoll-Rand
service personnel.
Steer Left ............................. G5
STEERING
Steering Cylinders
G1
Return Filter
Hydraulic Tank
Steering Valve
Steering Pump
EFF. W/ ALL S/N
September 2002
STEERING
STEERING CYLINDERS
HYDRAULIC TANK
SUCTION STRAINER
RETURN FILTER
G2
STEERING PUMP V
STEERING VALVE
OVERVIEW
September 2002
STEERING
STEERING CYLINDERS
HYDRAULIC TANK
RETURN FILTER
G3 SD-70/77 TF SERIES
L E G E N D
STEERING PUMP V
dashed lines
indicate
low pressure
STEERING VALVE
NEUTRAL
September 2002
STEERING
HYDRAULIC TANK
STEERING
SUCTION STRAINER CYLINDERS
RETURN FILTER
G4
L E G E N D
STEERING PUMP V
dashed lines
indicate
low pressure
STEERING VALVE
STEER RIGHT
September 2002
STEERING
HYDRAULIC TANK
STEERING
SUCTION STRAINER
CYLINDERS
RETURN FILTER
G5
L E G E N D
STEERING PUMP V
dashed lines
indicate
low pressure
STEERING VALVE
STEER LEFT
September 2002
SD-100/105 TF SERIES STEERING PUMP
TABLE OF CONTENTS ............................................ G6.1
SEAL KIT .................................................................. G6.2

Disassembly ........................................................ G6.2
Inspection ............................................................ G6.3
Assembly............................................................. G6.3

G6.1 Steering Pump
authorized
rebuilt
components
TABLE OF CONTENTS
September 2002
NOTICE:
warranty.
DISASSEMBLY
1. Place the pump in a vise from the flange side. Be careful not
to damage the pump housing (1) or flange (2).
2. Loosen and remove the screws (3) from the pump housing
(1) and flange (2), refer to Figure 1-1.
3. Place the pump on a table with the shaft end facing up.
4. Remove the flange (2) and dowel pins (4) from the pump
housing (1).
5. Clean up any oil left on the work surface after removing the
flange (2).
6. Carefully remove and discard the anti-extrusion ring (5) then
G6.2 the seal (6) from the flange (2).
WARNING
Safety glasses must be worn when removing the retaining ring
(7).
7. Place the flange (2) down on the work surface with a shop
towel beneath the flange. Remove the retaining ring (7) and
shaft seal (8) from the flange (2).
8. Remove the cover (9) and dowel pins (10) from the pump
housing (1).
9. Clean up any oil left on the work surface after removing the
cover (9).
10. Carefully remove and discard the anti-extrusion ring (5) then
the seal (6) from the cover (9). Figure 1-1
11. Carefully remove and discard the O-ring seal (11) from both
ends of the pump housing (1).
SEAL KIT
September 2002
INSPECTION
1. Carefully clean and dry all machined surfaces thoroughly.
2. Inspect all machined surfaces for burrs and sharp edges.
Remove burrs and sharp edges as required.
ASSEMBLY
1. Lightly lubricate the new O-ring seals (11) and seals (6) with
petroleum jelly.
2. Install the new O-ring seals (11) on both ends of the pump
housing (1), refer to Figure 1-1.
3. Install a new seal (6) in the cover (9).
4. Secure the seal (6) in the cover (9) by installing a new anti-
extrusion ring (5) to the outside diameter of the seal (6).
5. Install the dowel pins (10) and cover (9) onto the pump
housing (1).
G6.3 WARNING
Safety glasses must be worn when installing the retaining ring
(7).
6. Press a new shaft seal (8) into the flange (2) and secure
shaft seal (8) with the retaining ring (7).
7. Install a new seal (6) in the flange (2).
8. Secure the seal (6) in the flange (2) by installing a new anti-
extrusion ring (5) to the outside diameter of the seal (6).
9. Install the dowel pins (4) in the pump housing (1).
Figure 1-1
SEAL KIT
September 2002
CAUTION:
Be careful not to damage the shaft seal (8) on the splined shaft
when installing the flange (2).
10. Carefully install the flange (2) over the shaft and down onto
the pump housing (1), refer to Figure 1-1.
11. Place the pump in a vise from the flange side. Be careful not
to damage the pump housing (1) or flange (2).
12. Install the screws (3) to secure the cover (9) and the pump
housing (1) to the flange (2).
13. Torque the screws (3) to 50 to 55 N·m (36.9 to 40.5 lb-ft),
refer to the torque pattern in Figure 1-1.
G6.4
Figure 1-1
SEAL KIT
September 2002
SD-100/105 TF SERIES STEERING VALVE
TABLE OF CONTENTS ............................................ G7.1
STEERING VALVE ................................................... G7.2

Disassembly ........................................................ G7.2
Inspection ............................................................ G7.4
Assembly ............................................................. G7.4
Steering Valve

G7.1
authorized
rebuilt
components
TABLE OF CONTENTS
September 2002
NOTICE:
warranty.
DISASSEMBLY
1. Clean the exterior of the steering valve thoroughly.
2. Fasten the edges of the port face sides in a vise. Use
protective material on the vise jaws to prevent damage to the
housing (10), refer to Figure 1-1.
3. Loosen and remove the screws (1), special screw (2) and
washers (3) from the housing (10).
4. Remove the end cap (4).
5. Carefully remove the gerotor assembly (5) from the spacer
plate (6).
6. Remove and discard the seals (7) from the gerotor assembly
G7.2 (5).
7. Remove the spacer plate (6) and the drive (9), from the
housing (10).
8. Remove and discard the seal (11) from the housing (10).
9. Remove the housing (10) from the vise.
10. Remove the check valve (8) from the housing (10).
11. Remove the threaded bushing (12) over the ball (13) from
the housing (10).
12. Carefully remove the ball (13) from the valve port by tipping
the housing (10).
Figure 1-1
STEERING VALVE
September 2002
14. Press the spool (14) inward and the sleeve (15), bearing
races (16 and 17), needle bearing (18), and ring (19) will be
pushed out of the housing (10) together. Take care to keep
the pin (20) in the sleeve (15) and spool (14) horizontal, refer
to Figure 1-1.
15. Remove the ring (19), bearing races (16 and 17), and the
needle thrust bearing (18) from the spool (14) and sleeve
(15) assembly.
NOTE:
The outer bearing race (16) can sometimes “stick” in the housing
(10), therefore check that the outer bearing race (16) has come
out.
16. Push the pin (20) from the spool (14) and sleeve (15)
assembly.
17. Carefully press the spool (14) out from the control end of the
sleeve (15), then carefully remove the centering springs (21)
G7.3 from the spool (14) using only your hands.
18. Remove the dust seal (22) and the O-ring (23) from the
housing (10). Be careful not to damage the housing (10).
19. Remove the pressure relief valve assembly from the housing
(10).
NOTE:
The pressure relief valve assembly consists of a plug (25), seal
washer (26), set screw (27), spring (28), and a piston (29).
20. Loosen and remove the plug (25) and seal washer (26) from
the housing (10).
21. Remove the set screw (27) from the pressure relief valve
port.
22. Shake out the spring (28) and piston (29) from the housing
(10). Figure 1-1
STEERING VALVE
September 2002
INSPECTION
1. Inspect all mating surfaces for burrs and sharp edges.
Replace parts as required. Do not use grit paper or file or
grind these parts.
2. Clean all metal parts in a cleaning solvent. Blow dry all metal
parts. Do not wipe dry with cloth or paper towel.
ASSEMBLY
1. Install the two flat centering springs (21) in the centering
springs slots of the spool (14), refer to Figure 1-1.
2. Place the curved centering springs (21) between the flat
centering springs (21) that are already installed in the spool
(14).
3. Align the centering springs (21) within the spring slots of the
spool (14).
4. Install the spool (14) and sleeve (15) carefully so that the
G7.4 spring slots line up at the same end. Make sure the three
slots in the end of the spool (14) align with the three holes in
the sleeve (15) opposite to the end with the centering springs
slots.
5. Press the centering springs (21) together and push the
centering springs (21) into place in the sleeve (15).
6. Align the centering springs (21) and center them in the spool
(14) and sleeve (15) assembly.
7. Install the ring (19) over the spool (14) and on the sleeve
(15). Make sure the ring (19) can rotate smoothly over the
centering springs (21).
8. Insert the pin (20) through the spool (14) and sleeve (15)
assembly until the pin is flush on both sides of the sleeve
(15).
Figure 1-1
STEERING VALVE
September 2002
NOTE:
The inside chamfer on the inner bearing race (17) must face the
splined end of the spool (14).
9. Install the inner bearing race (17), needle bearing (18), and
the outer bearing race (16) on the splined end of the spool
10. Place the housing (10) on the work surface with the bore in a
horizontal position. Guide the outer part of the assembly tool
into the bore for the spool (14) and sleeve (15) assembly.
11. Lightly lubricate the new O-ring (23) with clean hydraulic oil
and place the O-ring (23) on the inner part of the assembly
tool.
12. Hold the outer part of the assembly tool in the bottom of the
housing (10) and guide the inner part of the assembly tool
into the bottom of the housing (10).
13. Press and turn the O-ring (23) into position in the housing
G7.5 (10).
14. Remove the inner and outer parts of the assembly tool out of
the housing (10) bore, leaving the guide from the inner part
in the bore.
15. Install the spool (14) and sleeve (15) assembly splined end
in the gerotor end of the housing (10). Make sure the parts
do not tilt out of position.
16. Push the spool (14) and sleeve (15) assembly gently into
place with slight rotating action, keeping the pin (20) nearly
horizontal.
17. The spool (14) and sleeve (15) assembly will push out the
assembly tool guide. The O-ring (23) is now in position.
18. Test for free rotation by turning the spool (14) and sleeve
(15) assembly with fingertip force at the splined end. Figure 1-1
STEERING VALVE
September 2002
19. Place the housing (10) on a clean, lint free cloth with the
bore in a vertical position.
20. Install the check valve (8) in the housing (10), refer to Figure
1-1.
21. Install the check ball (13) in the check valve port of the
housing (10).
22. Install the threaded bushing (12) in the check valve port of
the housing (10). The top of the threaded bushing (12) must
lie just below the surface of the housing (10).
23. Lightly lubricate the new seal (11) with clean hydraulic oil
and install the seal (11) in the housing (10).
24. Align the bolt holes in the spacer plate (6) with the bolt holes
in the housing (10) and install the spacer plate (6) on the
housing (10).
25. Install the drive (9), making sure the drive (9) is engaged with
the pin (20). Use the mounting fork tool to hold the drive (9)
G7.6 in position.
26. Lightly lubricate the seals (7) with clean hydraulic oil and
install the seals (7) on both sides of the gerotor assembly (5).
NOTE:
The gerotor assembly (5) and the drive (9) must fit together so
that a tooth base in the gerotor assembly (5) is positioned in
relation to the slot of the drive (9), refer to Figure 1-5.
27. Align the splines of the gerotor assembly (5) with those of
the drive (9) and install the gerotor assembly (5) on the
spacer plate (6).
28. Align the bolt holes in the gerotor assembly (5) with the bolt
holes in the spacer plate (6) without disengaging the gerotor
assembly (5) from the drive (9).
Figure 1-1
STEERING VALVE
September 2002
29. Install end cap (4) on the gerotor assembly (5), aligning the
bolt holes.
30. Remove the mounting fork tool from the drive (9).
31. Install the special screw (2) and washer (3) in the check
valve port bolt hole in the end cap (3).
32. Install the screws (1) and washers (3) in the end cap (4).
33. Cross tighten the screws (1) and special screw (2) and
torque the screws (1) and special screw (2) to 30 ± 6 N·m (22
± 4.4 lb-ft).
34. Install the pressure relief valve assembly in the housing (10).
NOTE:
The pressure relief valve assembly consists of a plug (25), seal
washer (26), set screw (27), spring (28), and a piston (29).
35. Install the piston (29) and spring (28) into the pressure relief
valve port.
G7.7 36. Install the set screw (27) in the pressure relief valve port and
adjust the set screw (27) to 95 to 100 bar (1380 to 1450 psi).
37. Install the seal washer (26) and plug (25) into the pressure
relief valve port.
38. Torque the plug (25) to 50 ± 10 N·m (36 ± 7 lb-ft).
39. Press the dust seal (22) into housing (10).
Figure 1-1
STEERING VALVE
September 2002
SD-100/105 TF SERIES STEERING CYLINDER
(S/Ns 169494, 169572)
TABLE OF CONTENTS............................................ G8.1
SEAL KIT .................................................................. G8.2

Disassembly ....................................................... .G8.2
Inspection ............................................................ G8.3
Steering Cylinders
Assembly............................................................. G8.4

G8.1
authorized
rebuilt
components
TABLE OF CONTENTS
September 2002
NOTICE: (S/Ns 169494, 169572)
warranty.
DISASSEMBLY
1. Clean the outside of the cylinder. If the hoses were removed
with the cylinder, remove the hoses from the cylinder.
2. Fasten the tube (1) in an acceptable repair stand or other
holding equipment, refer to Figure 1-1. Be careful not to
damage the tube (1).
3. Extend the piston rod (2) until the piston (3) bottoms out on
the head (4).
4. Loosen and remove the set screw (5) and nylon plug (16)
from the headcap (6).
5. Insert a spanner wrench into the holes provided. Remove the
G8.2 headcap (6) from the tube (1) by turning the headcap (6)
counterclockwise. If the headcap (6) is sruck or moves
erratically, tap the headcap (6) with a brass or plastic mallet
while turning it.
6. Wrap the headcap (6) with a soft cloth to prevent the inside
diameter of the headcap (6) from touching the piston rod (2).
7. Gently tap the piston (3) against the head (4) to drive the
piston rod (2) assembly from the tube (1).
8. Place the piston rod (2) assembly on a suitable work surface
that will not damage the piston rod (2).
Figure 1-1
SEAL KIT
September 2002
9. Loosen and remove the locknut (7) from the piston rod (2), (S/Ns 169494, 169572)
10. Remove the piston (3), head (4), and headcap (6) from the
piston rod (2).
11. Remove and discard the O-ring (8) from the piston rod (2).
12. Remove and discard the wiper (9), lip seal (10), and wear
rings (11) from the inside diameter of the head (4).
13. Remove and discard the O-ring (12) and backup ring (13)
from the outside diameter of the head (4).
14. Remove and discard the wear ring (14) and glyd-ring (15)
from the piston (3).
INSPECTION
1. Clean all parts in cleaning solvent. Use only lint free cloths
for cleaning and drying.
2. If the piston rod (2), piston (3), head (4), or the tube (1) are
G8.3 damaged in any way, a new cylinder assembly must be
used.
Figure 1-1
SEAL KIT
September 2002
ASSEMBLY (S/Ns 169494, 169572)
1. Install a new lip seal (10) in the middle groove in the inside
diameter of the head (4), refer to Figure 1-1.
2. Install a new wiper (9) in the front groove in the inside
diameter of the head (4).
3. Install new wear rings (11) in the back groove in the inside
diameter of the head (4).
4. Install a new backup ring (13) in the groove on the outside
diameter of the head (4) closest to the headcap (6).
5. Install a new O-ring (12) in the groove on the outside
diameter of the head (4) next to the backup ring (13).
6. Install a new glyd-ring (15) and wear ring (14) in the grooves
on the outside diameter of the piston (3).
7. Lubricate the inside and outside diameters of both the piston
(3) and head (4) with clean hydraulic oil.
G8.4 8. Place the piston rod (2) on a clean work surface.
9. Wrap the headcap (6) with a soft cloth to prevent the inside
diameter of the headcap (6) from touching the piston rod (2).
10. Install the headcap (6) onto the piston rod (2).
11. Install the head (4) followed by the piston (3) onto the piston
rod (2) noting the proper orientation of each component.
12. Secure the piston (3) onto the piston rod (2) with the lock nut
(7).
13. Torque the lock nut (7) to 610 to 664 N·m (450 to 490 lb-ft).
Figure 1-1
SEAL KIT
September 2002
14. Install the piston rod (2) assembly into the tube (1) until the (S/Ns 169494, 169572)
headcap (6) engages the threads of the tube (1). Turn the
headcap (6) counterclockwise until the first thread just
passes the engagement point, then turn the headcap (6)
clockwise until it is hand-tight or fully seated. Refer to Figure
1-1.
15. Use a spanner wrench to tighten the headcap (6) 1/8 to 1/4
turn past fully seated.
16. Install the nylon plug (16) and set screw (5) into the headcap
(6).
G8.5
Figure 1-1
SEAL KIT
September 2002
(All Other S/Ns)
TABLE OF CONTENTS............................................ G9.1
SEAL KIT .................................................................. G9.2

Disassembly ....................................................... .G9.2
Inspection ............................................................ G9.3
Steering Cylinders
Assembly............................................................. G9.3

G9.1
authorized
rebuilt
components
TABLE OF CONTENTS
September 2002
NOTICE: (All Other S/Ns)
Ingersoll-Rand service representative concerning warranty
issues.
DISASSEMBLY
1. Clean the outside of the cylinder. If the hoses were removed
with the cylinder, remove the hoses from the cylinder.
2. Fasten the tube (1) in an acceptable repair stand or other
holding equipment. Be careful not to damage the tube (1).
3. Extend the cylinder rod (4) until the piston (3) bottoms out on
the head (2).
4. Gently tap the piston (3) against the head (2) to drive the
cylinder rod (4) from the tube (1).
5. Place the cylinder rod (4) assembly on a suitable work
surface to prevent damage.
G9.2 6. Loosen and remove the locknut (25) from the cylinder rod
(4).
7. Remove the piston (3) and head (2) from the cylinder rod (4).
8. Remove and discard the rod seal (11) and the rod wiper seal
(13) from the inside diameter of the head.
9. Remove and discard the O-ring (10) and backup washer (40)
from the outside diameter of the head (2).
10. Remove and discard the seal (14) and wear ring (15) from
the piston (3).
Figure 1-1
SEAL KIT
September 2002
INSPECTION (All Other S/Ns)
1. Clean all parts in cleaning solvent. Use only lint-free cloths
for cleaning and drying.
2. If the cylinder rod (4), piston (3), head (2), or tube (1) is
damaged in any way, a new cylinder assembly must be
used.
ASSEMBLY
1. Install a new O-ring (11) and a new rod wiper seal (13) in the
inside diameter of the head (2) (refer to Figure 1-1).
2. Install a new backup washer (40) in the groove on the
outside diameter of the head (2).
3. Install a new O-ring (10) in the groove on the outside
diameter of the head (2) next to the backup washer (40).
4. Install a new seal (14) and a new wear ring (15) in the groove
on the outside diameter of the piston (3).
G9.3 5. Lubricate the inside and outside diameters of both the piston
(3) and head (2) with clean hydraulic oil.
6. Place the cylinder rod (4) on a clean work surface.
7. Install the head (2), followed by the piston (3), onto the
cylinder rod (4), noting the proper orientation of each
component.
8. Secure the piston (3) onto the cylinder rod (4) with the
locknut (25).
9. Torque the locknut (25) to 407 N·m (300 lb-ft).
10. Install the cylinder rod (4) in the tube (1) (refer to Figure 1-1).
Figure 1-1
SEAL KIT
September 2002
Table of Contents
Battery....................................H2
Grid Heater Relays
ELECTRICAL
Starter
Alternator
Grid Heaters
H1 Ignition Switch
Fuses
-
Starter Relay
Power Relay
Fuel Solenoid Relay
Batteries
Master Switch BATTERY
EFF. W/ ALL S/N
January 2003
POWER RELAY
87A
ELECTRICAL
30
87
FUEL SOLENOID
86
STARTER RELAY RELAY
87A 87A
85 30 30
87 87
86 86
IGNITION SWITCH 85 85
RD
OFF GRID HEATER
IGNITION
RD
START
RD
RD IGN
RD
F1 GRID HEATER RELAYS

FUSE
15 A
1.0
PR
GRN GRID HEATER
1.0
RD
H2
1.0
2.0
BATTERIES RD
RD
+ RD
5.0 5.0
.8 TO OPTIONAL FRONT LIGHT RELAY

RD
.8 TO OPTIONAL REAR
RD
CAP LIGHT RELAY.
B+ W
STATOR
STARTER SOLENOID
OOO
OO
OOOOOO
STARTER OOOOOOO
Regulator
MASTER SWITCH MOTOR O
OOO
O
(OPTIONAL)
D+
FUSE LINK
ALTERNATOR
BATTERY
January 2003
Table of Contents
Ignition ......................................H4
Air Filter Restriction Switch Backup Alarm Switch

Throttle Solenoid (Behind Hood) Seat Timer
Park Brake Emergency Diode
ELECTRICAL
Test Switch Stop Switch (In Harness)
Power
1225
20. 4
1425
23. 8
1250
1350
22. 5
20. 8
1625
27. 1
1450
24. 2
1550
25. 8
1650
2750
1825
30. 4
2025
33. 8
Port Backup Alarm
VPM
HZ
Throttle Fuses
Switch
Park Brake Power Relay
Switch
H3 Hi/Low Speed
Switch Seat Timer
Ignition Throttle Solenoid Timer

Switch
Seat Switch
(Under Seat)
Horn
Park Brake Pressure Switch
Vibration Speed Sensor
Hydraulic Oil Temperature Switch

IGNITION
Rear Speed Sensor
EFF. W/ ALL S/N
January 2003
SD-100/105
SD-100/105 TF
TF SERIES
SERIES
34 - BN
HORN TO HORN SWITCH
RD/BE CLOSES AT 180 F
ELECTRICAL
ELECTRICAL
11 - GY/OE
FUSES
1
TO INSTRUMENT CLUSTER F12 15A SPARE
SEE GAUGES 10 - BK/OE
F11 10A TO CAB OPTIONS HYDRAULIC OIL HIGH 2
F9 10A TEMP. SWITCH

36 - LGN AIR FILTER BACK UP ALARM
F10 10A TO I TERM. ON GAUGES
11 - GY/OE 11 - GY/OE
RESTRICTION SWITCH
F2 10A
12 - LGN/WE 12 - LGN/WE
F3 10A
A B
F4 15A 13 - DBE/YW TO LIGHT OPTIONS BACK UP ALARM
F5 5A SWITCH
POWER RELAY 16 - DBE/RD
F6 5A 17 - GY/GN
TO ANTI SPIN CONTROL OPTION HIGH / LOW SPEED
87A 12 - LGN/WE
30 F7 10A SWITCH
87 10 - RD/WE 18 - RD/BK HIGH
3
86 F8 30A BK 2
1
POWER PORT LOW
32 - WE
85 6 - LBE
PARK BRAKE
SWITCH
VIBRATION SPEED SENSOR
27 - DPE/WE 7 9 ON 21 - BN/BK
IGNITION SWITCH
H4
3 WE
6 - LBE 1A 2A 2 P B SGL
1 16 - DBE/RD RD
A
BK
OFF 1B 2B 5
6 PARK BRAKE C
4
IGNITION OFF PRESSURE SWITCH
START
EMERGENCY STOP
IGN 27 - DPE/WE
REAR SPEED SENSOR
6 - LBE 23 - RD/DGN WE SGL
THROTTLE SWITCH 16 - DBE/RD B
RD
A
3 HIGH
BRAKE TEST SWITCH C
BK
2
1
7 - OE/GN 27 - DPE/WE 2 3 TEST
6 1
5
PR 4 LOW 16 - DBE/RD
6 TO AUTO / MANUAL VIBRATION
GRN
5 4 SELECT SWITCH OPTION
27 - DPE/WE DRIVE 27 - DPE/WE
3 - OE/RD 25 - RD/BK
+ N/C
F1 15A COM TO FUEL SOLENOID
A
B N/O
27 - DPE/WE A B 22 - GY/RD C 29 - LGN/BK INIT
THROTTLE SOLENOID SEAT SWITCH SEAT TIMER SEAT TIMER

TIMER DIODE
HOLD
IGNITION
January 2003
Table of Contents
Start ...........................................H6
Air Filter Restriction Neutral Start Switch Diode
ELECTRICAL
(In Harness)
Indicator (On Instrument Cluster)
Grid Heater Fuel Solenoid
Control Module Air Filter
Restriction Switch
Emergency
Stop Switch Starter Solenoid
162 5
27. 1
145 0
142 5 182 5
23. 8 24. 2 30. 4
135 0
155 0
22. 5 25. 8
122 5 125 0 165 0 202 5

20. 4 20. 8 275 0 33. 8
VPM
HZ
H5
Throttle Switch
Park Brake Switch
Fuses
Neutral
Start
Hydraulic Oil Switch
Temperature
Indicator Ignition
Switch
Power Relay
Starter Relay
Fuel Solenoid Relay START
EFF. W/ ALL S/N
January 2003
34 - BN SD-100/105 TF SERIES
FUSES ELECTRICAL
TO INSTRUMENT CLUSTER HOLD
F12 15A RD
SEE GAUGES A
F11 10A
HYD. OIL TEMP. BK
C
BK FUEL SOLENOID
WE
B
F9 10A
PULL
F10 1/A TO AUDIBLE ALARM GRID HEATER CONTROL
71 - PK
OPTION CIRCUIT MODULE
F2 10A
AIR FILTER
F3 10A RESTRICTION
F4 15A
F5 5A
POWER RELAY A BE IGN
26 - OE/WE
F6 5A 59 - BK/RD RD LIGHT OUT
87A B
30 F7 10A C OE GRID RELAY OUT
30 - LGN/BE
87 10 - RD/WE D PE GRID RELAY OUT
E GN START IN
86 F8 30A TO AUDIBLE ALARM
71 - PK BN N/A
F
CIRCUIT TO EITHER
85
OPTION CIRCUIT
6 - LBE
AIR FILTER RESTRICTION
SWITCH PARK BRAKE
SWITCH
IGNITION SWITCH 6 - LBE 2A
7 9 ON FUEL SOLENOID RELAY
1A 3
2
1
H6
26 - OE/WE 85
OFF 1B 2B 9 - YW/BE
6
5
IGNITION 8 - DGN/OE 4
OFF
START 86
EMERGENCY STOP
87
IGN
30
6 - LBE 87A
STARTER RELAY 26 - OE/WE
HIGH
3 87A 28 - GY/BK
2 30
1
7 - OE/GN 87
6 C
5 86 28 - GY/BK B 62 - WE/BE
PR 4 LOW
A
GRN
NEUTRAL SWITCH
THROTTLE SWITCH 85
DIODE
3 - OE/RD
2 - DBE
F1 15A
BK B A
NEUTRAL START
SWITCH
STARTER SOLENOID
START
January 2003
Table of Contents
Brake/Shutdown -
Brakes Applied ................ H8
Brake Test Switch Emergency Stop Switch

Neutral Start
ELECTRICAL
Switch Diode
(In Harness)
14 25
23 8
.
13 50
16 25
27 1
.
14 50
24 2
.
15 50
18 25
30 4
.
Brake Test Diode
(In Harness)
22 5
. 25 8
.
12 25 20 25
12 50 16 50
20 4
. 20 8
. 27 50 33 8
.
VPM
HZ
Seat Switch
Park Brake Switch
(Under Seat)
H7
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

BRAKES APPLIED EFF. W/ ALL S/N
January 2003
ELECTRICAL
21 - BN/BK
PARK BRAKE
BRAKE LATCHING
PRESSURE SWITCH BRAKE TEST SWITCH RELAY
TEST
19 - LGN/YW 19 - LGN/YW 85
27 - DPE/WE 2 3
PARK BRAKE 1
BRAKE TEST DIODE BK 86
SWITCH 6
87
5 4 81 - YW/RD A B
7 9 ON 49 - PK/WE 30
3 87A
1A 2A 2 DRIVE
1
20 - LGN/YW
1B 2B 6 20 - YW/BK
5
4
OFF 20- YW/RD
BRAKE RELEASE PUMP RETURN TO
EMERGENCY STOP BRAKES APPLIED
SOLENOID NEUTRAL SOLENOID
A A 20 - YW/BK
H8
23 - RD/DGN
27 - DPE/WE
B B
NEUTRAL SWITCH
20 - YW/BK DIODE
20 - YW/BK C
B
A
27 - DPE/WE 27 - DPE/WE
+ N/C
COM 62 - WE/BE
A
B N/O TO FUEL SOLENOID
27 - DPE/WE A B 22 - GY/RD C 29 - LGN/BK INIT RUN CONDITION
SEAT SWITCH SEAT TIMER BK B A
OPERATOR OUT OF SEAT DIODE SEAT TIMER
NEUTRAL START
SWITCH
BRAKE / SHUTDOWN
BRAKES APPLIED
January 2003
Table of Contents
Brake/Shutdown -
Brakes Released ........... H10

Neutral Start
ELECTRICAL
Switch Diode
(In Harness)
14 25
23 8
.
13 50
16 25
27 1
.
14 50
24 2
.
15 50
18 25
30 4
.
Brake Test Diode
(In Harness)
22 5
. 25 8
.
12 25 20 25
12 50 16 50
20 4
. 20 8
. 27 50 33 8
.
VPM
HZ
Seat Switch
Park Brake Switch
(Under Seat)
H9
Seat Timer
Diode (In
Harness)
Fuses
Seat Timer
Pump Return To
Normal Solenoid

BRAKES RELEASED EFF. W/ ALL S/N
January 2003
ELECTRICAL
21 - BN/BK
PARK BRAKE BRAKE LATCHING

PRESSURE SWITCH BRAKE TEST SWITCH
RELAY
TEST
19 - LGN/YW 19 - LGN/YW 85
27 - DPE/WE 2 3
1
PARK BRAKE BRAKE TEST DIODE BK 86
SWITCH 6
87
5 4 81 - YW/RD A B
7 9 ON 49 - PK/WE 30
3 87A
1A 2A 2 DRIVE
1
20 - LGN/YW
1B 2B 6 20 - YW/BK
5
4
OFF 20- YW/RD
EMERGENCY STOP BRAKES RELEASED
SOLENOID NEUTRAL SOLENOID
A A 20 - YW/BK
23 - RD/DGN
27 - DPE/WE
H10 B B
NEUTRAL SWITCH
DIODE
20 - YW/BK
20 - YW/BK C
B
A
+ N/C
COM 62 - WE/BE
A
RUN CONDITION
OPERATOR IN SEAT DIODE SEAT TIMER
NEUTRAL START
SWITCH
BRAKE / SHUTDOWN
BRAKES RELEASED
January 2003
Table of Contents
Brake/Shutdown -
Brakes Released/
Operator Out of Seat.... H12
ELECTRICAL
Neutral Start
Switch Diode
(In Harness)
14 25
23 8
.
13 50
16 25
27 1
.
14 50
24 2
.
15 50
18 25
30 4
.
Brake Test Diode
(In Harness)
22 5
. 25 8
.
12 25 20 25
12 50 16 50
20 4
. 20 8
. 27 50 33 8
.
VPM
HZ
H11 Park Brake Switch

Seat Switch
(Under Seat)
Seat Timer
Diode (In
Harness)
Fuses
Seat Timer
Pump Return To
Normal Solenoid

BRAKES RELEASED
OPERATOR OUT OF SEAT EFF. W/ ALL S/N
January 2003
ELECTRICAL
21 - BN/BK
PARK BRAKE
PRESSURE SWITCH BRAKE LATCHING
BRAKE TEST SWITCH RELAY
TEST
19 - LGN/YW 19 - LGN/YW 85
27 - DPE/WE 2 3
1
PARK BRAKE BRAKE TEST DIODE BK 86
SWITCH 5
6
87
7 9 ON 4 81 - YW/RD A B
49 - PK/WE 30
3 87A
1A 2A 2 DRIVE
1
20 - LGN/YW
1B 2B 6 20 - YW/BK
5
4
OFF 20- YW/RD
EMERGENCY STOP BRAKES RELEASED SOLENOID NEUTRAL SOLENOID
A A 20 - YW/BK
23 - RD/DGN
H12 27 - DPE/WE
B B
NEUTRAL SWITCH
20 - YW/BK DIODE
20 - YW/BK C
B
A
+ N/C
COM 62 - WE/BE
A
SHUTDOWN CONDITION
OPERATOR OUT OF SEAT DIODE SEAT TIMER
NEUTRAL START
SWITCH
BRAKE / SHUTDOWN
BRAKES RELEASED/
OPERATOR OUT OF SEAT
January 2003
Table of Contents
Brake/Shutdown -
Brake Test/
Operator In Seat ........... H14
ELECTRICAL
Neutral Start
Switch Diode
(In Harness)
14 25
23 8
.
13 50
16 25
27 1
.
14 50
24 2
.
15 50
18 25
30 4
.
Brake Test Diode
(In Harness)
22 5
. 25 8
.
12 25 20 25
12 50 16 50
20 4
. 20 8
. 27 50 33 8
.
VPM
HZ
H13
Seat Switch
Park Brake Switch
(Under Seat)
Seat Timer
Diode (In
Harness)
Fuses
Seat Timer
Pump Return To
Normal Solenoid

BRAKE TEST
OPERATOR IN SEAT EFF. W/ ALL S/N
January 2003
ELECTRICAL
21 - BN/BK
PARK BRAKE BRAKE LATCHING

PRESSURE SWITCH BRAKE TEST SWITCH RELAY
TEST
19 - LGN/YW 19 - LGN/YW 85
27 - DPE/WE 2 3
PARK BRAKE 1
BRAKE TEST DIODE BK 86
SWITCH 6
87
5 4 81 - YW/RD A B
7 9 ON 49 - PK/WE 30
3 87A
1A 2A 2 DRIVE
1
20 - LGN/YW
1B 2B 6 20 - YW/BK
5
4
OFF 20- YW/RD
BRAKE RELEASE
PUMP RETURN TO
EMERGENCY STOP BRAKES APPLIED SOLENOID NEUTRAL SOLENOID
A A 20 - YW/BK
H14
23 - RD/DGN
27 - DPE/WE
B B
NEUTRAL SWITCH
20 - YW/BK DIODE
20 - YW/BK C
B
A
+ N/C
COM 62 - WE/BE
A
RUN CONDITION
OPERATOR IN SEAT DIODE SEAT TIMER
NEUTRAL START
SWITCH
BRAKE / SHUTDOWN
BRAKES TEST/
OPERATOR IN SEAT
January 2003
Table of Contents
Anti-Spin Control -
No Travel ...................... H16
ELECTRICAL
Speedometer
1625
27.1
1450
1425 1825
23.8 24.2 30.4
1350
1550
25.8
22.5
1225 2025
1250 1650
20.4 20.8 2750 33.8
VPM
HZ
Hi/Low Speed Switch Fuses
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
January 2003
SPEEDOMETER
ELECTRICAL
CONNECTOR AT ANTI SPIN MODULE
GY / GN
A1
S A2
I BK
G A3
RD / WE
B1
LBE / BL
B2
B3
LGN
C1 RD / WE
BK / WE LBE / BK
C2
C3
REAR SPEED SENSOR D1
D2 FRONT ASC SOLENOID
WE SGL LBE
B D3
DBE / RD RD BK / WE
A E1
BK BK
C
E2
E3
WE
FUSES HARNESS 4 PIN F1
CONNECTIONS XB F2
F12 15A F3
REFERENCE TO CONNECTOR PIN XC
F11 10A
REAR ASC SOLENOID
F9 10A
GY / GN
X
GY / GN
X ANTI - SPIN
F10 1/A A A1 CONTROL MODULE
F2 10A
IGN LBE / BK
F3 10A
H16
BK / WE SENSOR POWER
B1
F4 15A ANALOG IN 0 VALVE 0 X
ANALOG IN 1 VALVE 1 X
F5 5A D3
HIGH / LOW SPEED X ANALOG IN 2 DIGITAL OUTPUT B2
ANALOG IN 3 HARNESS 4 PIN CONNECTION
F6 5A
SWITCH X
CAN LOW
E1
F7 10A HIGH
3 CAN HIGH
D WE
PK / RD DIGITAL 0 / BOOT
LGN / WE 2 X X C1
1 TxD LGN
F8 30A LOW F1 DIGITAL 1 X
DIGITAL 2 RxD
GND X
HARNESS 4 PIN CONNECTION PK/RD C2 DBE / BK
MAINTENANCE JUMPER A3 X
6200 BK
C
X
GY / GN
LBE
DRUM SPEED SENSOR 2000
SGL BK B B
+ BN A A HARNESS 4 PIN CONNECTIONS
- BE C C
BK
X C
ANTI-SPIN CONTROL
NO TRAVEL
January 2003
Table of Contents
Anti-Spin Control -
Travel............................. H18
ELECTRICAL
Speedometer
1625
27.1
1450
1425 1825
23.8 24.2 30.4
1350
1550
25.8
22.5
1225 2025
1250 1650
20.4 20.8 2750 33.8
VPM
HZ
H17
Rear Anti-Spin
Control Solenoid
Front Anti-Spin
Control Solenoid
Drum Speed Sensor
Rear Speed Sensor

ANTI-SPIN CONTROL
TRAVEL EFF. W/ ALL S/N
January 2003
SPEEDOMETER
CONNECTOR AT ANTI SPIN MODULE
ELECTRICAL
GY / GN
A1
A2
S I BK
G A3
RD / WE
B1
LBE / BL
B2
B3
LGN
C1 RD / WE
BK / WE LBE / BK
C2
C3
WE SGL
D2
LBE FRONT ASC SOLENOID
B D3
DBE / RD RD BK / WE
A E1
BK BK
C E2
E3
WE
FUSES HARNESS 4 PIN
F1
F2
CONNECTIONS XB
F3
F12 15A
F11 10A
REAR ASC SOLENOID
F9 10A
GY / GN
X
GY / GN
X
ANTI - SPIN
H18 F2 10A
F3 10A SENSOR POWER

IGN LBE / BK
BK / WE B1
D3
F5 5A HIGH / LOW SPEED X ANALOG IN 2 DIGITAL OUTPUT B2
HARNESS 4 PIN CONNECTION
F6 5A SWITCH X
ANALOG IN 3
E1 CAN LOW
F7 10A HIGH
3 CAN HIGH
PK / RD D WE
2 DIGITAL 0 / BOOT
LGN / WE X X C1
1 TxD LGN
DIGITAL 2 RxD
GND X
HARNESS 4 PIN CONNECTION PK/RD C2 DBE / BK
A3 X
MAINTENANCE JUMPER
6200 BK
C
X
GY / GN

LBE
SGL BK B B
- BE C C
BK
X C
ANTI-SPIN CONTROL
TRAVEL
January 2003
Table of Contents
Anti-Spin Control -
Drum Spin ..................... H20
ELECTRICAL
Speedometer
1625
27.1
1450
1425 1825
23.8 24.2 30.4
1350
1550
25.8
22.5
1225 2025
1250 1650
20.4 20.8 2750 33.8
VPM
HZ
H19
Rear Anti-Spin
Control Solenoid
Front Anti-Spin
Control Solenoid
Drum Speed Sensor
Rear Speed Sensor

ANTI-SPIN CONTROL
DRUM SPIN EFF. W/ ALL S/N
January 2003
SPEEDOMETER
CONNECTOR AT ANTI SPIN MODULE ELECTRICAL
GY / GN
A1
S I A2
G BK
A3
RD / WE
B1
LBE / BL
B2
B3
LGN RD / WE
BK / WE C1
LBE / BK
C2
C3
D2 FRONT ASC SOLENOID
WE SGL LBE
DBE / RD B D3
A RD
BK / WE
BK E1 BK
C
E2
E3
WE
HARNESS 4 PIN
FUSES CONNECTIONS
F1
XB F2
F12 15A F3
F11 10A
REAR ASC SOLENOID
F9 10A
GY / GN
X
GY / GN
X ANTI - SPIN
F2 10A
H20 F3 10A
BK / WE SENSOR POWER
IGN
B1
LBE / BK

F5 5A D3
F6 5A ANALOG IN 3 HARNESS 4 PIN CONNECTION
SWITCH X
E1 CAN LOW
F7 10A HIGH
3 CAN HIGH
PK / RD D WE
2 X X DIGITAL 0 / BOOT
LGN / WE 1 C1
F8 30A LOW F1 DIGITAL 1 TxD LGN
X
DIGITAL 2 RxD X
HARNESS 4 PIN CONNECTION PK/RD
GND
C2 DBE / BK
MAINTENANCE JUMPER A3 X
6200 BK
C
X
GY / GN
LBE
SGL BK B B
+ BN A A
- BE C C
HARNESS 4 PIN CONNECTIONS
BK
X C
ANTI-SPIN CONTROL
DRUM SPIN
January 2003
Table of Contents
Anti-Spin Control -
Wheel Spin ................... H22
ELECTRICAL
Speedometer
1625
27.1
1450
1425 1825
23.8 24.2 30.4
1350
1550
25.8
22.5
1225 2025
1250 1650
20.4 20.8 2750 33.8
VPM
HZ
H21
Rear Anti-Spin
Control Solenoid
Front Anti-Spin
Control Solenoid
Drum Speed Sensor
Rear Speed Sensor

ANTI-SPIN CONTROL
WHEEL SPIN EFF. W/ ALL S/N
January 2003
SPEEDOMETER
CONNECTOR AT ANTI SPIN MODULE ELECTRICAL
GY / GN
A1
S I A2
G BK
A3
RD / WE
B1
LBE / BL
B2
B3
LGN RD / WE
C1
BK / WE LBE / BK
C2
C3
WE SGL
D2
LBE
FRONT ASC SOLENOID
DBE / RD B D3
A RD BK / WE
BK E1 BK
C
E2
E3
WE
FUSES HARNESS 4 PIN F1
CONNECTIONS XB F2
F12 15A F3
F11 10A
REAR ASC SOLENOID
F9 10A
GY / GN
X
GY / GN
X
ANTI - SPIN
H22
F2 10A
IGN LBE / BK
F3 10A SENSOR POWER
BK / WE B1
F5 5A D3
F6 5A SWITCH X ANALOG IN 3 HARNESS 4 PIN CONNECTION
E1 CAN LOW
F7 10A HIGH
3 CAN HIGH
D WE
PK / RD DIGITAL 0 / BOOT
LGN / WE 2 X X C1
1 TxD LGN
DIGITAL 2 RxD
X
HARNESS 4 PIN CONNECTION PK/RD
GND
C2 DBE / BK
A3 X
MAINTENANCE JUMPER
6200 BK
C
X
GY / GN
LBE
SGL BK B B
- BE C C
BK
X C
ANTI-SPIN CONTROL
WHEEL SPIN
January 2003
Table of Contents
High/Low Speed -
Low Speed/
Anti-Spin Activated ...... H24
ELECTRICAL
16 25
27 1
.
14 50
14 25 18 25
23 8
. 24 2
. 30 4
.
13 50 15 50
22 5
. 25 8
.
12 25 12 50 16 50 20 25
20 4
. 20 .8 27 50 33 8
.
VPM
HZ
Hi/Low Speed Switch

H23
High Speed Drum

Motor Solenoid
High Speed Axle

Motor Solenoid
HIGH/LOW SPEED
LOW SPEED/ANTI-SPIN
ACTIVATED EFF. W/ ALL S/N
January 2003
ELECTRICAL
HIGH SPEED AXLE MOTOR SOLENOID
( ON SD-120 ONLY )
31 - BK/OE A
HIGH LOW SPEED SWITCH BK
HIGH
31 - BK/OE
F3 10A
12 - LGN/WE
H24 LOW
31 - BK/OE
79 - PK/RD
BK B
TO ANTI SPIN CONTROL MODULE
HIGH SPEED DRUM MOTOR SOLENOID
HIGH / LOW SPEED

LOW SPEED/ANTI-SPIN ACTIVATED
January 2003
Table of Contents
High/Low Speed -
High Speed/
Anti-Spin Inactive......... H26
ELECTRICAL
16 25
27 1
.
14 50
14 25 18 25
23 8
. 24 2
. 30 4
.
13 50 15 50
22 5
. 25 8
.
12 25 12 50 16 50 20 25
20 4
. 20 .8 27 50 33 8
.
VPM
HZ
Hi/Low Speed Switch

H25
High Speed Drum

Motor Solenoid
High Speed Axle

Motor Solenoid
HIGH/LOW SPEED
HIGH SPEED/ANTI-SPIN
INACTIVE EFF. W/ ALL S/N
January 2003
ELECTRICAL
HIGH SPEED AXLE MOTOR SOLENOID
( ON SD-120 ONLY )
31 - BK/OE A
HIGH LOW SPEED SWITCH BK
HIGH
31 - BK/OE
F3 10A
12 - LGN/WE
H26 LOW
31 - BK/OE
79 - PK/RD
BK B
TO ANTI SPIN CONTROL MODULE
HIGH SPEED DRUM MOTOR SOLENOID
HIGH / LOW SPEED

HIGH SPEED/ANTI-SPIN INACTIVE
January 2003
Table of Contents
Automatic Vibration/Impact Meter
Vibration Off ................. H28
Impact Meter Vibration On/Off Switch
ELECTRICAL
VPM Meter
Speedometer
1625
27.1
1425 1450 1825

23.8 24.2 30.4
1350 1550
25.8
22.5
1225 1250 1650 2025

20.4 20.8 2750 33.8
VPM
HZ
Automatic/Manual
Fuses
Vibration Switch
High/Low Amplitude Low Vibration

H27 Switch Solenoid
High Vibration
Solenoid
Automatic Vibration
& Impact Meter
Control Module
Rear Speed Sensor
AUTOMATIC VIBRATION/
IMPACT METER
VIBRATION OFF EFF. W/ ALL S/N
January 2003
ELECTRICAL
AUTO/MANUAL VIBRATION VIBRATION
HIGH / LOW AMPLITUDE HIGH VIBRATION
SELECT SWITCH ON/OFF
SWITCH SOLENOID
AUTO.
F5 5A 1 HIGH 89- YW / WE
39- LPE 40-YW / BN 3 1
16- DBE / RD 2
2 2
3 1
LOW 3
MANUAL
BK 4
38- WE / OE
1
55- DBE / BK
2
SPEEDOMETER VPM METER IMPACT METER 16- DBE / RD 3
BK 4
LOW VIBRATION
S I S I S I
ZENER DIODE
500 OHM
SOLENOID
G G G Zd1
5.1 V
F10 1/A
5 WATT
36- LGN
RESISTOR
H28 43- LBE / RD

500 OHM
3 WATT
YW
IGN
SENSOR POWER
44 - DGN/YW
ANALOG IN 0 VALVE 0
ANALOG IN 1 VALVE 1
ANALOG IN 2 DIGITAL OUTPUT
WE
B SGL ANALOG IN 3
RD
45- BK / WE A
BK CAN LOW
C
CAN HIGH
BK DIGITAL 0 / BOOT
VIBRATION SPEED TxD 67- LGN
DIGITAL 1
SENSOR DIGITAL 2 RxD
GND
68- DBE / BK
45- BK / WE
BK
WE SGL
B
A RD
BK MACHINE NOT IN MOTION AUTO VIBRATION & IMPACT METER
16- DBE / RD C
BK CONTROL MODULE
REAR SPEED SENSOR
AUTOMATIC VIBRATION / IMPACT
METER - VIBRATION OFF
January 2003
Table of Contents
Manual/Low Amplitude..... H30
ELECTRICAL
VPM Meter
Speedometer
1625
27.1
1425 1450 1825

23.8 24.2 30.4
1350 1550
25.8
22.5
1225 1250 1650 2025

20.4 20.8 2750 33.8
VPM
HZ
Automatic/Manual
Fuses
Vibration Switch

H29 Switch Solenoid
High Vibration
Solenoid
Automatic Vibration
& Impact Meter
Control Module
Rear Speed Sensor
IMPACT METER
MANUAL/LOW AMPLITUDE EFF. W/ ALL S/N
January 2003
ELECTRICAL
AUTO/MANUAL VIBRATION VIBRATION HIGH / LOW AMPLITUDE HIGH VIBRATION
SELECT SWITCH ON/OFF SWITCH SOLENOID
AUTO.
39- LPE 40-YW / BN 3 1
16- DBE / RD 2
2 2
3 1
LOW 3
MANUAL
BK 4
38- WE / OE
1
55- DBE / BK
2
16- DBE / RD
SPEEDOMETER VPM METER IMPACT METER BK
3
4
LOW VIBRATION
S I S I S I
ZENER DIODE SOLENOID
500 OHM
G G G Zd1
5.1 V
F10 1/A
5 WATT
36- LGN
RESISTOR
H30
500 OHM
43- LBE / RD 3 WATT
YW
IGN
SENSOR POWER
44 - DGN/YW
ANALOG IN 0 VALVE 0
ANALOG IN 1 VALVE 1
WE
B SGL ANALOG IN 3
RD
45- BK / WE A
BK CAN LOW
C
CAN HIGH
BK
VIBRATION SPEED DIGITAL 0 / BOOT
67- LGN
DIGITAL 1 TxD
GND
68- DBE / BK
45- BK / WE
BK
WE SGL
B
A RD
16- DBE / RD C
BK MACHINE IN MOTION AUTO VIBRATION & IMPACT METER
BK CONTROL MODULE
REAR SPEED SENSOR
METER - MANUAL/LOW AMPLITUDE
January 2003
Table of Contents
Manual/High Amplitude.... H32
ELECTRICAL
VPM Meter
Speedometer
1625
27.1
1425 1450 1825

23.8 24.2 30.4
1350 1550
25.8
22.5
1225 1250 1650 2025

20.4 20.8 2750 33.8
VPM
HZ
Automatic/Manual
Fuses
Vibration Switch

H31 Switch Solenoid
High Vibration
Solenoid
Automatic Vibration
& Impact Meter
Control Module
Rear Speed Sensor
IMPACT METER
MANUAL/HIGH AMPLITUDE EFF. W/ ALL S/N
January 2003
ELECTRICAL
AUTO.
39- LPE 40-YW / BN 3 1
16- DBE / RD 2
2 2
3 1
LOW 3
MANUAL
BK 4
38- WE / OE
1
55- DBE / BK
2
16- DBE / RD
SPEEDOMETER VPM METER 3
BK 4
LOW VIBRATION
S I S I S I
ZENER DIODE SOLENOID
500 OHM
G G G Zd1
5.1 V
F10 1/A
5 WATT
36- LGN
RESISTOR
H32 43- LBE / RD
500 OHM
3 WATT
YW
IGN
SENSOR POWER
44 - DGN/YW
ANALOG IN 0 VALVE 0
ANALOG IN 1 VALVE 1
WE
B SGL ANALOG IN 3
RD
45- BK / WE A
BK CAN LOW
C
CAN HIGH
BK
VIBRATION SPEED DIGITAL 0 / BOOT
67- LGN
DIGITAL 1 TxD
GND
68- DBE / BK
45- BK / WE
BK
WE SGL
B
A RD
16- DBE / RD C
BK CONTROL MODULE
REAR SPEED SENSOR
METER - MANUAL/HIGH AMPLITUDE
January 2003
Table of Contents
Automatic/Low Amplitude.... H34
ELECTRICAL
VPM Meter
Speedometer
1625
27.1
1425 1450 1825

23.8 24.2 30.4
1350 1550
25.8
22.5
1225 1250 1650 2025

20.4 20.8 2750 33.8
VPM
HZ
Automatic/Manual
Fuses
Vibration Switch

H33 Switch Solenoid
High Vibration
Solenoid
Automatic Vibration
& Impact Meter
Control Module
Rear Speed Sensor
IMPACT METER
AUTOMATIC/LOW AMPLITUDE EFF. W/ ALL S/N
January 2003
AUTO/MANUAL VIBRATION VIBRATION HIGH / LOW AMPLITUDE
ELECTRICAL
HIGH VIBRATION
AUTO.
39- LPE 40-YW / BN 3 1
16- DBE / RD 2
2 2
3 1
LOW 3
MANUAL
BK 4
38- WE / OE
1
55- DBE / BK
2
16- DBE / RD
SPEEDOMETER VPM METER IMPACT METER BK
3
4
LOW VIBRATION
S I S I S I
ZENER DIODE
500 OHM
SOLENOID
G G G Zd1
5.1 V
F10 1/A
5 WATT
36- LGN
RESISTOR
500 OHM
H34 43- LBE / RD 3 WATT

YW
IGN
SENSOR POWER
44 - DGN/YW
ANALOG IN 0 VALVE 0
ANALOG IN 1 VALVE 1
WE
B SGL ANALOG IN 3
RD
45- BK / WE A
BK CAN LOW
C
CAN HIGH
BK DIGITAL 0 / BOOT
VIBRATION SPEED DIGITAL 1 TxD 67- LGN
GND
68- DBE / BK
45- BK / WE
BK
WE SGL
B
RD
A
BK
MACHINE IN MOTION AUTO VIBRATION & IMPACT METER
16- DBE / RD C
CONTROL MODULE
BK
REAR SPEED SENSOR
METER - AUTOMATIC/
LOW AMPLITUDE
January 2003
Table of Contents
Automatic/High Amplitude... H36
ELECTRICAL
VPM Meter
Speedometer
1625
27.1
1425 1450 1825

23.8 24.2 30.4
1350 1550
25.8
22.5
1225 1250 1650 2025

20.4 20.8 2750 33.8
VPM
HZ
Automatic/Manual
Fuses
Vibration Switch

H35 Switch Solenoid
High Vibration
Solenoid
Automatic Vibration
& Impact Meter
Control Module
Rear Speed Sensor
IMPACT METER
AUTOMATIC/HIGH AMPLITUDE EFF. W/ ALL S/N
January 2003
ELECTRICAL
AUTO.
39- LPE 40-YW / BN 3 1
16- DBE / RD 2
2 2
3 1
LOW 3
MANUAL
BK 4
38- WE / OE
1
55- DBE / BK
2
16- DBE / RD 3
SPEEDOMETER VPM METER IMPACT METER BK 4
LOW VIBRATION
S I S I S I
ZENER DIODE
500 OHM
SOLENOID
G G G Zd1
5.1 V
F10 1/A
5 WATT
36- LGN
RESISTOR
500 OHM
H36 43- LBE / RD 3 WATT

YW
IGN
SENSOR POWER
44 - DGN/YW
ANALOG IN 0 VALVE 0
ANALOG IN 1 VALVE 1
WE
B SGL ANALOG IN 3
RD
45- BK / WE A
BK CAN LOW
C
CAN HIGH
BK DIGITAL 0 / BOOT
VIBRATION SPEED DIGITAL 1 TxD 67- LGN
GND
68- DBE / BK
45- BK / WE
BK
WE SGL
B
A RD
16- DBE / RD C
BK CONTROL MODULE
REAR SPEED SENSOR
METER - AUTOMATIC/
HIGH AMPLITUDE
January 2003
Table of Contents
Automatic/Variable/
Impact Meter ................ H38
ELECTRICAL
VPM Meter
Speedometer
1625
27.1
1425 1450 1825

23.8 24.2 30.4
1350 1550
25.8
22.5
1225 1250 1650 2025

20.4 20.8 2750 33.8
VPM
HZ
Automatic/Manual
Fuses
Vibration Switch

H37 Switch Solenoid
High Vibration
Solenoid
Automatic Vibration
& Impact Meter
Control Module
Rear Speed Sensor
AUTOMATIC/VARIABLE/
IMPACT METER EFF. W/ ALL S/N
January 2003
SPEEDOMETER VPM METER IMPACT METER
ELECTRICAL
S I S I S I
G G G 200 OHM EACH
F10 1/A
36- LGN
200 OHM
SPEED 2
SPEED 3
SPEED 4
SPEED 5
SPEED 1
43- LBE / RD
200 OHM
TO VIB SPEED SENSOR
SIGNAL B TERMINAL
43- LBE / RD
45 - BK / WE AUTO/MANUAL HIGH / LOW 13 15 VARIABLE
14
VIBRATION VIBRATION AMPLITUDE 12 16 FREQUENCY
BK
SELECT SWITCH ON/OFF SWITCH SWITCH
AUTO. 11
HIGH
3 3
2 39-LPE 40- YW / BN 55- DBE / BK 54- LBE / BK
2
1 1
LOW 48- WE / BK
MANUAL
F5 5A C B A
38 - WE / OE
16 - DBE / RD HIGH VIBRATION

16- DBE / RD
SOLENOID
54- LBE / BK
41- DPE
1
16- DBE / RD ZENER DIODE
48- WE / BK 2
500 OHM
Zd1
5.1 V 3
REAR SPEED
H38 SENSOR
5 WATT
RESISTOR
BK 4
500 OHM
WE SGL
3 WATT
RD
1
BK
IGN IGN 2
C
B
A
SENSOR POWER SENSOR POWER 3

ANALOG IN 0 VALVE 0 BK 4
BK
ANALOG IN 0 VALVE 0
ANALOG IN 1 VALVE 1 90-YW ANALOG IN 1 VALVE 1
45- BE / WE ANALOG IN 2 DIGITAL OUTPUT ANALOG IN 2 DIGITAL OUTPUT 42- GY / WE LOW VIBRATION
44- DGN / YW
ANALOG IN 3
CAN LOW
ANALOG IN 3 SOLENOID
CAN LOW
CAN HIGH CAN HIGH
BK 40- YW / BN
DIGITAL 0 / BOOT DIGITAL 0 / BOOT
DIGITAL 1 TxD DIGITAL 1 TxD 60- PK / WE
C
A
B
DIGITAL 2 RxD DIGITAL 2 RxD

GND GND
WE
RD
BK
61- LGN / OE
64- RD / BE
SGL
AUTO VIB. & BK
IMPACT METER 63- GY BK

PROGRAM PORT
VIBRATION CONTROL MODULE
SPEED 44- DGN / YW VARIABLE VIBRATION
SENSOR CONTROL MODULE
AUTOMATIC/ VARIABLE /
PROGRAM PORT
IMPACT METER
January 2003
Table of Contents
Grid Heater..............................H40
Grid Heaters
ELECTRICAL
1 62 5
2 7.1
1 42 5 1 45 0 1 82 5
2 3.8 2 4. 2 3 0.4
1 35 0 1 55 0
2 2. 5 2 5. 8
1 22 5 1 25 0 1 65 0 2 02 5
2 0.4 2 0. 8 2 75 0 3 3. 8
V PM
HZ
Fuel Solenoid
Grid Heater Indicator

H39 (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
January 2003
SEAT TIMER
ELECTRICAL
ENGINE RUN CONDITION
+ N/C
COM
N/O
47- WE / BN
INIT
UEL SOLENOID RELAY
HOLD
87A RD
A A
30 BK
C C
BK FUEL SOLENOID
87 WE
B B
86 71- PK
PULL
85
50- RD GRID HEATER
GRID HEATER
52- LGN / RD
CONTROL MODULE
BK
IGN BE A RD
LIGHT OUT RD B 37 - BN /RD RD
GRID RELAY OUT OE C GRID HEATER RELAYS
GRID RELAY OUT PE D
GN E 53- LGN WE
H40
START IN
N/A BN F
51- RD GRID HEATER
A
RD
5.0
TEMP.
GND
RD
37- BN / RD
YW BK BK
GRID HEATER B+
CAP
W
INDICATOR
BK B A
STATOR
92- RD / BK O
OO
OO
OOOOOO
OOOOOOO
Regulator
O
OO
O
B A O
BK
34- BN
TEMPERATURE
SENSOR D+
ALTERNATOR
F9 10A
GRID HEATER
January 2003
Table of Contents
Gauges ....................................H42
Engine Oil
ELECTRICAL
VPM Meter
Pressure Gauge
Hydraulic Oil Engine Oil
Temperature Pressure Sender
1225
1425
20. 4
23. 8
1250
1350
22. 5
20. 8
1625
27. 1
1450
24. 2
1550
25. 8
1650
2750
1825
30. 4
2025
33. 8
Gauge
VPM
HZ
Voltmeter
Speedometer
Impact Meter
H41
Fuses
Hydraulic Oil
Temperature Sender
Rear Speed Sensor

GAUGES EFF. W/ ALL S/N
January 2003
ELECTRICAL
FROM WORK LIGHT SWITCH TERM. 3
HYDRAULIC OIL
VOLTMETER TEMPERATURE OIL PRESSURE SPEEDOMETER VPM METER IMPACT
73 - 0E 73 - 0E 73 - 0E 73 - 0E 73 - 0E
73 - 0E
36 - LGN 36 - LGN 36 - LGN 36 - LGN 36 - LGN
43 - LBE/RD
36 - LGN 44 - DGN/YW
TO AUTOVIB. & IMPACT METER

82 - YW/GN
CONTROL MODULE, TERM. B1
H42 45 - BK/WE
F10 10A
TO AUTOVIB. & IMPACT METER
CONTROL MODULE, TERM. E1
P WE SGL VIBRATION
B
RD
83 - DGN/BK A
BK SPEED
C
SENSOR
BK
ENGINE OIL
PRESSURE
SENDER TO AUTOVIB. & IMPACT METER CONTROL MODULE, TERM. D3
TO ANTISPIN CONTROL MODULE, E1
T WE SGL
B
A RD REAR SPEED
BK
C SENSOR
BK
HYDRAULIC OIL
TEMPERATURE
SENDER GAUGES
January 2003
Table of Contents
Instrument Cluster .................H44
ELECTRICAL
Coolant Level Hydraulic Oil Temperature
Indicator (In Indicator (In Instrument Cluster)
Instrument Cluster)
Engine Coolant Coolant Temperature
Temperature Gauge Sender Engine Oil
Air Filter Pressure Sender
Tachometer Restriction Switch
H43 Grid Heater Indicator

(In Instrument Cluster)
1625
Alternator Charge
27.1
1450
1425 1825
23.8 24.2 30.4
1350 1550
22.5 25.8
1225 1650 2025

20.4 1250 2750 33.8
20.8
VPM
HZ
Indicator (In
Instrument Cluster)
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
January 2003
ELECTRICAL
ALTERNATOR LOW OIL

CHARGE PRESSURE
INDICATOR I
INDICATOR
ENGINE COOLANT
TEMERATURE GAUGE TACHOMETER FUEL LEVEL GAUGE
I I
RPM
G
T T
G
DIODE G
AIR FILTER HYDRAULIC OIL

RESTRICTION TEMPERATURE
INDICATOR BACK BACK BACK
INDICATOR
LIGHT LIGHT LIGHT
GRID HEATER
INDICATOR COOLANT
H44 LEVEL
INDICATOR
14 - LGN/BK 73 - OE
78 - GY
34 - BN FROM LIGHT SWITCH
77 - TN 15 - DBE/WE 35 - WE/RD
30 - LGN/BE
FROM SIGNAL OPTION
37 - BN/RD
FROM B TERM ON GRID 85 - DGN 5 - YW FROM FUEL GAUGE SENDER
HEATER CONTROL MODULE
4 - OE/BE
34 - BN
P
FROM ALTERNATOR
D+ TERM
LAMP RESISTOR
68 OHM \ 5 WATT
F9 10A ENGINE OIL PRESSURE
T SENDER
FROM ALTERNATOR
AIR FILTER W TERM
RESTRICTION
SWITCH COOLANT TEMPERATURE INSTRUMENT CLUSTER
SENDER
January 2003
Table of Contents
Fuses .......................................H46
Voltmeter Instrument Cluster Work Lights Beacon Light
ELECTRICAL
VPM Meter Air Filter Backup Alarm
Engine Oil
Pressure Gauge Coolant Level
Sensorr
Speedometer
1625
27.1
1425 1450 1825

23.8 24.2 30.4
1350 1550
22.5 25.8
1225 1250 1650 2025

20.4 20.8 2750 33.8
VPM
HZ
Power
Port
Seat Switch
Park Brake (Under Seat)
Switch
Automatic/Manual
H45 Vibration Switch
Fuel
Impact Meter Throttle
Solenoid
Fuses
Anti-Spin Control
Module
Horn
Ignition Switch
Hydraulic Oil
Temperature Switch
FUSES EFF. W/ ALL S/N
January 2003
ELECTRICAL
AMPERE
FUSE NO CIRCUIT
RATING
KEY SWITCH, E-STOP, IGNITION, FUEL & THROTTLE SOLENOID HOLD CIRCUITS, SEAT SWITCH AND
F1 15 AMP PARK BRAKE
F2 10 AMP HORN, AIR FILTER, HYDRAULIC OIL TEMPERATURE & COOLANT LEVEL CIRCUITS
F3 10 AMP TWO SPEED CIRCUIT & BACK UP ALARM
F4 15 AMP WORK LIGHTS, BEACON & TURN SIGNAL / HAZARD LIGHTS
F5 5 AMP AUTO / MANUAL VIBRATION & IMPACT METER
F6 5 AMP ANTI-SPIN CONTROL

H46
F7 10 AMP POWER PORT
F8 30 AMP THROTTLE SOLENOID PULL-IN CIRCUIT
F9 10 AMP INSTRUMENT CLUSTER
F10 10 AMP VOLTMETER, OIL PRESSURE, SPEEDOMETER, VPM & IMPACT METER GAUGES
F11 10 AMP CAB OPTIONS
F12 10 AMP STRIKE OFF BLADE OPTION
FUSES
January 2003
SD-100/105 TF SERIES / ROPS/FOPS REPLACEMENT
TABLE OF CONTENTS............................................. J1.1
ROPS/FOPS.............................................................. J1.2
Tools Required ..................................................... J1.2
Safety ................................................................... J1.2
Removal ............................................................... J1.3
Inspection ............................................................. J1.4
Installation ............................................................ J1.4
ROPS/FOPS
J1.1
021402AA
TABLE OF CONTENTS
January 2003
SD-100/105 TF SERIES/ ROPS/FOPS REPLACEMENT
TOOLS REQUIRED:
• Safety glasses
• Torque multiplier • Loctite number 271
• Sockets and wrenches for these models
• Lifting device with straps and chains, and sufficient
capacity for lifting weight specified on ID tag located on the
ROPS/FOPS
SAFETY
Appropriate safety practices should be observed at all times.
Refer to the AEM Safety Manual for safety instructions.
These safety practices include the use of safety glasses and
adherence to common safety procedures, which should
include safety practices pertaining to your specific location and
situation.
J1.2
WARNING:
Lifting equipment should be in perfect condition and have
sufficient capacity for lifting the weight specified on the ID tag
located on the rollover protective structure (ROPS)/falling
object protective structure (FOPS). Take note of the lifting
height to ensure that the ROPS/FOPS will clear the unit, and
check for overhead power lines or other obstructions.
When attaching chains or straps, examine them closely to
ensure they are free from defects.
Figure 1-1
ROLLOVER PROTECTIVE
STRUCTURE (ROPS)
January 2003
REMOVAL
NOTE
To ensure the safe removal and installation of your ROPS/
FOPS, refer to and view the service video which is available
from your Ingersoll-Rand distributor.
WARNING:
Use care when attaching and securing the lifting device to
avoid risk of accidents. Use a lifting device that is in perfect
condition and with sufficient capacity for lifting components
being serviced or repaired. Check for overhead obstructions.
1. Attach the straps or chains of the suitable lifting device to
the ROPS/FOPS (1).
2. Once the lifting device is attached, take out the slack so the
straps or chains are fully supporting the ROPS/FOPS (1).
3. Remove the plastic plugs (10) covering the ROPS
J1.3 attaching hardware.
4. Remove the capscrews (2), hex nuts (4), and flatwashers
(3).
WARNING:
All assisting personnel should stay clear of pinch points and
avoid standing under the suspended ROPS/FOPS at all times.
5. Check above the unit for obstructions. Lift the ROPS/FOPS
(1) clear of the frame with the suitable lifting device and
move to desired location.
Figure 1-1
ROLLOVER PROTECTIVE
STRUCTURE (ROPS)
January 2003
INSPECTION
1. Check the ROPS/FOPS (1) for signs of fatigue or cracks. If
cracks are found, the machine should be placed out of
service and the ROPS/FOPS and all mounting hardware
replaced.
2. Check all mounting hardware for damage and wear.
Replace as necessary.
INSTALLATION
1. Attach a suitable lifting device with straps or chains to the
ROPS/FOPS.
WARNING:
All assisting personnel should stay clear of pinch points and
avoid standing under the suspended ROPS/FOPS at all times.
2. Check overhead for obstructions and lift the ROPS/FOPS
J1.4 (1) slowly over the unit and lower it into position.
3. Apply Loctite #271 to the capscrews (2).
4. Install the capscrews (2), hex nuts (4), and flatwashers (3)
and secure the ROPS/FOPS.
5. Torque the capscrews (2) to 637 N·m (470 lbs-ft).
6. Install the plastic plugs (10).
7. Remove the lifting device from the ROPS/FOPS (1).
Figure 1-1
ROLLOVER PROTECTIVE
STRUCTURE (ROPS)
January 2003
SD-100/105 TF SERIES / SWIVEL BEARING REPLACEMENT
TABLE OF CONTENTS............................................. J2.1
SWIVEL BEARING .................................................... J2.2

Tools Required ..................................................... J2.2
Safety ................................................................... J2.2
Removal and Disassembly................................... J2.4
Cleaning and Inspection....................................... J2.7
Assembly.............................................................. J2.7
J2.1
021402AA
TABLE OF CONTENTS
January 2003
TOOLS REQUIRED:
• Safety glasses • Basic sockets and wrenches
• Torque wrench • Loctite number 271
• Feeler gauges • Petroleum jelly
• Sledge hammer • Heat resistant gloves
• Non-residue type solvent • Straps or chains
• Anti-seize
• Lifting device, such as a 3,000 lb. Auto-Crane that is in
perfect condition
SAFETY
Accidents are caused by failure to follow simple, fundamental
safety rules and precautions. Refer to the AEM Safety Manual
for safety instructions. Most accidents can be avoided by
J2.2 paying attention, using common sense, and following the
instructions.
WARNING:
Improper maintenance can be hazardous.
Study the Operator’s Manual and Service Manual before
starting, operating, maintaining, fueling, or servicing the
compactor. 021402AA
No unauthorized person should be allowed to operate, service,

or maintain this compactor.
Read and understand all unit mounted safety labels before
starting, maintaining, fueling, or servicing this unit.
WARNING:
Unexpected machine motion or moving parts can cut or crush. Figure 1-1
TOOLS REQUIRED AND SAFETY

January 2003
WARNING:
Oil under pressure can cause serious cuts or injury.
Exercise extreme caution when working around pressurized
hydraulic systems. Do not work on a hydraulic system while the
engine is running or pressure is still in the system. Ensure all
pressure is relieved from the system before performing
maintenance.
When handling oil, grease, or other chemical substances,
observe the product related safety regulations.
Substances such as oil, grease or fuel could be hazardous to
health if used incorrectly. Avoid ingestion, skin contact, and
breathing fumes.
Keep hands and fingers from between small parts. Wear

protective gear such as safety glasses, heavy gloves, and
J2.3 safety shoes.
Do not perform any work on the equipment that is
unauthorized.
Avoid whenever possible servicing, cleaning, or examining the
compactor with the engine running.
Before starting any work, check the de-energized parts for the
presence of power. Ground or short circuit them in addition to 021402AA
insulating adjacent live parts and elements.

NOTE
Clean the machine, especially connections, of any traces of oil,
fuel, or preservatives before carrying out maintenance or
repair. Never use aggressive detergents. Use lint free cleaning
rags.
Figure 1-1

January 2003
WARNING:
When draining fluids, ensure that adequate sealable
containers are available and that every care is taken to prevent
spillage. Always ensure waste fluids are disposed of in an
environmentally safe manner.
REMOVAL AND DISASSEMBLY

WARNING:
Crushing hazard.
Improper support of the frame could cause death or severe
injury.
Ensure that adequate supports are used prior to working in or
around the articulation joint area.
1. Park the machine on a level surface with ample clearance
for working.
J2.4 2. Block the tires of the machine to prevent the machine from
moving, (Figure 1-2).
3. Block the drum frame in such a manner that it can be
moved back when the articulation joint is unbolted, (Figure
1-2).
Block Drum Frame
WARNING:
pressure is relieved from the system before disconnecting
hydraulic lines and performing maintenance.
4. Tag and disconnect the hydraulic lines to the propulsion,
vibration, and blade systems that are routed between the
Figure 1-2
drum frame and rear frame. Cap or plug all lines and
openings.
JACK AND BLOCK PLACEMENT
January 2003
SD-100/105 TF SERIES SWIVEL BEARING REPLACEMENT
5. Tag and disconnect any electrical harnesses connected
between the two frames.
WARNING:
hydraulic systems. Do not work on a hydraulic system while
the engine is running or pressure is still in the system. Ensure
all pressure is relieved from the system before disconnecting
6. Remove the drum assembly (1) and scraper from the drum
frame (2). Refer to the Drum and Drum Drive Teardown
and Rebuild Procedure J3.
WARNING:
J2.5 being serviced or repaired. Check for overhead obstructions.
7. Attach an adequate lifting/supporting device to the drum
frame (2).
8. Remove the capscrews (27) and washers (28) from the
lock plate (26) on the drum frame and swivel horizontal
oscillating pin (5, Figure 1-3).
9. Remove the lock plate (26).
10. Loosen the stop nut (6) on the drum frame oscillating pin
(5).
11. Remove the pin (5), washer (7) and nut (6) from the swivel
and drum frame.
12. Remove the hitch pin (16) and remove the lock pin (9).
13. Move the drum frame clear of the swivel. Figure 1-3
14. Remove and discard the bearings (4) and dust seals (24
and 25) from the drum frame (2).
DRUM FRAME AND SWIVEL BEARINGS
January 2003
15. Tag and disconnect the hydraulic lines to the steering
cylinder (6, Figure 1-4). Cap and plug all lines and
openings.
NOTE: Steer cylinder barrel
16. Support the rod end of the steer cylinder (6).
ends to frame attaching
17. Remove the roll pin (12, Figure 1-3) and cylinder pivot pin hardware shown in this
(11) from the steering cylinder rod end. illustration.
18. Remove the steer cylinder rod end from the swivel (3,
Figure 1-3). Refer to Figure 1-3 for rod
19. Remove and discard the bushings (10, Figure 1-3) from the end attaching hardware.
top of the frame swivel (3).
20. Repeat steps 15 through 19 for the other steer cylinder.
J2.6
Figure 1-4
REAR FRAME AND STEER CYLINDERS

January 2003
WARNING:
21. Attach an adequate lifting device to the swivel (3, Figure 1-
5).
22. Remove the capscrews (27) and washers (28) from the
lock plate (26) on vertical swivel oscillating pin (5, Figure 1-
5).
23. Remove the lock plate (26).
24. Remove the stop nut (6) and washer (7) from the pin (5).
25. Remove the pin (5) from the swivel (3) and rear frame.
26. Using the lifting device, remove the swivel (3).
27. Remove and discard the bearings (7) and dust seals (9 and
J2.7 10, Figure 1-4) from the top and bottom of the rear frame
swivel mounting sleeve.
CLEANING AND INSPECTION
1. Ensure all parts are cleaned in a type solvent.

2. Inspect all fasteners for damage.
3. Discard all gaskets and seals.
ASSEMBLY AND INSTALLATION

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

January 2003
2. Apply a coat of grease to the new bearings (7).
NOTE:
Bearings are to be cooled to -18°C (0°F) for 2 to 4 hours before
NOTE: Steer cylinder barrel
installation.
ends to frame attaching
3. Lower the temperature of the bearings (7, Figure 1-6). hardware shown in this
4. Install the new bearings (7) into the top and bottom of the illustration.
rear frame swivel mounting sleeve.
5. Install new dust seals (9 and 10, Figure 1-6) onto the top Refer to Figure 1-5 for rod
and bottom of the rear frame swivel mounting sleeve end attaching hardware.
J2.8
Figure 1-6
REAR FRAME AND STEER CYLINDERS

January 2003
WARNING:
6. Attach an adequate lifting device to the swivel (3, Figure 1-
7).
7. Apply a light coat of Never-Seize to the large diameter of
the vertical swivel oscillating pin (5).
8. Using the adequate lifting device, install the swivel (3) to
the rear frame swivel mount, being careful not to damage
the drum frame horizontal oscillating pin temporarily
installed in the swivel.
9. Install the vertical swivel oscillating pin (5) into the swivel
(3) and rear frame mounting sleeve.
J2.9 10. Install the washer (7) and stop nut (6) onto the oscillating
pin (5).
11. Torque the pin (5) to 340 N·m (250 lbs-ft).
12. Install the new O-ring (41).
13. Install the lock plate (26).
15. Install the washers (28) and capscrews (27) into the lock
plate (26).
17. Apply a coat of grease to the new bushings (10).
18. Install the new bushings (10) into the top of the swivel (13).
Figure 1-7

January 2003
19. Connect the steer cylinder (6, Figure 1-6) rod end to the
swivel (3).
20. Install the steer cylinder pivot pin (11, Figure 1-7) and
connect the steer cylinder to the frame swivel (3). Install
the roll pin (12).
21. Repeat steps 19 and 20 for the other steer cylinder.
22. Uncap, unplug and connect the hydraulic lines to the steer
cylinders as tagged during disassembly.
NOTE:
Bearings are to be cooled to -18°C (0°F) for 2 to 4 hours before
installation.
24. Lower the temperature of the bearings (4, Figure 1-7).
25. Install the bearings (4) into the drum frame (2).
26. Install the dust seals (24 and 25) onto the drum frame (2).
J2.10
WARNING:
27. Attach an adequate lifting device to the drum frame (2).
28. Using the lifting device, align the drum frame (2) with the
swivel (3). Keep the lifting device attached to the drum
frame.
29. Remove the temporarily installed swivel horizontal
oscillating pin (5) from the swivel (3).
30. Apply a light coat of Never-Seize to the large diameter of
the pin (5). Figure 1-7

January 2003
NOTICE:
During installation of the horizontal swivel oscillating pin (5),
ensure the weight of the drum frame (2) is off of the pin so as
not to cause damage to the pin.
31. Install the horizontal swivel oscillating pin (5) into the drum
frame (2) and swivel (3).
32. Ensure the pin (5) is centered in the drum frame (2).
33. Install the washer (7) and stop nut (6) onto the pin (5).
34. Torque the pin (5) to 340 N·m (250 lbs-ft).
35. Install the lock plate (26).
37. Install the washers (28) and capscrews (27) into the lock
plate (26).
J2.11 39. Install the drum assembly (1) and scraper into the drum
frame (2). Refer to the Drum and Drum Drive Teardown
and Rebuild Procedure J3.
40. Connect the hydraulic lines to the propulsion, vibration, and
blade systems.
41. Connect the electrical harness between the two frames.
42. Lubricate the articulation joint and pins, steer cylinder pins,
steer cylinder bearings and swivel pins. Refer to the
Operation and Maintenance Manual for maintenance
instructions.
43. Operate the machine and check for proper operation and
leaks.
44. It is recommended that after the first 50 to 100 hours of
operation, the articulation joint fasteners be checked for Figure 1-7
proper torque.

January 2003
SD-100/105 TF SERIES DRUM AND DRUM DRIVE
TABLE OF CONTENTS ............................................. J3.1
DRUM AND DRUM DRIVE........................................ J3.2

Tools Required .............................................. J3.2
Safety ............................................................ J3.2
Removal and Disassembly............................ J3.4
Drum Drive Motor Removal and Disassembly
...................................................................... J3.7
Drum Drive Side Disassembly ...................... J3.8
Carrier Disassembly...................................... J3.9
Vibration Side Disassembly ....................... J3.10
Cleaning and Inspection ..............................J3.11
Vibration Side Assembly ..............................J3.11 DRUM AND DRUM DRIVE
J3.1 Carrier Assembly......................................... J3.14

Drive Side Assembly and Installation
.................................................................... J3.15
Drum Drive Assembly and Installation
.................................................................... J3.17
Assembly and Installation ........................... J3.19
021402AA
TABLE OF CONTENTS
January 2003
TOOLS REQUIRED:
• 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 • Torque wrench
and blue
perfect condition
SAFETY
J3.2
paying attention, using common sense, and following the
instructions.
WARNING:
Improper maintenance can be hazardous.
Study the Operator’s Manual and Service Manual before
021402AA
starting, operating, maintaining, fueling, or servicing the

compactor.
No unauthorized person should be allowed to operate, service,
or maintain this compactor.
Read and understand all unit mounted safety labels before
starting, maintaining, fueling, or servicing this unit. Figure 1-1
WARNING:
Unexpected machine motion or moving parts can cut or crush. TOOLS REQUIRED AND SAFETY
January 2003
WARNING:
Oil under pressure can cause serious cuts or injury.
pressure is relieved from the system before performing
maintenance.
When handling oil, grease, or other chemical substances,
observe the product related safety regulations.
Substances such as oil, grease or fuel could be hazardous to
health if used incorrectly. Avoid ingestion, skin contact, and
breathing fumes.
Keep hands and fingers from between small parts. Wear

protective gear such as safety glasses, heavy gloves, and
J3.3 safety shoes.
Do not perform any work on the equipment that is
unauthorized.
Avoid whenever possible servicing, cleaning, or examining the
compactor with the engine running.
Before starting any work, check the de-energized parts for the
presence of power. Ground or short circuit them in addition to 021402AA
insulating adjacent live parts and elements.

NOTE
Clean the machine, especially connections, of any traces of oil,
fuel, or preservatives before carrying out maintenance or
repair. Never use aggressive detergents. Use lint free cleaning
rags.
NOTE Figure 1-1
Take extra care when working around or on the hydraulic
system to ensure its complete cleanliness.
January 2003
WARNING:
When draining fluids, ensure that adequate sealable
containers are available and that every care is taken to prevent
spillage. Always ensure waste fluids are disposed of in an
environmentally safe manner.
REMOVAL AND DISASSEMBLY

1. Park the machine on a level surface with ample clearance
for working. This should include space to allow for rolling
the drum assembly out from the frame of the compactor.
2. Install the articulation lock pin and chock the tires securely
to prevent movement when removing the drum assembly.
3. Jack at the center articulation joint to raise the frame,
(Figure 1-2).
4. To allow for easier removal of the drum mounting hardware,
J3.4 measure from the inner drum shell to the top and bottom of
the frame rail; positions A and B. Adjust the jack up or
down until the measurements are roughly equal. This will
relieve any load on the shock mounts.
5. Repeat the previous procedure on the other side of the
drum. Block Drum Frame
WARNING:
6. Attach an adequate lifting/supporting device to the scraper.
Figure 1-2
JACK AND BLOCK PLACEMENT

January 2003
7. Remove the capscrews (42), flatwashers (21), shims (19
and 20), and nuts (23) from the scraper and drum frame (2,
Figure 1-3).
8. Tag and wire the shims (19 and 20) together so that they
can be reinstalled at the same locations.
9. Using the lifting device, remove the scraper from the drum
frame (2).
WARNING:
hydraulic systems. Do not work on a hydraulic system while
the engine is running or pressure is still in the system. Ensure
all pressure is relieved from the system before disconnecting
NOTE’
Steps 11 and 12 are usually done after drum assembly is
J3.5 removed from drum frame.
10. Tag and disconnect the hydraulic lines to the vibration
motor (27, Figure 1-5) (left side of the drum).
11. Remove the capscrews (37) and flatwashers (36) securing
the vibration motor (27) to the carrier assembly (23, Figure
1-5).
12. Remove the vibration motor (27) and O-ring (28) from the
carrier assembly (23).
13. Tag and disconnect the hydraulic lines and the electrical
line to the drum drive motor (1, Figure 1-4). Cap or plug all
lines and openings.
Figure 1-3
DRUM, DRUM FRAME AND SCRAPER

January 2003
14. Remove the capscrews (22), flatwashers (21), shims (19
and 20) and hex nuts (23) securing the drum assembly (1)
to the drum frame (2, Figure 1-3).
15. Tag and wire the shims (19 and 20) together so that they
can be reinstalled at the same location.
16. Carefully roll the drum assembly (1) out of the drum frame
(2) and block into position for further maintenance.
J3.6
Figure 1-3
DRUM, DRUM FRAME AND SCRAPER

January 2003
DRUM DRIVE REMOVAL AND DISASSEMBLY
WARNING:
1. Use an adequate lifting/supporting device to support drive
motor (1) and drive plate (2, Figure 1-4).
2. Remove the nuts (35), flatwashers (34) and washers (39)
securing the drive motor assembly (33, Figure 1-5) to the
shock mounts (16).
3. Using the lifting device, remove the drive motor (1), drive
plate (2) and mounting plate (3, Figure 1-4) from the drum.
4. Remove the capscrews (30, Figure 1-5) and flatwashers
(29) securing the shock mounts (16) to the drum (1).
J3.7 5. Remove the shock mounts(16) from the drum (1).
6. Remove the capscrews (7, Figure 1-4) and flatwashers (4)
from the drive plate (2) and drive motor (1).
7. Remove the capscrews (5), flatwashers (4), and hex nuts
(6) from the mounting plate (3) and drive motor (1).
8. Separate the drum drive motor (1) from the drive plate (2)
and mounting plate (3).
9. If maintenance of the drum drive motor (1) is required, refer
to the Drum Drive Motor service information for this model.
Figure 1-4
DRUM DRIVE
January 2003
DRUM DRIVE SIDE DISASSEMBLY
1. Remove the capscrews (13) and flatwashers (12) from the
cover (11, Figure 1-5).
2. Remove the cover (11) from the bearing housing drive (2).
3. Remove and discard the O-ring (9).
WARNING:
Safety glasses must be worn when removing the retaining ring.
4. Remove the retaining ring (19) from the eccentric (5).
WARNING:
5. Attach an adequate lifting/supporting device to the bearing
J3.8 housing drive (2).
6. Remove the bolts (10) and flatwashers (8) securing the
bearing housing drive (2) to the drum (1).
7. Using the lifting device, remove the bearing housing drive
(2) from the drum (1).
8. Remove and discard the O-ring (20) from the bearing
housing drive (2).
WARNING:
Safety glasses must be worn when removing the retaining
rings.
9. Remove the retaining rings (7) and remove the bearings (6)
from the bearing housing drive (2).
Figure 1-5
DRUM ASSEMBLY
January 2003
CARRIER DISASSEMBLY
WARNING:
1. Attach an adequate lifting/supporting device to the shock
mounting plate (10, Figure 1-6).
2. Remove the nuts (12). flatwashers (11) and washers (9)
securing the shock mount plate (10) to the shock mounts
(6).
3. Using the lifting device, remove the shock mount plate (10).
WARNING:
J3.9 condition and with sufficient capacity for lifting components
4. Attach an adequate lifting device to the carrier plate (1).
5. Remove the capscrews (8) and the flatwashers (7)
securing the shock mounts (6) to the carrier plate (1).
6. Using the lifting device, remove the carrier plate (1) from
the drum.
7. Remove and discard the oil seal (5) from the carrier plate
(1).
Figure 1-6
CARRIER ASSEMBLY
January 2003
VIBRATION SIDE DISASSEMBLY
1. Remove the coupling (24) and splined shaft (26, Figure 1-
7) from the drum (1).
WARNING:
housing spindle (3).
3. Remove the bolts (10) and flatwashers (8) from the bearing
4. Using the lifting device, remove the bearing housing
spindle (3) from the drum (1).
5. Remove and discard the O-ring (20) from the bearing
J3.10 housing spindle (3).
WARNING:
Safety glasses must be worn when removing the retaining
rings.
6. Remove the retaining ring (18) from the spindle (3).
7. Remove the bearing (15).
8. Remove the spacer (4) and bearing (15).
9. Remove and discard the V-ring seal (17).
10. Remove the wear sleeve (14).
11. Remove the eccentric (5) from the drum (1).
12. If maintenance of the eccentric assembly is required, refer
to the Eccentric Assembly service information for this Figure 1-7
model.
DRUM ASSEMBLY
January 2003
1. Clean all metal parts in a nonresidue type solvent.
2. Check all mounting hardware for damage or wear. Replace
as necessary.
3. Inspect all threaded holes.
4. Check the carrier plate for cracks, wear, or other damage.
5. Check the bearings for wear, spalling, or other damage.
6. Check shocks for cracks, wear or other damage. Replace
as necessary.
7. Clean the inside of the drum.
VIBRATION SIDE ASSEMBLY

1. Install the wear sleeve (14) onto the bearing housing
spindle (3).
J3.11
2. Apply petroleum to the new V-ring seal (17).
3. Install the new V-ring seal (17) onto the bearing housing
spindle (3).
4. Heat the bearings (15) to 107° C (225° F) for 15 to 30
minutes before installation.
WARNING:
Wear protective heat resistant gloves when handling heated
parts. Contact with hot bearings will cause severe burns.
NOTE
Bearings are to be cooled to -18°C (0° F) for 2 to 4 hours
before installation.
5. Lower the temperature of the new bearings (15).
Figure 1-7
7. Install the new bearing (15) and the spacer (4) onto the
bearing housing spindle (3). DRUM ASSEMBLY
January 2003
WARNING:
Safety glasses must be worn when installing the retaining
rings.
8. Install a new bearing (15) and the retaining ring (18) onto
the bearing housing spindle (3).
9. Apply petroleum jelly to the new O-ring (20).
10. Install the new O-ring (20) into the bearing housing spindle
(3).
WARNING:
housing spindle (3, Figure 1-7).
J3.12
12. Using the lifting device, install the bearing housing spindle
(3) into the drum (1).
13. Apply Loctite #271 (red) to the bolts(10).
14. Install the bolts (10) and flatwashers (8) into the bearing
15. Torque the bolts (10) to 373 N·m (275 lbs-ft).
WARNING:
16. Using the lifting device, install the eccentric assembly (5)
into the drum from the drive side of the drum and into the Figure 1-7
bearing housing spindle (3).
DRUM ASSEMBLY
January 2003
17. Support the eccentric assembly (5) until the bearing
housing drive (2) is installed.
18. Coat the contact areas of both ends of the splined shaft
(26) with Dow Corning Moly-Kote grease prior to
installation into the coupling (24) and eccentric (5).
19. Install the splined shaft (26) and coupling (24) into the drum
(1).
20. Check the eccentric oil. Refer to the Operation and
Maintenance Manual for this model.
J3.13
Figure 1-7
DRUM ASSEMBLY
January 2003
CARRIER ASSEMBLY
1. Install new oil seal (5) into the carrier plate (1).
3. Install the shock mounts (6) onto the carrier plate (1).
4. Install the capscrews (8) and flatwashers (7) onto the
shock mounts (6)
WARNING:
6. Attach an adequate lifting device to the shock mount plate
(10).
J3.14 7. Install the shock mount plate (10) to the shocks (6).
8. Install the washers (9), flatwashers (11) and nuts (12) in to
the shock mount plate (10).
9. Torque the nuts to 373 N·m (275 lbs-ft).
WARNING:
10. Attach an adequate lifting device to the carrier assembly.
NOTE
Ensure the carrier plate assembly is fully installed onto the
spindle and that the V-ring seal on the spindle does not roll
Figure 1-8
under the edge of the carrier plate assembly during installation.
11. Install the carrier plate assembly into the drum and onto the
bearing housing spindle. CARRIER ASSEMBLY
January 2003
DRIVE SIDE ASSEMBLY AND INSTALLATION
1. Install a new O-ring (20) 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).
WARNING:
J3.15 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 lbs-ft).
WARNING:
rings.
11. Install the retaining ring (19) onto the eccentric (5). Figure 1-9
DRUM ASSEMBLY
January 2003
12. Apply petroleum jelly to the new O-ring (9).
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 (13) and flatwashers (12) into the
cover (11).
17. Torque the capscrews (13) to 28.5 N·m (21 lbs-ft).
J3.16
Figure 1-9
DRUM ASSEMBLY
January 2003
DRUM DRIVE ASSEMBLY AND INSTALLATION
1. Apply Loctite #271 to capscrews (5, Figure 1-10).
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 ft-lbs).
WARNING:
5. Using an adequate lifting/supporting device, position the
drive motor (1) onto the drive plate (2).
6. Apply loctite #271 to the capscrews (7).
J3.17 7. Install the capscrews (7) and flatwashers (4) into the drive
plate (2) and drive motor (1).
8. Torque the capscrews (7) to 575 N·m (420 ft-lbs).
9. Apply Loctite #271 (red) to the capscrews (30, Figure 1-
11).
10. Install the shock mounts (16, Figure 1-11) to the drum (1).
shock mounts (16).
12. Torque the capscrews (30) to 149 N·m (110 ft-lbs)
WARNING:
condition and with sufficient capacity for lifting components Figure 1-10
13. Attach an adequate lifting/supporting device to the drive
motor (1), drive plate (2) and mounting plate (3). DRUM DRIVE
January 2003
14. Apply Loctite #271 (red) to the nuts (35, Figure 1-11).
15. Using the lifting device, install the drive plate (2), drive
motor (1) and mounting plate (3) to the shock mounts (16,
Figure 1-11).
16. Install the nuts (35), flatwashers (4) and washers (39) into
the drum drive plate (2).
17. Torque the nuts (35) to 373 N·m (275 ft-lbs).
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 1-11
DRUM ASEMBLY
January 2003
ASSEMBLY AND INSTALLATION
WARNING:
1. Attach an adequate lifting device to the drum assembly (1).
1. Carefully roll the drum assembly into position in the drum
frame.
2. Measure the distance between the frame sides at positions
A and D in (Figure 1-12). Measurement A should be no
more than 25.4 mm (1.0 in.) greater than measurement D.
Ensure the gap is consistent between the siderails along
the entire length of the siderail.
3. Measure the scraper bar length. The difference between
J3.19 the length of the scraper bar and the distance in position A
is the required shim pack thickness for the scraper bar
installation.
WARNING:
4. Attach an adequate lifting device to the scraper.
NOTE
Locate smooth drum scraper or tooth scraper with a 20 mm
(0.79 gap between drum shell and closest edge of scraper.
5. Align scraper into the drum frame (2, Figure 1-13).
Figure 1-12
DRUM ALIGNMENT
January 2003
6. Preload the drum assembly by shimming the vibration side
only. Fill gap on both sides of mounting bracket, then add
the smallest thickness 1.5 mm (0.06 in.) shim to each side
of mounting bracket.
7. Align the drum mounting holes by rocking the drum forward
and backward until the mounting capscrews can be
inserted temporarily on each side. Install capscrews (22),
flat washers (21) and nuts (23).
8. Take clearance measurements B and C on both ends of
the drum. Measure between the edge of the drum shell and
the drum frame. Shift the drum until these measurements
are equal, refer to (Figure 1-12).
9. Measure to determine the shim thickness on each end at
the drum mounting location E in (Figure 1-12).
10. Compare this to the thickness of the shim packs removed
at disassembly. Add or subtract shims equally to both sides
J3.20 as necessary to meet the required thickness.
11. Install required shims (19 and 20, Figure 1-13) at each end
of the drum.
13. Alternately torque the capscrews (22) to 1780 N·m (1310 ft-
lbs).
NOTE
Scraper shim packs should result in the scraper total length to
nearly match, but not exceed the distance between the drum
frame siderails.
14. Install scraper shims (19 and 20, Figure 1-13).
15. Apply Loctite to the capscrews (42).
16. Install the capscrews (42), flatwashers (21), and nuts (23) Figure 1-13
into the scraper and drum frame.
DRUM, DRUM FRAME, AND SCRAPER
January 2003
17. Torque the cappscrews (42) to 1780 N·m (1313 lbs-ft).
18. Connect the hydraulic lines to the drum drive motor (1,
Figure 1-10).
19. Apply petroleum jelly to new O-ring (28, Figure 1-14).
20. Install the vibration motor (27, Figure 1-14) and new O-ring
(28) into the drum.
21. Apply Loctite #271 (red) to the capscrews (37).
vibration motor (27, Figure 1-14) and carrier assembly (23).
24. Connect the hydraulic lines to the vibration motor (27).
25. Lubricate the drum assembly prior to operation.
26. Check the system hydraulic oil. Refer to the Operations
and Maintenance Manual for these models for mainte-
J3.21 nance instructions.
27. Operate the compactor and check for proper operation,
and ensure there are no oil leaks.
Figure 1-14
DRUM ASSEMBLY
January 2003
SD100/105 TF SERIES / ECCENTRIC ASSEMBLY
TABLE OF CONTENTS. ............................................ J4.1
ECCENTRIC ASSEMBLY.......................................... J4.2

Tools Required ..................................................... J4.2
Safety ................................................................... J4.2
Disassembly ......................................................... J4.2
Cleaning and Inspection....................................... J4.3
Assembly.............................................................. J4.3
Eccentric Assembly
J4.1
021402AA
TABLE OF CONTENTS
January 2003
TOOLS REQUIRED:
• Torque wrench • Loctite number 271 (red)
• Non-residue type solvent • Grease
• Hammer • Punch
perfect condition
SAFETY
paying attention, using common sense, and following the
instructions.
J4.2
DISASSEMBLY
1. Remove the capscrew (9, Figure 1-1) and flatwasher (7)
from the spline coupling (6).
2. Remove the spline coupling (6) from the non-drive side
journal (4).
3. Remove and discard the oillite bearing (5) from the non-
drive side journal (4).
non-drive side journal (4).
5. Remove the roll pin (10) from the non-drive journal (4) and
eccentric shaft (2).
6. Pull the eccentric shaft (2) from the non-drive side journal
(4). Figure 1-1
ECCENTRIC ASSEMBLY
January 2003
drive side journal (1).
8. Remove the drive side journal (1) from the eccentric shaft
housing (2).
9. Remove and discard the oillite bearing (5) from the
eccentric shaft (3).
10. Remove the eccentric shaft (3) from the eccentric shaft
housing (2).

1. Clean all parts in a non-residue type solvent.
2. Check all mounting hardware for damage and wear.
3. Inspect all threaded holes for debris or foreign material.
4. Thoroughly clean threaded holes of cosmoline, oil, dirt,
J4.3 metal chips, and any other contaminants that could
interfere with curing of Loctite.
ASSEMBLY
1. Install the eccentric shaft (3) in the shaft housing (2).
2. Polish the drive side journal end of housing.
3. Polish the journal end of housing.
4. Install the new oillite bearing (5) onto the eccentric shaft
(3).
5. Install the drive side journal (1) onto the end of eccentric
housing (2).
6. Apply enough Loctite #271 (red) to both the capscrews (8)
and the hole threads to completely fill the thread Figure 1-1
engagement length once the capscrews (8) are installed.
ECCENTRIC SHAFT ASSEMBLY

January 2003
7. Install the capscrews (8) and flatwashers (7) in the drive
side journal (1).
9. Install the new bearing (5) into the non-drive side journal
(4).
10. Install the non-drive side journal (4) onto eccentric housing
(2).
11. Apply Loctite #271 (red) to the capscrews (8).
12. Install the capscrews (8) and flatwashers (7) into the hub
non-drive side journal (4).
14. Apply enough Loctite #271 (red) to both the capscrews (9)
and the hole threads to completely fill the thread
engagement length once the capscrews (9) are installed.
15. Install the spline coupling (6) to the non-drive side journal
J4.4 (4) and secure with the capscrews (9) and flatwashers (7).
Figure 1-1
ECCENTRIC SHAFT ASSEMBLY

January 2003
SD100/105 TF SERIES / VIBRATION CONTROL SYSTEM
TABLE OF CONTENTS. ............................................K3.1
VIBRATION CONTROL SYSTEM .............................K3.2

Major Components ...............................................K3.2
Troubleshooting....................................................K3.4
Fault Codes ..........................................................K3.6
CHARTS
Vibration Control Components .............................K3.2
Microprocessor LED Functions ............................K3.3
Troubleshooting Chart..........................................K3.4
Fault Code Troubleshooting Chart .......................K3.6
K3.1
021402AA
TABLE OF CONTENTS
January 2003
VIBRATION CONTROL SYSTEM
The variable frequency vibration option controls the speed and
direction of rotation of the eccentric weight. There are five VPM
set points for the high amplitude range and five VPM set points
for the low amplitude range. The system maintains the
selected VPM during natural fluctuations in machine
performance. This is achieved by supplying a signal from a
speed sensor at the eccentric motor to a microprocessor. This
microprocessor then regulates the output of the vibration pump
to maintain the selected VPM.
MAJOR COMPONENTS
Vibration Control Components
• A microprocessor (1, Figure 1-2) labeled "SX C. Loop
Vibration Control" located in the battery compartment.
K3.2 • A speed sensor located at the vibration motor.
• A five-position selector switch located on the instrument
panel (1, Figure 1-1).
• The electronic displacement control located on the
vibration pump.
The microprocessor (1, Figure 1-2) contains four LED indicator

lights located vertically on the front of the case. Refer to the
Microprocessor LED Function Chart.
Figure 1-1
INSTRUMENT PANEL SELECTOR SWITCH

January 2003
Microprocessor LED Functions
Power Indicates power is being supplied to the
microprocessor.
System Indicates the microprocessor is functioning
normally.
Mode Will blink amber when power is being supplied to
microprocessor.
• A blink rate of about 10 times per second
indicates no application is loaded or an
application is loaded with faults.
• A blink rate of once per second indicates an
application is loaded with no faults.
This would be the normal or required condition.
Status Will display a red four-blink code only if a fault
K3.3 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
January 2003
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 Check Correction
1 Establish that power is Determine power
being supplied to the interruption by:
K3.4 microprocessor.
• Is the vibration on/off
Is the power LED button in the “ON”
illuminated? position?
• Is the F5 fuse OK?
• Is there a fault in the
vibration on/off
button wiring circuit?
Refer to Fault Codes.
2 Is the system LED on the If system LED is not
microprocessor illuminated and the
illuminated? POWER LED is
illuminated, an internal
problem exists in the Figure 1-2
microprocessor and it
will require replacement
MICROPROCESSOR
January 2003
Troubleshooting Chart (Continued)
3 Is status LED displaying a In order for the fault
red four-blink fault code? codes to be illuminated,
the ignition switch must
remain in the “on
position” from the time
the fault occurs.
To accomplish this, stop

the machine travel and
apply park brake.
Observe the status LED

on the variable vibration
K3.5 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
January 2003
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.
• SLLS = Coil at EDC on vibration pump is open or shorted.
This fault will shut down the vibration until fault is cleared
K3.6 and machine is restarted.
Fault Code Troubleshooting Chart

Code Symptom Check
LLSS • The vibration shuts • Check the integrity of
down. wiring and
connections between
the five-position
selector switch and
microprocessor.
Figure 1-2
MICROPROCESSOR
January 2003
Fault Code Troubleshooting Chart (Continued)
Code Symptom Check
LLSS • The machine continues Check the function of the
(Cont) to vibrate at whatever five-position selector
position the selector switch by unplugging the
switch was in when the three-pin wire connector
fault occurred. Under at the five-speed selector
this condition the speed switch and using a
of the vibration will not multimeter, check
change if the selector resistance between
switch is repositioned. terminals A & B at each
of the five VPM settings.
Note: When this fault occurs, the “signal from speed sensor is
out of range” (LLLS) fault may also be displayed. Under these
conditions it’s possible that the LLLS fault could be displayed
K3.7 even though the sensor may be functioning correctly.
The readings should be as follows:

• Setting 1 should be approximately 1000 Ohms
LLLS • Signal from speed • Check the integrity of
sensor in vibration is out wiring and
of range connections between
speed sensor and
micro processor.
Figure 1-2
MICROPROCESSOR
January 2003
Code Symptom Check
LLSS • Signal from speed • Check that speed
(Cont) sensor in vibration is out sensor is properly
of range. (Cont) adjusted.
a. To adjust speed
sensor, loosen locking
nut and turn sensor in
until it bottoms out, then
back sensor out 3/4 of a
turn and tighten locknut.
NOTE: This fault will not shutdown 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
K3.8 VPM setting. Some changes or variations in VPM may be
noticed.
SLLS • Coil at EDC on vibration • Check the integrity of
is open or shorted. the wiring and
connections between
the EDC and the
microprocessor.
• Check the resistance
across the coil at the
EDC. There should be
19 ohm resistance
between A-B and 16.5
ohm resistance
between C-D. Figure 1-2
MICROPROCESSOR
January 2003
Code Symptom Check
NOTE: When this fault occurs, the “signal from speed sensor
is out of range” (LLLS) fault may also be displayed. Under
these conditions it’s possible that the LLLS fault could be
displayed even though the sensor is functioning correctly.
K3.9
Figure 1-2
MICROPROCESSOR
January 2003
SD100/105 TF SERIES / TRACTION ENHANCEMENT SYSTEM
TABLE OF CONTENTS. ............................................ 43.1
TRACTION ENHANCEMENT SYSTEM....................K4.2

Major Components ...............................................K4.2
Troubleshooting....................................................K4.4
Fault Codes ..........................................................K4.6
CHARTS
Traction Enhancement Components ....................K4.2
Microprocessor LED Functions ............................K4.3
Troubleshooting Chart..........................................K4.4
Fault Code Troubleshooting Chart .......................K4.7
K4.1
021402AA
TABLE OF CONTENTS
January 2003
TRACTION ENHANCEMENT SYSTEM
The purpose of the Traction Enhancement system is to limit the
amount of slip between the front and rear drive motors. The
speed of each motor is transmitted to a microprocessor, which
continuously compares the speed of one motor to the other. If
one motor begins to over-speed (drum or wheel slip) the
microprocessor directs a proportional valve to reduce the flow
(depending on the direction of travel) either to or from that
motor. This reduction in flow to or from the spinning motor
increases the relative tractive effort of the end of the roller
(drum or tires) that is not slipping or spinning.
MAJOR COMPONENTS
Traction Enhancement Components
• A microprocessor (1, Figure 1-2) labeled “SX Traction
K4.2 Control,” is located in the battery compartment.
• Two speed sensors; one located on the drum drive motor
and one located on the axle drive motor.
• A resistor pack is located in the drum speed sensor
harness just inside the swivel area.
• A traction control valve is located on the inside of the main
frame on the right hand side opposite the battery
compartment. 021402AA
• A remote loop-flushing valve is located on the inside of the

main frame on the left-hand side. Note: The loop-flushing
valve in the axle drive motor is disabled on units equipped
with the traction enhancement system.
Figure 1-1
TRACTION ENHANCEMENT SYSTEM

January 2003
The microprocessor (1, Figure 1-2) contains four LED indicator
lights located vertically on the front of the case. Refer to the
Microprocessor LED Function Chart.
Microprocessor LED Functions

Power Indicates power is being supplied to the
microprocessor.
System Indicates the microprocessor is functioning
normally.
Mode Will blink amber when power is being supplied to
microprocessor.
• A blink rate of about 10 times per second
indicates no application is loaded or an
application is loaded with faults.
• A blink rate of once per second indicates an
K4.3 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
January 2003
TROUBLESHOOTING
If a problem occurs with the traction enhancement system the
following steps will aid in the troubleshooting process.
WARNING:
If it is required for the engine to be operating to perform any
testing or repair, ensure the articulation locking device is
installed and the wheels and drum are chocked.
Unplug all micro controllers prior to welding.

NOTE
The traction enhancement system only functions in the
compaction or low travel speed setting.
Troubleshooting Chart
K4.4 Step Check Correction
1 Establish that power is Determine power
being supplied to the interruption by:
microprocessor.
• Is the Hi/Low travel
Is the power LED on the switch directing
microprocessor current to the F1
illuminated? terminal on the
microprocessor?
• Is the F3 fuse OK?
• Is the maintenance
jumper, which is
located in the
harness next to the Figure 1-2
microprocessor,
installed?
MICROPROCESSOR
January 2003
Troubleshooting Chart (Continued)
2 Is the system LED on the If system LED is not
microprocessor illuminated and the
illuminated? POWER LED is
illuminated, 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,
the ignition switch must
remain in the “on
position” from the time
the fault occurs.
K4.5
To accomplish this, stop
the machine travel and
apply park brake.
Observe the status LED

on the traction control
microprocessor with the
engine running or shut
down the engine with the
emergency stop switch.
NOTE
Do not turn the ignition switch to the off position, as this will
reset the microprocessor. Figure 1-2
MICROPROCESSOR
January 2003
FAULT CODES
The following is a list of possible fault codes (S = short and L =
long)
• SSLS = Current supplied to front valve coil on the traction

valve is out of range. This fault would indicate either a short
in the wiring/coil or an open circuit. When this fault occurs a
blink code will be displayed on microprocessor and the
system will continue to try to perform anti-spin.
• LSLS = Current supplied to rear valve coil on the traction
valve is out of range. This fault would indicate either a short
in the wiring/coil or an open circuit. When this fault occurs a
blink code will be displayed on microprocessor and the
system will continue to try to perform anti-spin.
• SLLS = Front (drum) speed sensor signal out of range. The
K4.6 speed signal from the rear motor is above the minimum
(this would indicate that the wheels are turning) but no
signal is being received from front motor (this would
indicate that the drum is not turning). For this fault to occur
the condition described above must exist for a minimum of
30 seconds.
• LLLS = Rear (axle) speed sensor out of range. The speed
signal from the front motor is above the minimum (this
would indicate that the drum is turning) but no signal is
being received from rear motor (this would indicate that the
tires are not turning). For this fault to occur the condition
described above must exist for a minimum of 30 seconds.
Figure 1-2
MICROPROCESSOR
January 2003
Fault Code Troubleshooting Chart
Code Symptom Check
SSLS • Current supplied to • Check continuity of
front valve coil on the the wire that runs from
traction valve is out of the B1 terminal at the
range microprocessor to the
front valve coil at the
traction valve.
• Check continuity of
the wire that runs from
the front valve coil to
ground/frame.
• Check the resistance
across the coil to
K4.7 determine condition of
coil.
Resistance to be
approximately. 6.0
ohms)
LSLS • Current supplied to rear • Check continuity of
valve coil on the the wire that runs from
traction valve is out of the B2 terminal at the
range. microprocessor to the
rear valve coil at the
traction valve.
• Check continuity of
the wire that runs from
the front valve coil to Figure 1-2
ground frame.
MICROPROCESSOR
January 2003
Code Symptom Check
LSLS • Current supplied to rear • Check the resistance
(Cont) valve coil on the across the coil to
traction valve is out of determine condition of
range. (Cont) coil. (Resistance
should be
approximately. 6.0
ohms)
SLLS • Front (drum) speed • Check the integrity of
sensor signal out of the wiring at the front
range. drive-motor speed
sensor.
a. Check continuity of
the signal wire between
K4.8 the sensor and the
microprocessor. It
should be noted that
there is a resistor pack
located in this circuit. A
reading of 1900 to 2100
Ohms of resistance
would be typical.
b. With the key switch in

the run position confirm
that system voltage is
present at the “A” or B+
terminal of the sensor
Figure 1-2
connector.
MICROPROCESSOR
January 2003
Code Symptom Check
SLLS • Front (drum) speed c. Check continuity
(Cont) sensor signal out of between the “C” or “B-“
range. (Cont) terminal of the sensor
connector and ground/
frame.
• After the wiring and
connectors have been
inspected reset the
microprocessor by
cycling the ignition
switch to the off
position. Restart the
machine and test the
K4.9 operation of traction
system. The unit must
be propelled for at
least 30 seconds at 1
mph in one direction
for a fault (if present)
to be displayed.
• If the problem persists
the speed sensor may
be damaged or out of
adjustment.
Figure 1-2
MICROPROCESSOR
January 2003
Code Symptom Check
SLLS • Front (drum) speed a. If upon inspection it
(Cont) sensor signal out of is found that there is
range. (Cont) evidence of scratching
or scuffing on the end of
the sensor, it is very
likely that it has been
damaged and it should
be replaced.
b. To determine if the
sensor is out of
adjustment, the sensor
would have to be
K4.10 removed and reinstalled
with a new clearance tab
applied and then the
unit test run.
c. When installing the

speed sensor in the
drum drive motor, the
following procedure
applies:
LLLS • Rear (axle) speed • Check the integrity of
sensor (1, Figure 1-3) the wiring and
out of range. connectors between
the speed sensor on
axle drive motor and Figure 1-3
microprocessor.
REAR AXLE SPEED SENSOR
January 2003
Code Symptom Check
LLLS • Rear (axle) speed a. Check continuity of
(Cont) sensor (1, Figure 1-3) the signal wire between
out of range. (Cont) terminal ‘B” at the sensor
connector and terminal
“E1” at the
microprocessor.
b. With the key switch

in the run position
confirm that system
voltage is present at the
“A” terminal of the
sensor connector.
K4.11
c. Check continuity
between the “C” terminal
of the sensor connector
and ground/frame.
• After verifying the
integrity of wiring and
connectors, reset
microprocessor
bycycling ignition
switch to the off
position and then
restarting the
machine.
Figure 1-3

January 2003
Code Symptom Check
LLLS • Rear (axle) speed • The unit must be
(Cont) sensor (1, Figure 1-3) propelled for at least
out of range. (Cont) 30 seconds at 1 mph
in one direction for a
fault (if present) to
requester.
• If after resetting
microprocessor the
traction system fails to
operate correctly,
verify the axle drive
motor speed sensor is
properly adjusted.
K4.12 a. Loosen the locking
nut on speed sensor.
Turn speed sensor in
until it bottoms out, then
back speed sensor out
3/4 turn and re-tighten
lock nut.
• If after adjusting the
rear speed sensor the
traction system fails to
operate correctly,
replace the speed
sensor.
Figure 1-3

January 2003
NOTE: There is a paper tab on the inboard end of speed
sensor. This tab must remain on the sensor when installing. Its
purpose is to ensure that the proper clearance is maintained
between sensor and motor block. If an existing speed sensor is
removed for inspection a new clearance tab would have to be
applied before that sensor could be reinstalled. Extra speed
sensor clearance tabs are available under part number
13284203.
With paper tab in place install the sensor into the motor until it
bottoms out. Orient the notch located at the connector end of
the sensor so that it points toward the center of the motor. This
will result in the connector being positioned in the manner
displayed in the picture above. Once the sensor has been
bottomed out and the notch is correctly positioned, the sensor
may be secured in place.
K4.13
Figure 1-3

January 2003
SD-100/105TF SERIES HYDRAULIC
L3
D13190731 Rev.4
MACHINE HYDRAULIC SCHEMATIC

January 2003
SD-100/105TF SERIES HYDRAULIC
L4
D13190731 Rev.4
MACHINE HYDRAULIC SCHEMATIC

January 2003
SD-100/105TF SERIES ELECTRICAL
L5
D59292995 Rev. 4
MACHINE ELECTRICAL SCHEMATIC

January 2003
L6
D59292995 Rev. 4

January 2003
L7
D59292995 Rev. 4

January 2003

Volvo EN SD100 SD105 TF PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Volvo EN SD100 SD105 TF PDF

Uploaded by

Copyright:

Available Formats

VOLVO CONSTRUCTION EQUIPMENT

MORE CARE. BUILT IN.

Steering Pump ...................................... G6 regarding Authorized Rebuilt Components.

EFF. W/ ALL S/N

FEATURES OF THIS MANUAL

TABLE OF CONTENTS 4. Check and adjust the charge pressure as required.

CHARGE RELIEF VALVES

• Hose routing diagram w/ components labeled.

• Colors are standard

EFF. W/ ALL S/N

ILLUSTRATED HOSE SCHEMATIC

Steering Pump Right

D1 Charge Filter Left

Suction Filter Drum Drive Motor

EFF. W/ ALL S/N

ILLUSTRATED HOSE SCHEMATIC

Hydraulic Tank Steering

Steering Pump Right

Traction Control Valve

Suction Filter Drum Drive Motor

EFF. W/ ALL S/N

Settings and Specifications - Propulsion* 100D 105DX 105F

PROPULSION PUMP CHARGE FILTER

DUMP / BRAKE / 2 SPEED MANIFOLD

NEUTRAL - BRAKES APPLIED

CHARGE FILTER TRACTION ENHANCEMENT VALVE

NEUTRAL - BRAKES APPLIED

FORWARD - BRAKES RELEASED

LOOP AXLE MOTOR

PROPULSION PUMP CHARGE FILTER TRACTION ENHANCEMENT VALVE

LIP SEAL AND SHAFT............................................E13.2

LIP SEAL AND SHAFT

LIP SEAL AND SHAFT

MULTI-FUNCTION VALVE CARTRIDGES

CHARGE RELIEF VALVE

LIP SEAL AND SHAFT

LIP SEAL AND SHAFT

LOOP FLUSHING VALVE

CHARGE RELIEF VALVE

LIP SEAL AND SHAFT............................................E15.2

DISTRIBUTION VALVE ...........................................E16.2

Drum Drive Motor

CYLINDER BLOCK AND CAM

CYLINDER BLOCK AND CAM

LOOP FLUSHING VALVE .......................................E17.2

Save time and money by contacting your authorized

LOOP FLUSHING VALVE

CHARGE RELIEF VALVE

Thermal Bypass Valve

EFF. W/ ALL S/N

CLOCKWISE - HIGH AMPLITUDE

VIBRATION PUMP dashed lines

CHARGE RELIEF VALVE..........................................F6.5

CHARGE CHECK AND HIGH

CHARGE RELIEF VALVE

ELECTRICAL DISPLACEMENT CONTROL

ELECTRICAL DISPLACEMENT CONTROL

SHAFT SEAL............................................................. F7.2

Save time and money by contacting your authorized

Table of Contents Settings and Specifications - Steering* 100D 105DX 105F

EFF. W/ ALL S/N

SEAL KIT .................................................................. G6.2

Save time and money by contacting your authorized