JCB Vibromax Roller 70B Sevice Manual - PDF DOWNLOAD

WALK-BEHIND ROLLER SERVICE MANUAL SM31001 February 2000

Model 70B

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

table of contents

SECTION ONE GENERAL ......................................................................................... 1 - 1 MACHINE DESCRIPTION .............................................................................. 1 - 4 MODEL 70B DIMENSIONAL DATA ................................................................ 1 - 7 FLUID CAPACITIES ....................................................................................... 1 - 7 MODEL 70B OPERATING DATA ................................................................... 1 - 8 ENGINE ..................................................................................................... 1 - 8 WEIGHTS .................................................................................................. 1 - 8 TRAVEL SPEED ........................................................................................ 1 - 8 VIBRATION SYSTEM ................................................................................ 1 - 8 STANDARD TORQUE DATA ......................................................................... 1 - 9 METRIC/USA CONVERSIONS .................................................................... 1 - 10 DIESEL FUEL SPECIFICATION ................................................................... 1 - 11 ENGINE OIL SPECIFICATION ..................................................................... 1 - 12 VIBRATORY SYSTEM OIL ........................................................................... 1 - 13 DRIVE GEARS LUBRICATION .................................................................... 1 - 13 HYDRAULIC SYSTEM OIL ........................................................................... 1 - 13 MACHINE STORAGE ................................................................................... 1 - 14 SAFETY ........................................................................................................ 1 - 15 SPARK ARRESTER ..................................................................................... 1 - 15 PERSONAL ................................................................................................... 1 - 15 MACHINE OPERATION ............................................................................... 1 - 16 MAINTENANCE ............................................................................................ 1 - 17

SECTION TWO ENGINE ............................................................................................. 2 - 1 ENGINE SPECS. ............................................................................................ 2 - 2 RUN-IN PERIOD............................................................................................. 2 - 2 DIESEL FUEL SPECIFICATION..................................................................... 2 - 3 ENGINE OIL SPECIFICATION ....................................................................... 2 - 4

SECTION THREE ELECTRICAL .................................................................................... 3 - 1 ENGINE ELECTRICAL ................................................................................... 3 - 2 UNDERSTANDING STARTERS ..................................................................... 3 - 2 STARTER SOLENOID .............................................................................. 3 - 3 70B STARTING CIRCUIT FUNCTION ........................................................... 3 - 4 ELECTRICAL SCHEMATIC 70B ................................................................... 3 - 5

1

table of contents

SECTION FOUR HYDRAULIC ...................................................................................... 4 - 1 70B HYDRAULIC SYSTEM ............................................................................ 4 - 2 HYDRAULIC DESCRIPTION .......................................................................... 4 - 4 CHARGE RELIEF ............................................................................................ 4 - 6 VIBRATION VALVE ........................................................................................ 4 - 6 HYDRAULIC PRESSURE TEST .................................................................... 4 - 8

SECTION FIVE FINAL DRIVE .................................................................................... 5 - 1 LOWER DRIVE UNIT ...................................................................................... 5 - 2 LOWER UNIT ASSEMBLY ............................................................................. 5 - 6

SECTION SIX VIBRATION SYSTEM ....................................................................... 6 - 1 VIBRATION SYSTEM ..................................................................................... 6 - 2 VIBRATION FREQUENCY & AMPLITUDE ..................................................... 6 - 3 VIBRATORY SYSTEM DIAGNOSTICS .......................................................... 6 - 4 VIBRATION VALVE ........................................................................................ 6 - 5 VIBRATORY SHAFT........................................................................................ 6 - 7

SECTION SEVEN DRIVE CONTROLS .......................................................................... 7 - 1 GUIDE BAR .................................................................................................... 7 - 2 DRIVE CONTROL & CABLE .......................................................................... 7 - 3 DRIVE CABLE RETURN MECHANISM ....................................................... 7 - 10

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SECTION ONE

GENERAL

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1-1

SM31001 - SECTION 1

GENERAL

These symbols mean ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED. The message that follows the symbol contains important information about safety. Carefully read the message. Make sure you fully understand the causes of possible injury or death.

IF THIS MACHINE IS USED BY AN EMPLOYEE, IS LOANED, OR RENTED, MAKE SURE THAT THE TWO INSTRUCTIONS BELOW ARE FOLLOWED. BEFORE THE OPERATOR STARTS THE ENGINE: •

GIVE INSTRUCTION TO THE OPERATOR ON SAFE AND CORRECT USE OF THE MACHINE.

•

MAKE SURE THE OPERATOR READS AND UNDERSTANDS THE OPERATOR’S MANUAL FOR THIS MACHINE.

IMPROPER OPERATION OF THIS MACHINE CAN CAUSE INJURY OR DEATH! LEARN AND PRACTICE SAFE USE OF MACHINE CONTROLS IN A SAFE, CLEAR AREA BEFORE YOU OPERATE THIS MACHINE ON A JOB SITE! IT IS YOUR RESPONSIBILITY TO OBSERVE PERTINENT LAWS AND REGULATIONS AND TO FOLLOW MANUFACTURER’S INSTRUCTIONS ON MACHINE OPERATION AND MAINTENANCE.

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SM31001 - SECTION 1

GENERAL

MODEL W70B ENGINE DATA

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Make

Hatz

Model

1D81S

Type

single cyl., air cooled, 4 stroke, diesel

Displacement

40.0 cubic inch (667 cc)

HP Rating

12.0 hp (8.9 kW) SAE net

Operating speed

2400 rpm

Starter type

Hand crank

Air cleaner type

Dry element

Fuel filter type

In-line Cartridge

Fuel consumption

0.52 gal/hr (2.0 liter/hr)

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SM31001 - SECTION 1

GENERAL

MACHINE DESCRIPTION

Rear

Right

Left

Front

The walk-behind tandem rollers are designed on a modular basis and feature a uniform design and a common mode of operation.

The speed and direction controls allow for safe and easy operation.

These machines are equipped with diesel engines for greater torque at a lower fuel consumption rate.

Walk-behind rollers are larger and heavier than vibratory plates and are most often used on jobs that do not require the compaction forces found on the larger ride-on roller models.

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SM31001 - SECTION 1

GENERAL

MODEL 70B

Enter the model number, serial number, and engine serial number in the spaces below. When ordering parts or requesting information on your machine, please have these numbers available when you contact your dealer.

Model: Serial No. (product identification - PIN) Engine: make

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model

1-5

serial no.

SM31001 - SECTION 1

GENERAL

MODEL 70B

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SM31001 - SECTION 1

GENERAL

MODEL 70B DIMENSIONAL DATA

a Inch (mm)

b Inch (mm)

d Inch (mm)

23.6

30.7

17.7

(600)

(780)

(450)

g Inch (mm)

h Inch (mm)

39.4

47.6

(1000) (1210)

k Inch (mm) 6.3 (160)

l Inch (mm)

n Inch (mm)

90.9

48.0

(2310) (1220)

o Inch (mm)

w Inch (mm)

0.8

25.6

(20)

(650)

FLUID CAPACITIES Fuel Tank Engine Oil Hydraulic Reservoir Oil Exciter Oil Sprinkler Water

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1.8 gallons 2.0 quarts 6.6 gallons 1.10 quarts 9.2 gallons

1-7

7.0 liters 1.9 liters 25 liters 1.0 liters 35 liters (each, front & rear)

SM31001 - SECTION 1

GENERAL

MODEL 70B OPERATING DATA ENGINE Make and Model ......................................................................HATZ 1D81S Displacement.................................................................. 40.0 cu.in. (667cc) SAE Net Horsepower .................... 12.0@ 2400 rpm. (8.9kW@ 2400 rpm.)

Full Throttle Speed ...................................................................... 2400 rpm.

Idle Speed ...................................................................... 1000 to 1100 rpm.

Intake Valve Clearance (cold)........................................ 0.004 in. (0.10mm) Exhaust Valve Clearance (cold) .................................... 0.004 in. (0.10mm)

WEIGHTS Operating weight ...............................................................1763 lb. (800 kg) Distribution (front)................................................................793 lb. (360 kg) Distribution (rear).................................................................970 lb. (440 kg)

TRAVEL SPEED Forward Reverse

................................................ 0 to 3.0 mph (0 to 5.0 km/hr) ................................................ 0 to 1.5 mph (0 to 2.5 km/hr)

VIBRATION SYSTEM Exciter frequency............................................................. 3300 vpm (55 Hz) Nominal Amplitude ........................................................ 0.017 in. (0.42mm) Exciter Force .................................................................... 4496 lb. (20 kN) Exciter Force/Drum Width ............................................ 88 lb/in. (154 N/cm) Compaction Depth...............................................................13.8 in. (35 cm)

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SM31001 - SECTION 1

GENERAL

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

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

STANDARD TORQUE SPECIFICATIONS +/- 10% GRADE 8.8

GRADE 10.9

GRADE 12.9

SIZE

ft.-lbs

Nm

ft.-lbs

Nm

ft.-lbs

Nm

5mm

4

5.5

5.5

7.5

6.6

9

6mm

6.6

9

9.2

12.5

11

15

8mm

16.5

22.5

23

31.5

26.5

36

10mm

32

44

45

62

55

75

12mm

57

77.5

81

110

95

130

14mm

88

120

125

170

155

210

16mm

140

190

195

265

236

320

18mm

192

260

269

365

320

435

20mm

273

370

383

520

457

620

22mm

369

500

516

700

619

840

24mm

471

640

665

900

796

1080

27mm

702

950

996

1350

1195

1620

30mm

955

1300

1328

1800

1593

2160

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

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NEWTONS/METER 20 35 45 60

1-9

POUNDS/FOOT 14.5 26 33.2 44

SM31001 - SECTION 1

GENERAL

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

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

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

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

NEWTONS/METER 28 55 90 145 230

POUNDS/FOOT 21 41 67 107 170

METRIC/USA CONVERSIONS

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

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

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

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

C x 1.8 + 32 = oF Nm x.737 = lb ft.

Nm x 8.85 = lb in liters x .264 = gallons liters x 1.056 = quarts

cubic centimeters (cm3)

cubic inches (in3)

cm3 x .061 = in3

1 - 10

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

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SM31001 - SECTION 1

GENERAL

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

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

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

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

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

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

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

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SM31001 - SECTION 1

GENERAL

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

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

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

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SM31001 - SECTION 1

GENERAL

VIBRATORY SYSTEM OIL Capacities:

Model 70B

1.10 quart, 1.00 liter

Oil Type:

API. CC/CD SAE 30 Engine Oil

The vibration oil on the model 70B is drained and filled through the plug located on the right side of the machine on the vibration shaft end cap. The left side of the machine has to be elevated to drain the vibration system oil.

Do not overfill the vibration system. An over full system consumes engine horsepower and causes the vibration system to run at a lower than normal speed.

DRIVE GEARS LUBRICATION Lubricate the drive gears every 1000 hours with molydisulfide grease.

The gears are located under the gear cover on the left side of the machine. Remove the cover and clean the old grease off the gears with a cleaning solvent. Apply fresh grease and reinstall the gear cover.

HYDRAULIC SYSTEM OIL Reservoir Capacities: Model 70B 6.6 gallons, 25.0 liter Oil Type: cold weather HLP 46 hot weather HLP 68

Suggested:

DIN 51524/2 DIN 51524/2

Mobil DTE Shell Tellus Amoco Rykon Texaco Rando

25, 26, 27 OL 46, 68 HD 46, 68 HD 46, 68

It is recommended that the hydraulic oil and filter be changed every 1000 hours. The filler cap breather and reservoir should also be cleaned at this time. It is best to drain the system after it has been running to insure removal of system contaminants.

Model 70B:The hydraulic oil can be drained by removing a return hose from the reservoir.

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SM31001 - SECTION 1

GENERAL

MACHINE STORAGE If the machine is to be stored for more than 30 days, park the machine inside a building. If a building is not available, park the machine in a dry area on wood boards and cover the machine with a waterproof covering.

Preparation •

Drain the water tank and system.

•

Wash the machine. Paint any areas where paint has been damaged.

•

Add approximately 1.0 quart (1.0 liter) of diesel flushing oil to the fuel tank. Run the engine until the exhaust smoke is blue-white. Stop the engine and drain the fuel tank.

•

Put one level teaspoon of Shell Oil Company VPI 260 crystals in the fuel tank.

•

Change the engine oil and filter. Change the air filter oil.

•

Remove or loosen the drive belt.

•

Clean and lubricate the drive gears.

•

Put a DO NOT OPERATE tag on the machine.

Removal from storage •

Change the fuel filter.

•

Check the engine oil level.

•

Install or tighten the drive belt.

•

Fill the fuel tank.

•

Remove the DO NOT OPERATE tag.

•

Inject engine oil into the starting aid port on the rocker cover.

•

Follow the instructions for starting the engine found in the operations section of this manual.

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SM31001 - SECTION 1

GENERAL

SAFETY The information in this manual does not replace any safety rules and laws used in your area. Before operating this machine, learn the rules and laws for your area and make sure your machine has the correct equipment according to these rules and regulations. Before starting the engine study the operator’s manual.

•

Know the location and function of all machine controls.

•

Clear the area of other persons before you start the engine.

•

Check all controls in a safe area before you operate the machine.

•

Understand the limits of the machine.

•

Do not try to do too much too fast.

•

Keep the machine under control at all times.

SPARK ARRESTER NOTE: Rules or laws in some areas may require that this machine be equipped with a spark arrester or spark arrester muffler. Check the rules or laws in your area.

PERSONAL

Loose clothing and jewelry can cause an accident. Do not wear loose clothing or jewelry that can catch on controls, etc. Do wear safety shoes, hard hat, heavy gloves, etc. when required for your protection.

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

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

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

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SM31001 - SECTION 1

GENERAL

Holes, obstructions, debris, and other work area hazards can cause injury or death.

Always walk-around and look for these and other hazards before you operate your machine in a new work area.

Lack of, or incomplete, machine inspection and maintenance can cause accidents.

Always follow the instructions in operator’s manual for machine inspection and maintenance.

Always wear the proper ear protection when operating this machine. Permanent hearing loss can result from extended exposure to loud noises.

The following decal is located on the guide bar. Check the decal daily. Clean or replace as needed.

MACHINE OPERATION

Dust, smoke, fog, etc. can decrease your vision and cause an accident. Always stop or slow the machine until you can clearly see your work area and the surrounding traffic.

Sparks from the electrical system or engine exhaust can cause a fire or explosion.

Before you operate this machine in an area with flammable dust or vapors, use good ventilation to remove the flammable dust or vapors.

Engine exhaust fumes can cause injury or death. If you operate this machine in an enclosed area, use good ventilation to replace the exhaust fumes with fresh air.

The vibrations from this machine can cause the walls of a trench or high bank to collapse. Make sure the walls of the trench or bank are braced. If you do not follow these instructions, you can cause personal injury. or death to persons working in these areas.

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SM31001 - SECTION 1

GENERAL

A machine out of control can cause injury or death. You must make a judgement if weather and earth conditions will permit safe operation on a hill, ramp, or rough ground.

Adjust machine operation accordingly.

Operating this machine too close to High Voltage electrical lines can cause injury or death. Follow the guide lines listed below.

NOTE: IF THE CLEARANCES IN THE SPECIFICATIONS BELOW ARE LESS THAN THE CLEARANCES GIVEN IN THE RULES AND LAWS OF YOUR AREA, YOU MUST FOLLOW THE RULES AND LAWS OF YOUR AREA! Table 1: Electrical Safety Rules Minimum Clearance From Cable When Machine is Working

Minimum Clearance From Cable When Transporting Machine

50,000 volts or less

10 feet (3 meters)

4 feet (1.2 meters)

50,000 volts to 345,000 volts

10 feet (3m) plus 1/2 inch (13mm) for every 1000 volts over 50,000 volts

10 feet (3 meters)

345,000 volts to 750,000 volts

10 feet (3m) plus 1/2 inch (13mm) for every 1000 volts over 50,000 volts

16 feet (5 meters)

Cable Voltage

MAINTENANCE

Engine fuel is flammable and can cause a fire or an explosion. Do not fill the fuel tank or service the fuel system while the machine is running, or near an open flame, welding, burning cigars and cigarettes, etc.

Machine movement without an operator can cause injury or death. If you must service this machine with the engine running, have another person help you and follow the instructions in the machine manuals.

Improper service or repair can cause injury or death. If you do not understand the service procedures for this machine, see your Vibromax dealer.

Flammable cleaning solvents can cause injury or death. Use nonflammable cleaning solvents for cleaning purposes.

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1 - 17

SM31001 - SECTION 1

GENERAL

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

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

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

Batteries produce explosive gases. Protect from and keep flames away. Ventilate when charging. Always wear eye protection when working near batteries. Do not wear jewelry or watch bands when working on batteries.

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

Never charge or jump a battery when the electrolyte is frozen. If you do not follow this instruction the battery can explode.

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

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SECTION TWO

ENGINE

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2-1

SM31001 - SECTION 2

ENGINE

ENGINE SPECIFICATIONS Make and Model ......................................................................HATZ 1D81S Type ...........................Four stroke, single cylinder, direct injection, diesel Bore / Stroke .......................................................................100mm / 85mm Displacement.................................................................. 40.0 cu.in. (667cc) Rotation ........................................................................... counter-clockwise SAE Net Horsepower .................... 12.0@ 2400 rpm. (8.9kW@ 2400 rpm.)

Full Throttle Speed ...................................................................... 2400 rpm.

Idle Speed ...................................................................... 1000 to 1100 rpm.

Injection pressure ............................................. 3600 +115 psi (250 +8 bar) Intake Valve Clearance (cold)........................................ 0.004 in. (0.10mm) Exhaust Valve Clearance (cold) .................................... 0.004 in. (0.10mm) Oil capacity with oil filter ................................................ 2 quarts (1.9 liters) Net weight ............................................................................201 lbs. (91kg)

RUN-IN PERIOD The first 20 hours of operation are considered the machine’s run-in period. During this time you are asked to follow some special guidelines. These guidelines should also be followed if the engine has been rebuilt or a new engine is installed.

•

Read or review the operators manual.

•

Take time to become acquainted with your machine controls.

•

Operate the machine with normal loads.

•

Keep the engine at normal operating temperatures.

•

Do not run the engine at idle speed for long periods of time.

•

Make additional walk-around inspections.

•

Check your engine oil more often than normal.

After completion of the first 20 hours of operation do the following: •

Change the engine oil.

•

Check the engine speed at idle and full throttle.

•

Check valves for correct clearance.

•

Check air cleaner connections and oil level in bowl.

•

Check fuel system for leaks.

•

Tighten all hose clamps.

During the machine warranty period the engine warranty is covered by Hatz Diesel.

Contact your Hatz Dealer for additional service information and materials.

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SM31001 - SECTION 2

ENGINE

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

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

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

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

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

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

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

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2-3

SM31001 - SECTION 2

ENGINE

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

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

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

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2-4

SECTION THREE

ELECTRICAL

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3-1

SM31001 - SECTION 3

ELECTRICAL

ENGINE ELECTRICAL The Vibromax Model 70B offers an electric starter option. This option includes a battery, starter, key switch, alternator, charge indicator light, engine oil pressure switch, and low oil pressure indicator light.

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

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

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

Pre-engaged starters are used on most engines. They provide a positive engagement by not allowing full battery power to the starter motor until the drive pinion is fully engaged into the flywheel.

3-2

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SM31001 - SECTION 3

ELECTRICAL

STARTER SOLENOID A starter solenoid has two coils. They are the “hold-in coil” (1) which connects to ground, and the “closing coil” (2) which is connected to ground through the starter motor windings.

When the switch is “ON”, current passes through the hold-in coil (1), creating a magnetic field around the plunger (3). Current also passes through the closing coil (2), creating a second field.

The current that flows from the closing coil into the starter motor windings causes the motor to rotate slowly. The combined magnetic fields of the two coils causes the plunger to engage.

This moves the arm (4) causing engagement of the drive pinion into the flywheel.

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3-3

SM31001 - SECTION 3

ELECTRICAL

When the plunger (3) moves to full stroke and the drive pinion is fully engaged, the solenoid contacts (5) are closed, allowing full power to the starter motor.

70B STARTING CIRCUIT FUNCTION The key switch (S1) receives power from the battery (G1) at terminal #30. When the key switch is turned to the “ON� position (first position), power is connected to terminals #15/54, energizing all switch controlled components through a fuse (F1). The alternator indicator light (H1) and the oil pressure indicator light (H2) will illuminate, indicating the key switch is on but the engine is not running and there is no alternator output. The ground for alternator indicator light (H1) is through the regulator (V1).

To start the machine the key switch is turned to the start position (second position) providing a current path from the key switch (S1) terminal #50a to the starter motor (M1) terminal #50 on the starter solenoid. Note that the battery is connected to the starter motor (M1) at terminal #30. With current to the starter solenoid, contacts within the solenoid close the connection to the battery causing the starter to turn.

When the engine is started the key switch is turned back to the first position removing current to the starter. The alternator (G2) provides output current and the regulator (V1) provides 12 volts in place of ground. The alternator indicator light (H1) will extinguish as a result of having 12 volts on each side of the lamp. Engine oil pressure will rise when the engine is started. The oil pressure will open oil pressure switch (S2) removing the ground connection and extinguishing the oil pressure indicator light (H2).

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3-4

SM31001 - SECTION 3

ELECTRICAL

ELECTRICAL SCHEMATIC 70B

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SM31001 - SECTION 3

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ELECTRICAL

3-6

SECTION FOUR

HYDRAULIC

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4-1

70B HYDRAULIC SYSTEM

4-2

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4-3

SM31001 - SECTION 4

HYDRAULIC

HYDRAULIC DESCRIPTION The propulsion system on the Model 70B consists of a Sauer Sundstrand Series 15 variable displacement piston pump primed by a built-in charge pump. The charge pump draws oil from the hydraulic reservoir and feeds a regulated (7 bar / 100 psi) flow into the propulsion system. The Series 15 cross-center piston pump then supplies flow into a Danfoss bi-directional hydraulic drive motor. Note that there is no relief valve in the drive system due to the limited available engine horsepower. Pressure test ports MP1 and MP2 are located on the propulsion pump for checking the drive system pressures. The drive motor rotates the front and rear drums though a gear box built into the lower unit of the machine. The gear box will be covered later in this book.

The vibration system consists of a Sauer Sundstrand fixed displacement gear pump driving a single direction gear type motor attached to dual eccentric exciter shafts. A bypass valve is mounted in a parallel flow path with the exciter shaft motor to control vibration “ON” and “OFF”. Built into the bypass control valve is a 1700 psi (120 bar) relief valve which protects the vibration system from over pressurization. The vibration system components are matched to obtain a vibratory action of 55 Hz (3300 vibrations per minute).

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SM31001 - SECTION 4

HYDRAULIC

CHARGE RELIEF Connect a 300 psi (20 bar) pressure gauge to test point MP3 at the charge pump. With the engine running at high idle and the system at normal operating temperature the pressure must be 100 psi (7 bar).

The charge pressure relief valve is installed in the side of the drive pump housing. To reset the charge pressure remove the plug and increase the number of shims to increase charge pressure or decrease the number of shims to decrease charge pressure.

NOTE: If the drive system has extremely high amounts of internal leakage, adding shims to the charge relief valve might not have an effect on the charge pressure.

VIBRATION VALVE The vibration control (bypass) valve is located on the guide handle and is used to turn the vibratory action “ON” and “OFF”. When vibration is “OFF” the oil flow will bypass the vibration motor and return to tank. To start vibratory operation the bypass valve is closed causing the oil to flow through the hydraulic motor and back to tank.

A 1700 psi (120 bar) pressure relief is built into the vibration control (bypass) valve. To test the pressure relief valve block the flow path through the vibration motor and install a pressure gauge on test port MP4 at the vibration control valve. With the vibration control valve in the vibratory operation position all flow will be across the pressure valve relief (see drawing on the following page).

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SM31001 - SECTION 4

HYDRAULIC

HYDRAULIC PRESSURE TEST Hydraulic testing must be conducted by a trained technician. See your Vibromax dealer.

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

Test ports are located on the machine as follows: MP1

propulsion pump housing

MP2

propulsion pump housing

MP3

charge pump housing

MP4

vibration valve inlet

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SECTION FIVE

FINAL DRIVE

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5-1

SM31001 - SECTION 5

FINAL DRIVE

LOWER DRIVE UNIT The lower drive unit consists of a hydraulic motor driving an input gear, a front and rear intermediate gear, a front and rear drive gear, a front and rear drum, and supporting side frames.

The gear box is located on the left side of the machine as viewed from the operator’s position and is concealed by a cover housing.

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SM31001 - SECTION 5

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FINAL DRIVE

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SM31001 - SECTION 5

FINAL DRIVE

5-4

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SM31001 - SECTION 5

FINAL DRIVE

LOWER UNIT ASSEMBLY 1.

Install the four bearings (9) into the left and right side panels (7 & 8) and secure into place with the proper snap ring (10).

2.

Place the drum seals (6) over the drum shafts.

3.

Assemble the side frames (7 & 8) onto the drums and secure the side frames to the cross braces (44) using capscrews (45) with Loctite 271 and torque to 140 ft. lbs.

(190 Nm).

4.

Install the drive motor to the left side frame using capscrews (34) with Loctite 271 and torque to 140 ft. lbs. (190 Nm). Insert the shaft key (27) and assemble the input gear (30) and secure in place with capscrew (32) and washer (31) using Loctite 271.

Torque the capscrew (32) to 17 ft. lbs. (23 Nm).

5.

Install the intermediate gear stub shafts into the left side frame using capscrew (16) and Loctite 271. Torque the capscrews to 17 ft. lbs. (23 Nm).

6.

Install the intermediate gear bearings (19) into the intermediate gears (18) and secure in place with inner and outer snap rings (20).

7.

Install the intermediate gear assembly onto the stub shafts (15) and secure into place with the proper snap ring (21).

8.

Install key (25) onto the drum shafts and install the drum drive gear (24) and secure in place with the proper snap ring (26).

9.

Pack the bearing and gears with Mobiltac 81, or Mobilplex 47 or equivalent grease.

10.

Install the gear box cover housing (48).

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SM31001 - SECTION 5

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FINAL DRIVE

5-7

SM31001 - SECTION 5

FINAL DRIVE

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SECTION SIX

VIBRATION SYSTEM

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6-1

SM31001 - SECTION 6

VIBRATION SYSTEM

VIBRATION SYSTEM

The vibration system gear pump draws oil from the reservoir and pumps oil into the vibration system. When control valve VB1 is opened the oil will take the path of least resistance and return to the reservoir bypassing the vibration motor. When the vibration control valve is manually turned to stop the oil from bypassing, all oil is directed through the vibration motor which will turn the eccentric shaft and cause a vibratory motion of 3300 vibrations per minute (55Hz). A relief valve is built into the vibration control valve to protect the system from pressure overloads.

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SM31001 - SECTION 6

VIBRATION SYSTEM

VIBRATION FREQUENCY & AMPLITUDE

AMPLITUDE AND FREQUENCY

AMPLITUDE

h1

frequency = cycles per TIME

h1 above = Jumping Height 1/2 of h1 = Amplitude

JUMPING HEIGHT

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AMPLITUDE

6-3

One half the vertical distance that the drum travels is called the amplitude. The amplitude for any given machine will vary depending on the soil conditions. The amplitude and the height the machine lifts itself off the ground will gradually increase as the soil becomes more dense or compacted. The frequency would equal the number of jumps the machine makes per minute (vpm), or seconds (Hz).

SM31001 - SECTION 6

VIBRATION SYSTEM

VIBRATORY SYSTEM DIAGNOSTICS The vibration system consists of a Sauer Sundstrand fixed displacement gear pump driving a single direction gear type motor attached to dual eccentric exciter shafts. A bypass valve is mounted in a parallel flow path with the exciter shaft motor to control vibration “ON” and “OFF”. Built into the bypass control valve is a 1700 psi (120 bar) relief valve which protects the vibration system from over pressurization. The vibration system components are matched to obtain a vibratory action of 55 Hz (3300 vibrations per minute).

Vibration frequency is related to the speed at which the vibration shaft is rotated and can be measured with a frequency meter. Low frequency problems will normally show up as a rough operating machine (often referred to as bucking).

VT9013

VT9012

Because the Model 70B vibration system is designed with a fixed displacement pump and motor, low vibration frequency would normally be due to a low engine speed. However, there are the possibilities that low vibration frequency could be caused by leakage at the vibration control valve and worn pump or motor components.

If leakage at the control valve is suspected, a pressure test should be conducted to insure that the system relief is properly set and that the system is not running at higher than normal pressure due to vibratory shaft bearing problems (see next page).

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SM31001 - SECTION 6

VIBRATION SYSTEM

VIBRATION VALVE The vibration control (bypass) valve is located on the guide handle and is used to turn the vibratory action “ON” and “OFF”. When vibration is “OFF” the oil flow will bypass the vibration motor and return to tank. To start vibratory operation the bypass valve is closed causing the oil to flow through the hydraulic motor and back to tank.

A 1700 psi (120 bar) pressure relief is built into the vibration control (bypass) valve. To test the pressure relief valve block the flow path through the vibration motor and install a pressure gauge on test port MP4 at the vibration control valve inlet. With the vibration control valve in the vibratory operation position and the motor port blocked all flow will be across the pressure relief valve.

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VIBRATORY SHAFT

SM31001 - SECTION 6

VIBRATION SYSTEM

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SM31001 - SECTION 6

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VIBRATION SYSTEM

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SM31001 - SECTION 6

VIBRATION SYSTEM

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SECTION SEVEN

DRIVE CONTROLS

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7-1

SM31001 - SECTION 7

DRIVE CONTROLS

GUIDE BAR

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SM31001 - SECTION 7

DRIVE CONTROLS

The guide bar is attached to the rear of the machine frame and is used to control the machine during operation. Located on the guide bar are the engine throttle control and cable, the vibration control valve, and the drive system control lever and cable. At the operator’s end of the guide bar is the operator’s grip handle. The following section deals with the removal, installation, and setup of the drive controls and cable.

DRIVE CONTROL & CABLE 1.

Remove the access panel on the left side of the machine.

2.

Remove the clevis pin attaching the drive control cable to the drive pump lever.

3.

Loosen the drive cable lock nuts at the cable mounting bracket and remove the cable.

4.

Remove the two socket head capscrews, washers, and clips that fasten the drive cable to the guide bar.

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SM31001 - SECTION 7

DRIVE CONTROLS

5.

Remove the two nuts that fasten the spring tensioning eye bolt to the anchor bracket.

Take note of the number of turns required to remove the nuts to insure the proper setting during reassembly. Remove the eye bolt and the spring from the control housing.

6.

Remove the drive control lever and cable assembly from the machine.

7.

Loosen the nut holding the outer cable to the control lever assembly. Pull the outer and inner cable rack away from the control lever housing.

NOTE: The sealing sleeve on the end of the outer cable can be tight in the control housing tube. If necessary, hold the outer cable and lightly hit the control housing with a soft faced hammer to separate the parts.

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SM31001 - SECTION 7

8.

DRIVE CONTROLS

The control lever assembly can be disassembled as needed. (see illustration on the following page)

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SM31001 - SECTION 7

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DRIVE CONTROLS

7-6

SM31001 - SECTION 7

DRIVE CONTROLS

9.

Make repairs as needed to the inner and outer cable assembly.

10.

To install a new cable insert the inner cable into the outer cable and loosely attach the inner cable clevis. Adjust the lock nut on the rack end of the cable so that it is 10mm (0.39 inch) from the end of the threads.

11.

Install the cable control rack and tighten the lock nut.

12.

Final adjustment of the cable assembly is made at a later time by setting the outer cable into the cable mounting bracket at 15mm (0.60 inch) as shown above then adjusting the clevis to match the pump neutral position. NOTE: final adjustments are made after the control lever and housing have been assembled.

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SM31001 - SECTION 7

13.

DRIVE CONTROLS

Reassemble the cable rack and control lever to obtain the following relationship.

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SM31001 - SECTION 7

DRIVE CONTROLS

14.

Reinstall the control housing and cable assembly onto the guide bar.

15.

Install the spring onto the pull wire and install the eye bolt onto the spring and the anchor bracket. Using the same number of turns as noted during disassembly install and tighten the two nuts onto the eye bolt.

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7-9

SM31001 - SECTION 7

DRIVE CONTROLS

DRIVE CABLE RETURN MECHANISM The cable return mechanism shown below is required because the Sauer Sundstrand series 15 pump does not have a return to neutral position feature.

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7 - 10

index

B before starting engine.................................................................................... 1 - 2 bolt torque chart.............................................................................................. 1 - 9

C cable adjustment ............................................................................................ 7 - 7 cable return mechanism................................................................................ 7 - 7 California Proposition 65 ..................................................................................... 2 charge pump relief ......................................................................................... 4 - 6

D diesel fuel specification ...................................................................... 1 - 11, 2 - 3 dimensional data ............................................................................................ 1 - 7 drive cable ....................................................................................................... 7 - 3 drive control..................................................................................................... 7 - 3 drive gear lube .............................................................................................. 1 - 13 drive lever assembly ...................................................................................... 7 - 6 drum drive........................................................................................................ 5 - 3

E electrical........................................................................................................... 3 - 2 electrical schematic........................................................................................ 3 - 5 engine oil specification ....................................................................... 1 - 12, 2 - 4 engine specs................................................................................................... 2 - 2

F fluid capacities ................................................................................................ 1 - 7

G guide bar.......................................................................................................... 7 - 2

H hydraulic oil ................................................................................................... 1 - 13 hydraulic pressure testing ............................................................................. 4 - 8 hydraulic system............................................................................................. 4 - 2

L lower drive unit................................................................................................ 5 - 2

1

index

M machine description ....................................................................................... 1 - 4 machine storage ........................................................................................... 1 - 14 metric conversions ....................................................................................... 1 - 10

O operating data ................................................................................................. 1 - 8

R removal from storage................................................................................... 1 - 14 roller frame ...................................................................................................... 5 - 4 run-in-period..................................................................................................... 2 - 2

S safety introduction .......................................................................................... 1 - 2 safety, during maintenance ........................................................................ 1 - 17 safety, electrical rules .................................................................................. 1 - 17 safety, general .............................................................................................. 1 - 15 safety, machine operation........................................................................... 1 - 16 safety, personal ............................................................................................ 1 - 15 spark arrester................................................................................................ 1 - 15 start circuit function ........................................................................................ 3 - 4 starters explained ........................................................................................... 3 - 2

T torque data ....................................................................................................... 1 - 9

V vibration amplitude explained....................................................................... 6 - 3 vibration control valve.................................................................................... 4 - 6 vibration frequency meters ........................................................................... 6 - 4 vibration system.............................................................................................. 6 - 2 vibratory oil capacity .................................................................................... 1 - 13 vibratory oil type ........................................................................................... 1 - 13 vibratory shaft ................................................................................................. 6 - 7

W warning symbols............................................................................................. 1 - 2

2

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VIBROMAX AMERICA INC. 2823 Carlisle Avenue Racine, WI. 53404 USA Phone: 1-262-637-8111 Fax: 1-262-637-8211

VIBROMAX GmbH Erkrather Str. 343 40231 Dusseldorf, GERMANY Phone: (49) 211-9866-402 Fax: (49) 211-9866-555

VIBROMAX COMPACTION EQUIPMENT GmbH Schaeferberg 1 06466 Gatersleben, GERMANY Phone: (49) 39482-9331 Fax: (49) 39482-9102

VIBROMAX COMPACTION EQUIPMENT GmbH 72, Pasir Ris Heights SINGAPORE 519279 Phone: (65) 5838297 Fax: (65) 5838301

2/25/2000