en SD116 TF Voe21a1004254h PDF

VOLVO CONSTRUCTION EQUIPMENT
SERVICE MANUAL
Sd116
MORE CARE. BUILT IN.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals and other related
accessories contain lead and lead compounds,
chemicals known to the State of California to cause
cancer and other reproductive harm.
Wash hands after handling.
SD-116 TF SERIES
Table of Contents.............................................. A1 Component Teardown & Rebuild
Features of This Manual................................... B1 Propulsion Pump............................................... E13
Safety Information ............................................ C1 Axle ................................................................... E14
Illustrated Hose Schematic
TABLE OF CONTENTS
Axle Motor......................................................... E15
Option Without Traction Control ............. D1
Loop Flush Valve .............................................. E16
Option With Traction Control ................... D2
HYDRAULIC
Propulsion / Braking
Schematics .................................................. E1
Overview
Standard Parallel on D & F................ E2
Standard on DX, Optional on D & F .. E3
Neutral - Brakes Applied
Standard Parallel on D & F................ E4
Standard on DX, Optional ................ E5
A1 Forward - Brakes Released
Standard Parallel on D & F..... ........... E6
Reverse - Brakes Released
Standard Parallel on D & F..... ........... E8
Forward - Brakes Released (Tire Spin)
Standard on DX, Optional on D & F..E10
Forward - Brakes Released (Drum Spin)
Reverse - Brakes Released (Tire Spin)
EFF. W/ ALL S/N

SD-116 TF SERIES
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 LeftG5
Component Teardown & Rebuild
A2 Steering Pump ........................................ G6
Steering Valve......................................... G7
Steering Cylinder
(S/Ns 169494,169572) ........................... G8
Steering Cylinder(All other S/Ns)............ G9
EFF. W/ ALL S/N

SD-116 TF SERIES
ELECTRICAL
Schematics.................................................. H1 Automatic/Variable/Impact Meter ...................... H37
Battery .................................................... H1 Grid Heater ....................................................... H39
Ignition .................................................... H3 Gauges ............................................................. H41
Start ........................................................ H5 Instrument Cluster ............................................ H43
TABLE OF CONTENTS
Brake/Shutdown - Brakes Applied .......... H7 Fuses ................................................................ H45
Brake/Shutdown - Brakes Released ....... H9
Brake/Shutdown - Brakes Released/ MACHINE
Operator Out of Seat....................... H11 Component Teardown & Rebuild
Brake/Shutdown - Brakes Test/ ROPS/FOPS Replacement.................................. J1
Operator In Seat ............................. H13 Swivel Bearing Replacement............................... J2
Anti-Spin Control/No Travel .................. H15 Drum and Drum Drive.......................................... J3
Anti-Spin Control/Travel ....................... H17 Eccentric Assembly ............................................. J4
Anti-Spin Control/Drum Spin ................. H19
Anti-Spin Control/Wheel Spin................ H21 TROUBLESHOOTING
High/Low Speed - Hydraulic..............................................................K1
A3 Low Speed/Anti-Spin Activated ....... H23 Electrical ..............................................................K2
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
Hydraulic Symbol Quick Reference Chart................ L1
Electrical Schematic Wire Color Code
Manual, Low Amplitude................... H29
Reference Chart ................................................L2
Automatic Vibration/Impact Meter - Hydraulic Schematic ................................................L3
Manual, High Amplitude.................. H31 Electrical Schematic.................................................L5
Automatic, Low Amplitude .............. H33
Automatic, High Amplitude.............. H35
EFF. W/ ALL S/N

SD-122 TF SERIES PROPULSION PUMP
at ic s &
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
S c he
SD-70/77TF
SD 122TF SERIES PROPULSION PUMP
Assembly...............................................................................................E13.8
Inspection.................................................................... E13.2 MANUAL DISPLACEMENT CONTROL................................................E13.9 DISASSEMBLY
FEATURES OF THIS MANUAL

Assembly..................................................................... E13.3 Disassembly..........................................................................................E13.9
DISASSEMBLY
MULTI-FUNCTION VALVE CARTRIDGES..................E13.4 Assembly.............................................................................................. E13.9 NOTE:
Disassembly................................................................ E13.4 To maintain original adjustment, mark the plug(7), the locknut
ting
(8), and the housing (2).
CHARGE RELIEF VALVE............................................................E13.5
Inspection.................................................................... E13.4
DISASSEMBLY
1. Loosen the locknut (8) and remove the plug (7) by
Assembly..................................................................... E13.4ly................................................................... E13.5 unscrewing the plug (7) from the housing (2), refer to
Disassemb
Inspection.......................................................................E13.5
CHARGE RELIEF VALVE............................................E13.5
INSPECTION
Figure 1-3.
2. Remove and diskard the O-ring (6) from the plug (7).
Assembly........................................................................E13.5
Disassembly................................................................ E13.5 3. Remove the spring (5) and charge relief valve (4) from the
plug (7).
Inspection.................................................................... E13.5
E13.1 Assembly..................................................................... E13.5
INSPECTION
INSPECTION
1. Inspect the charge relief valve (4) and mating seat in the
end cap for damage or foreign material.
CHARGE PUMP.......................................................... E13.6
ASSEMBLY
Disassembly................................................................
Save time and money by contac ting your author ized E13.6
CAUTION:
repr esentative for infor mation
Inspection....................................................................
regar ding Authorized Rebuilt Components. E13.6 Do not interchange parts with another valve.
oo
1. Install the charge relief valve (4) and spring (5) onto the
Assembly..................................................................... E13.7 plug (7).
PropulsionPump
2. Install a new O-ring (6) onto plug (7).
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
Tr
R
(38 lb-ft).
authorized
h
4. Check and adjust the charge pressure as required.
rebuilt
components CHARGE RELIEF VALVES
Figure 1-3.
oubles
TABLE OF CONTENTS
CHARGE RELIEF 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
SD-122 TF SERIES one functional
PROPULSION
HYDRAULIC TANK
SUCTION S TRAINER subsystem.
DUM P / BRAKE / 2 SP EED MANIFOLD
LOOP
FLUSH
M1
AXLE MOTOR
• Operational status is
identified by color.
VALVE
140 F CR ACK ING
165 F OPEN A
25 PSI
THERMAL
• Standard symbols are

BYPASS B
VALVE
M2 L2
CHARGE FILTER
PROPULSION PUMP
used.
E8 M6 M3 D E
M1
• Colors are standard

DRUM MOTOR
A M1
M5
M4
HI / LO
L
throughout manual.
R BR AK
AKEE
B
M2 L2
M2
L1 S
REVERSE - BRAKES RELEASED

dashed lines
indicate STANDARD PARALLEL ON D & F
low pressure
S ept embe r 2 002
EFF. W/ ALL S/N

SD-116 TF SERIES
Before performing any maintenance or service procedures
SAFETY INFORMATION
on your SD-116 TF SERIES, refer to the Safety section of the
SD-116 TF SERIES operation and maintenance manual and
the AEM Safety Manual for Safety Instructions.
C1
032503AA
EFF. W/ ALL S/N

SD-116 TF SERIES
ILLUSTRATED HOSE SCHEMATIC

OPTION WITHOUT TRACTION CONTROL
Hydraulic Tank
Check Valve 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

SD-116 TF SERIES
ILLUSTRATED HOSE SCHEMATIC

OPTION WITH TRACTION CONTROL
Hydraulic Tank Check Valve 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

SD-116 TF SERIES
Table of Contents
PROPULSION / BRAKING
Overview
Standard Parallel on D & F........................E2
Standard on DX, Optional on D & F ..........E3
Neutral - Brakes Applied
Hydraulic Tank Brake Valve
Standard Parallel on D & F........................E4 Oil Cooler
Standard on DX, Optional on D & F ..........E5 Loop
Flush
Forward - Brakes Released Valve
Propulsion Pump
Standard Parallel on D & F........................E6
Standard on DX, Optional on D & F ..........E7
Traction
Reverse - Brakes Released Control
Thermal
Standard Parallel on D & F........................E8 Axle Bypass Valve
Standard on DX, Optional on D & F ..........E9 Valve
Axle Drive Charge
E1 Forward - Brakes Released (Tire Spin) Motor Filter
Standard on DX, Optional on D & F ........E10

Forward - Brakes Released (Drum Spin)
Standard on DX, Optional on D & F ........ E11
Reverse - Brakes Released (Tire Spin)
Standard on DX, Optional on D & F ........E12 Drum Drive Motor
Settings and Specifications - Propulsion* 116D 116F

Engine RPM (Hi/Low) 2457/950 X X
Flow at Input Speed 219.3 l/m 57.9 g/m X X
System Relief Pressure (psi/bar) 6090/420 X X
Charge Relief Pressure (psi) 350 X X
* For specific application settings, contact your authorized service
EFF. W/ ALL S/N
personnel.
HYDRAULIC TANK SD-116 TF SERIES
PROPULSION
SUCTION STRAINER
DUMP / BRAKE / 2 SPEED MANIFOLD

OIL
AXLE MOTOR
LOOP FLUSH VALVE M1
140 F CRACKING
165 F OPEN A
25 psi
BYPASS
B
M2 L2
CHARGE FILTER
PROPULSION PUMP
E2 M6 M3 D E
M1
A X
DRUM MOTOR BR
M5
M4
G
BRAKE
B
X
M2
L1 S
OVERVIEW
STANDARD PARALLEL
STANDARD ONON
PARALLEL D &DF& F
HYDRAULIC TANK
SD-116 TF SERIES
SUCTION STRAINER
PROPULSION
OIL
COOLER AXLE MOTOR
LOOP FLUSH VALVE M1
140 F CRACKING
165 F OPEN A
25 psi
THERMAL
BYPASS
B
M2 L2
CHARGE FILTER
PROPULSION PUMP
E3 M6 M3 D E
M1
A X
DRUM MOTOR BR
M5
M4
G
BRAKE
B
X T
M2
L1 S
OVERVIEW
STANDARD ON DX
OPTIONAL ON D & F
HYDRAULIC TANK
SUCTION STRAINER
SD-116 TF SERIES
PROPULSION
OIL
AXLE MOTOR
LOOP FLUSH VALVE M1
COOLER
140 F CRACKING
165 F OPEN A
25 psi
BYPASS
THERMAL B
M2 L2
CHARGE FILTER
PROPULSION PUMP
M6 M3 D E
M1
E4 A X
DRUM MOTOR BR
M5
M4
G
B BRAKE
B
X T
M2
L1 S
dashed lines
NEUTRAL - BRAKES APPLIED
indicate
low pressure
STANDARD PARALLEL ON D & F
PROPULSION
SUCTION STRAINER

OIL
COOLER AXLE MOTOR
LOOP FLUSH VALVE M1
140 F CRACKING
165 F OPEN A
25 psi
THERMAL
BYPASS
B
M2 L2
CHARGE FILTER TRACTION ENHANCEMENT VALVE

PROPULSION PUMP
M6 M3 D E
M1
E5 A X
DRUM MOTOR BR
M5
M4
G
B BRAKE
B
X T
M2
L1 S
NEUTRAL - BRAKES APPLIED

dashed lines
indicate
STANDARD ON DX
low pressure OPTIONAL ON D & F
SD-116 TF SERIES
PROPULSION
OIL
COOLER AXLE MOTOR
LOOP FLUSH VALVE M1
140 F CRACKING
165 F OPEN A
25 psi
THERMAL
BYPASS
B
M2 L2
CHARGE FILTER
PROPULSION PUMP
M6 M3 D E
M1
E6 A
X DRUM MOTOR BR
M5
M4
G
B
BRAKE
B
X T
M2
L1 S
dashed lines
FORWARD - BRAKES RELEASED
indicate
low pressure STANDARD PARALLEL ON D & F
HYDRAULIC TANK
SD-116 TF SERIES
PROPULSION
SUCTION STRAINER

OIL
COOLER AXLE MOTOR
LOOP FLUSH VALVE M1
140 F CRACKING
165 F OPEN A
25 psi
THERMAL
BYPASS
B
M2 L2
CHARGE FILTER
PROPULSION PUMP
M6 M3 D E
M1
E7 A X
DRUM MOTOR BR
M5
M4
G
B BRAKE
B
X T
M2
L1 S

dashed lines STANDARD ON DX
indicate
HYDRAULIC TANK
SD-116 TF SERIES
SUCTION STRAINER
PROPULSION
OIL
COOLER AXLE MOTOR
LOOP FLUSH VALVE M1
140 F CRACKING
165 F OPEN A
25 psi
THERMAL
BYPASS
B
M2 L2
CHARGE FILTER
PROPULSION PUMP
M6 M3 D E
M1
E8 M5
A X
DRUM MOTOR BR
M4
G
B BRAKE
B
X T
M2
L1 S
dashed lines
indicate
low pressure STANDARD PARALLEL ON D & F
HYDRAULIC TANK
SUCTION STRAINER
SD-116 TF SERIES
PROPULSION
OIL
COOLER AXLE MOTOR
LOOP FLUSH VALVE M1
140 F CRACKING
165 F OPEN A
25 psi
THERMAL
BYPASS
B
M2 L2
CHARGE FILTER
PROPULSION PUMP
M6 M3 D E
M1
E9 M5
A X
DRUM MOTOR BR
M4
B
BRAKE
B
X T
M2
L1 S

dashed lines
indicate STANDARD ON DX
PROPULSION
SUCTION STRAINER

OIL
COOLER AXLE MOTOR
LOOP FLUSH VALVE M1
140 F CRACKING
165 F OPEN A
25 psi
THERMAL
BYPASS
B
M2 L2
CHARGE FILTER
PROPULSION PUMP
M6 M3 D E
M1
E10 A X
DRUM MOTOR BR
M5
M4
B BRAKE
B
X T
M2
L1 S

dashed lines
indicate TIRE SPIN - STANDARD ON DX
PROPULSION
SUCTION STRAINER

OIL
COOLER AXLE MOTOR
LOOP FLUSH VALVE M1
140 F CRACKING
165 F OPEN A
25 psi
THERMAL
BYPASS
B
M2 L2
CHARGE FILTER
PROPULSION PUMP
M6 M3 D E
M1
E11 A X
DRUM MOTOR
BR
M5
M4
G
B BRAKE
B
X T
M2
L1 S

dashed lines
indicate DRUM SPIN - STANDARD ON DX
PROPULSION
SUCTION STRAINER

OIL
COOLER AXLE MOTOR
LOOP FLUSH VALVE M1
140 F CRACKING
165 F OPEN A
25 psi
THERMAL
BYPASS
B
M2 L2
CHARGE FILTER
PROPULSION PUMP
M6 M3 D E
M1
E12 M5
A X DRUM MOTOR BR
M4
G
B BRAKE
B
X
M2
L1 S

dashed lines
indicate
TIRE SPIN - STANDARD ON DX
TABLE OF CONTENTS ...........................................E13.1
LIP SEAL AND SHAFT............................................E13.2

Disassembly .......................................................E13.2
Inspection ...........................................................E13.2
Assembly............................................................E13.3
MULTI-FUNCTION VALVE CARTRIDGES ..............E13.4
Disassembly .......................................................E13.4
Inspection ...........................................................E13.4
Assembly............................................................E13.4
CHARGE RELIEF VALVE........................................E13.5
Disassembly .......................................................E13.5
Inspection ...........................................................E13.5
Assembly............................................................E13.5
E13.1
CHARGE PUMP ......................................................E13.6
Disassembly .......................................................E13.6
Propulsion Pump
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
NOTICE:
Prior to performing repairs on this component, contact a
service representative concerning issues of warranty.
DISASSEMBLY
1. Position the motor with the shaft end facing up.
2. Remove screws (1, Figure 1-1) securing the retainer plate
(2).
3. Remove the retainer plate (2) and seal carrier (3) from the
housing (4).
4. Remove the O-ring (5) from the seal carrier (3).
5. Press out the lip seal (6) from the seal carrier (3).
6. If necessary, remove the shaft (9) and bearing assembly
(8) from the housing (4).
7. Remove the retaining ring (7) that secures the bearing
assembly (8) on the shaft (9).
E13.2 8. Remove the bearing assembly (8) from the shaft (9) and
discard the shaft (9).
INSPECTION
1. Inspect the seal carrier (3), new lip seal (6) and O-ring (5)
for any damage or nicks.
2. Inspect the sealing area on the shaft (9) for rust, wear, or
contamination. Polish the sealing area on the shaft (9) as
necessary.
3. Inspect the bearing assembly (8) for damage. Use a new
bearing assembly (8) as required.
Figure 1-1
LIP SEAL AND SHAFT

ASSEMBLY
1. If necessary, install the original bearing assembly (8,
Figure 1-1) or a new bearing assembly (8) on a new shaft
(9).
2. Secure the bearing assembly (8) on the shaft (9) with the
retaining ring (7).
3. Install the shaft (9) and bearing assembly (8) into the
housing (4).
4. Lightly lubricate the outside diameter of the new lip seal (6)
with Loctite High Performance Sealant #59231.
5. Press the new lip seal (6) into the seal carrier (3).
6. Install a new O-ring (5) on the outside diameter of the seal
carrier (3).
CAUTION:
To prevent damage to the lip seal (6), wrap the spline or key
end of the shaft (9) with thin plastic.
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

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

DISASSEMBLY
NOTE:
To maintain original adjustment, mark the plug (7, Figure 1-3),
the locknut (8), and the housing (2).
1. Loosen the locknut (8, Figure 1-3) and remove the plug (7)
by unscrewing the plug (7) from the housing (2).
2. Remove and discard the O-ring (6) from the plug (7).
3. Remove the spring (5) and charge relief valve (4) from the
plug (7).
INSPECTION
end cap for damage or foreign material.
ASSEMBLY
CAUTION:
E13.5 Do not interchange parts with another valve.
plug (7).
made at disassembly and torque the locknut (8) to 52 N·m
(38 lb-ft.).
Figure 1-3
CHARGE RELIEF VALVE

DISASSEMBLY
1. Remove the screws (1, Figure 1-4) flange cover (2) and O-
ring (3). Discard the O-ring (3).
2. Remove the screws (4), washers (5), and flange adapter
(6) from the end cap (17).
CAUTION:
Do not allow the force of the cylinder block spring and
swashplate leveler springs to separate the flange adapter from
the charge pump housing.
3. Remove the screws (7), retaining plate (8) and O-ring (9).
Discard the O-ring (9).
4. Remove the charge pump cover (10), bushing (11), and
coupling (12). Note the orientation of the gerotor assembly
(15).
5. Remove the charge pump shaft (13) and key (14) from the
end cap (17).
E13.6 6. Remove the charge pump gerotor assembly (15) and
alignment pin (16).
INSPECTION
1. Surfaces need to be clean and free of any foreign material
or paint prior to assembly.
2. Inspect for abnormal wear or damage.
Figure 1-4
CHARGE PUMP
ASSEMBLY
NOTE:
Be sure to install the charge pump in the proper orientation.
1. Apply a small amount of petroleum jelly to the charge pump
gerotor assembly (15, Figure 1-4), both inside diameter and
outside diameter.
2. Install the charge pump gerotor assembly (15) and alignment
pin (16).
3. Install the charge pump shaft (13) and key (14) into the end
cap (17). The internally splined end of the shaft must engage
the main pump shaft.
4. Install the coupling (12), bushing (11), and charge pump
cover (10).
CAUTION:
In order to avoid loss of charge pressure, always install the
charge pump cover (10, Figure 1-4) with the drain hole located
E13.7 on the same side of the end cap (17) as the charge inlet port.
5. Install the retaining plate (8) and secure the retaining plate
(8) with screws (7).
6. Torque the screws (7) to 13.5 N·m (10 lb-ft.).
7. Install a new O-ring (9) around the charge pump cover (10).
8. Install the flange adapter (6), washers (5), and screws (4)
onto the end cap (17).
10. Install a new O-ring (3), flange cover (2), and screws (1) onto
the flange adapter (6).
Figure 1-4
CHARGE PUMP
DISASSEMBLY
1. Loosen the swivel locknut (19, Figure 1-5).
2. Remove the filter manifold (17) from the end cap (21).
3. Remove and discard the O-ring (20) from the filter manifold
(17).
INSPECTION
1. Inspect the filter manifold (17) and tube (18) for blockage or
foreign material.
ASSEMBLY
1. Install a new O-ring (20) onto the filter manifold (17).
2. Rotate the filter manifold (17) so the threads engage with the
threads in the end cap (21), continue to rotate clockwise 6 or
7 turns.
3. Place filter manifold (17) in the 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
DISASSEMBLY
1. Clean external surfaces prior to removal.
2. Remove the screws (1, Figure 1-6) that secure the manual
displacement control (2) to the housing (8).
3. Remove the manual displacement control (2) with neutral
start switch (9), the orifice check valve (3), the spring (4), the
spring retainer (5), and the gasket (6) from the housing (8).
CAUTION:
Protect exposed surfaces and cavities from damage and foreign
material.
ASSEMBLY
1. Install a new gasket (6) on the housing (8).
2. Install the orifice check valve (3), the spring (4), and the
spring retainer (5) into the manual displacement control (2).
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, Figure 1-6) “neutral” must be
readjusted after reassembling the manual displacement control Figure 1-6
module.
MANUAL DISPLACEMENT
CONTROL
SD-116 TF SERIES AXLE
TABLE OF CONTENTS. ..........................................E14.1
BRAKES ..................................................................E14.2
Disassembly .......................................................E14.2
Assembly............................................................E14.4
PLANETARY REDUCTION AND AXLE SHAFT .....E14.7
Disassembly .......................................................E14.7
Assembly............................................................E14.9
DIFFERENTIAL ..................................................... E14.11
Removal ........................................................... E14.11
Disassembly .....................................................E14.12
Assembly..........................................................E14.13
Axle
Installation ........................................................E14.13
REDUCTION GEAR AND PINION ........................E14.17
E14.1 Disassembly .....................................................E14.17
Assembly..........................................................E14.19
TABLE OF CONTENTS
DISASSEMBLY
1. Remove the lower plug from the axle arm and drain the oil.
2. Attach a suitable lifting device to the axle arm to be removed.
3. Loosen and remove the screws (29, Figure 1-1) and nuts
(17) securing the axle arm to the axle cylinder.
4. Remove the arm from the cylinder, together with the brakes
and axle shaft. Using the sling for support, stand the arm on
end with the open end facing up.
5. Loosen the screws (93) on the cylinder in an alternate
manner and remove them.
6. Move the cylinder outward while supporting the Belleville
washers (82).
7. Remove the Belleville washers (82), noting the orientation of
the washers.
8. Remove the cylinder from the center housing, complete with
piston (84).
E14.2
9. Remove and discard the O-rings (18) from the cylinder.
10. Slowly introduce low-pressure compressed air through the
connection member for the negative brake, in order to
remove the piston (84).
CAUTION:
Hold the piston (84, Figure 1-1) back, as it may be suddenly
ejected and damaged.
11. Remove and discard the O-rings (85 and 86) from the piston
(84).
12. Remove the checking and guiding screws (79) from the
pressure plate (87).
Figure 1-1
BRAKES
NOTE:
Loosen the screws (79, Figure 1-1) in sequence and
proportionally.
13. Remove the pressure plate (79) from the axle arm.
NOTICE:
Note the orientation of the components. The flow regulator wall
and oil drain holes must face the oil drain plug.
14. Remove the springs (78) from the axle arm.
NOTE:
Check the springs for warping or other deformation. Any
deformation of the springs requires spring replacement.
15. Remove the brake discs (76 and 77), noting the orientation.
NOTE:
If the discs are not to be replaced, avoid changing their position.
16. Remove the pinion (89) and O-ring (92) from the axle arm.
Discard the O-ring (92).
E14.3 17. Unscrew and extract the brake disc clearance adjustment
crown wheel (88).
Figure 1-1
BRAKES
ASSEMBLY
1. Lubricate the threaded portion of the crown wheel (88,
Figure 1-1) and screw it into the axle arm as far as it will go.
2. Lightly lubricate a new O-ring (92) and install it onto the
pinion (89).
3. Lubricate and install the pinion (89) into the slot provided on
the axle arm, inserting the pinion teeth into the crown wheel
(88) teeth.
4. Lightly lubricate the first steel brake disc (76), then install it
into the axle arm.
5. Lubricate the first friction disc (77), then install it into the axle
arm.
6. Complete the brake disc assembly, alternating steel discs
(76) and friction discs (77).
NOTICE:
The oval holes of the friction discs (77, Figure 1-1) must be
E14.4 aligned.
7. Position the springs (78) into the slots of the arm.
8. Install the pressure plate (87) into the axle arm ensuring that
the flow regulator and oil drains are oriented toward the axle
arm’s oil drain plug.
NOTICE:
Check the orientation of the pressure plate (87, Figure 1-1) to
ensure the flow regulator and oil drains are oriented toward the
axle arm’s oil drain plug.
9. Lock the pressure plate (87) into position with screws (79).
NOTICE:
Tighten the screws (79, Figure 1-1) in sequence and a little at a
time.
Figure 1-1
10. Tighten the screws (79) to 20 to 30 N.m (16 to 22 lb-ft.).
11. Lightlyghtly lubricate new O-rings (85 and 86) and install the
O-rings onto the piston (84). BRAKES
12. Lubricate the piston (84, Figure 1-1) and install the piston
into the cylinder, ensuring that the piston relief is facing
downward.
NOTE:
Use a plastic hammer and lightly hammer all around the edge of
the piston (84) in an alternate sequence to install the piston into
the cylinder.
13. Lightly lubricate new O-rings (18) and install the O-rings onto
the cylinder. Position the cylinder on the studs of the center
housing without fastening.
14. Position the Belleville washers (82) into the cylinder.
NOTE:
Check the Belleville washers (82, Figure 1-1) for proper direction
and relative centering.
15. Secure the cylinder in place on the center housing with the
screws (93). Torque the screws (93) to 86 to 89 N.m (63 to
E14.5 66 lb-ft).
16. Install the axle arm onto the cylinder and center housing.
NOTE:
To assist with axle shaft centering, slightly move the wheel hub.
17. Temporarily secure the axle arm with nuts (17) previously
coated with Loctite 242. Tighten the nuts (17) lightly to make
the axle arm touch the cylinder and center housing.
18. Check to ensure the axle arms are level. Secure the arm
into its final position, using screws (29) adequately coated
with Loctite 242. Torque the screws to 182 to 202 N.m (134
to 149 lb-ft.). Tighten the screws using the criss-cross
method.
19. Connect an external pump to the union piece “A” of the
negative brake and introduce pressure of 15 to 30 bar (218 Figure 1-1
to 435 psi).
BRAKES
20. Remove the screw (91, Figure 1-1) and safety plate (90)
from the axle arm. Rotate the adjustment pinion (89)
counterclockwise to eliminate all existing clearance between
the brake discs. Rotate the pinion (89) up to a torque of 8 to
10 N.m (6 to 7 lb-ft.).
21. Rotate the pinion (89) clockwise 4 turns to determine the
required clearance of 1 mm.
NOTE:
A turn of the adjuster produces a clearance of 0.25 mm (1 mm =
4 turns).
22. Install the safety plate (90) and secure in place with the
screw (91). Torque the screw to 10 to 11 N.m (7 to 8 lb-ft.).
E14.6
Figure 1-1
BRAKES
DISASSEMBLY
1. Remove the locking screws (61, Figure 1-2) from the
planetary cover.
2. Using two screwdrivers or two levers inserted in the slots
provided, pry the planet gear carrier assembly (59) away
from the hub (7).
NOTE:
The axle shaft (54, Figure 1-2) can only be removed after the
planet gear carrier assembly (59) has been removed.
3. Rotate the hub (7) until one of the screw holes in the planet
gear carrier assembly (59) appears at the top.
4. Attach a suitable lifting device to the screw hole and use the
lifting device to remove the planet gear carrier assembly (59)
from the hub (7).
5. If the ring gear (72) is not being disassembled, mark a
position between one of the teeth of the axle shaft (54) and
E14.7 the ring gear (72).
6. Remove the axle shaft (54) from the axle arm.
7. Loosen the screws (53) securing the the ring gear support
(69) to the hub (7) and remove the screws (53). Remove the
ring gear support (69) from the hub (7).
8. Remove the snap ring (71) from the ring gear (72).
9. Re-install and partially tighten five of the ten screws (53) in
an alternate and proportional manner.
10. Using a puller and applying counter pressure to the screws
(53), disengage the ring gear (72) from the hub (7).
11. Remove the partially-tightened screws (53) and the ring gear
(72) from the hub (7).
12. Remove the O-ring (73) from the hub (7). Discard the O-ring Figure 1-2
(73).
PLANETARY REDUCTION
AND AXLE SHAFT
13. Attach a suitable lifting device to the hub (7, Figure 1-2), then
partially tighten a screw (53) and with the help of a hammer,
shift the hub (7) and the external bearing (74).
14. Remove the bearing cone (74) and the hub (7) from the axle
arm. Remove the hub (7), complete with the seal (74) and
internal bearing (74).
15. Using a puller, remove the centering ring (49) and the seal
(48), noting the orientation of the centering ring (49) and seal
(48).
16. Remove the bolts (67) and locking plates (66) securing the
rear cover to the planet gear carrier (59), then remove the
rear cover from the planet gear carrier (59).
17. Remove the planet gear assemblies from the planet gear
carrier.
18. To disassemble the planet gear assembly, remove the snap
ring (55) from the planet pin (57), then remove the friction
E14.8 washer (56), planet gear (65), needle bearing (64), and
friction washer (56). If necessary, remove the O-ring (58) and
snap ring (55) from the opposite end of the planet pin (57).
Discard the O-ring (58) and snap rings (55). Repeat for the
remaining planet gear assemblies.
NOTE:
Note the orientation of the planetary gears.
19. If necessary, use a puller to remove the friction washer (62)
from the planet gear carrier.
20. Remove the seal (75) from the hub (7) and discard the seal
(75).
21. Remove the internal bearing cone (74) from the hub (7).
22. Remove the internal and external bearing cups (74) from the
hub (7) using a pin-driver. Hammer in an alternate sequence Figure 1-2
to prevent deformation of the bearing cups.
PLANETARY REDUCTION
AND AXLE SHAFT
ASSEMBLY
1. Position the wheel hub (7, Figure 1-2) under a press.
Lubricate the seat of the external bearing cup (74) and press
the bearing cup into the hub (7).
2. Install the bearing cone (74) into the hub (7).
3. Apply an appropriate sealant to the outer surface of the seal
(75).
4. Position the seal (75) into the hub (7), checking for correct
orientation.
5. Press the seal (75) into its seat in the hub (7). Turn the hub
(7) upside down, lubricate the seat of the internal bearing
cup (74) and press the bearing cup (74) into the hub (74).
6. If the fricton washer (62) has been removed, apply a sealant
for removable seals to the outer surface of the friction
washer (15) and, using a suitable driver, tap it into the planet
gear carrier (59).
E14.9 7. To assemble the planet gear assembly, lightly lubricate a
new O-ring (58) and install the O-ring and a new snap ring
(55) onto the end of the planet pin (57). Lighly lubricate the
planet pin (57) and install the friction washer (56), needle
bearing (64), planet gear (65), and friction washer (56).
Install a new snap ring (55) on the end of the planet pin (57).
Repeat for the remaining planet gear assemblies.
CAUTION:
The jointed portion of the internal ring of the needle bearings
(64, Figure 1-2) must face the bottom of the planet pin (57).
8. Install the rear cover onto the planet gear carrier (5) and
secure it in place with the locking plates (66) and bolts (67).
9. Lubricate and install the centering ring (49) and snap ring
(48) into the axle arm, paying particular attention to the Figure 1-2
orientation of the rings.
10. Lubricate the inside diameter of the seal (75) and the outside PLANETARY REDUCTION
of the axle arm hub.
AND AXLE SHAFT
11. Install the hub (7, Figure 1-2) onto the axle arm hub.
12. Install the external bearing cone (74) into the hub (7).
NOTE:
Move the bearing cone (74, Figure 1-2) to the limit stop by
hammering lightly all around the edge.
13. Install the ring gear (72) into the hub (7) and drive it into place
using a suitably-sized driver.
14. Install a new snap ring (71) into the ring gear (72).
15. Lubricate the outer edge of the ring gear support (69), then
install the ring gear support (69) into the ring gear (72).
16. Coat the screws (53) with Loctite 270 and install them into
the ring gear support (69).
17. Tighten the screws (53) in two stages, using the criss-cross
method. Torque the screws (53) to an initial torque of 120
N.m (89 lb-ft.), then to a final torque of 219 to 242 N.m (162 to
178 lb-ft.).
E14.10
18. Lubricate the seal (48), centering ring (49), and the toothed
portions and sealing surface of the axle shaft (54).
19. Install the axle shaft (54) into the axle arm, making sure that it
is properly inserted into the braking discs and the differential
unit.
20. Lubricate a new O-ring (73) and install it into the hub (7).
21. Install the planet gear carrier assembly (59) onto the hub (7).
NOTICE:
Line up the locating release points.
22. Secure the planet gear carrier (59) to the hub (7) with screws
(61). Torque the screws to 40 N.m (30 lb-ft.).
Figure 1-2
PLANETARY REDUCTION
AND AXLE SHAFT
REMOVAL
1. Remove the axle arms and the reduction unit from the
differential housing.
2. Remove the stud screws (23, Figure 1-3) from the
intermediate cover and remove the intermediate cover from
the side of the differential opposite the beveled gear (46).
3. Remove and discard the O-ring (18) from the intermediate
cover.
4. Remove the bolt (35) and locking plate (34), then remove the
ring nut (33) from the intermediate cover.
5. Using a suitable driver, remove the bearing cup (41) from the
intermediate cover.
6. Remove the stud screws (24) from the intermediate cover
and remove the intermediate cover from the side of the
differential housing nearest the beveled gear (46).
7. Remove and discard the O-ring (18) from the intermediate
E14.11 cover.
8. Remove the bolt (35) and locking plate (34), then remove the
ring nut (33) from the intermediate cover.
9. Using a suitable driver, remove the bearing cup (41) from the
intermediate cover.
10. Position a stop block made from a soft metal (aluminium,
etc.) between the differential housing and the toothed portion
of the beveled gear (46).
11. With the beveled gear (46) resting on the stop block, remove
the screws (40) and spring washers (39) securing the
differential carrier (37) to the beveled gear (46).
12. Using a suitable driver, push the differential carrier (37) away
from the beveled gear (46) to disengage the differential
carrier (37) from the beveled gear (46). Figure 1-3
DIFFERENTIAL
13. Remove the differential carrier (37, Figure 1-3) from the
beveled gear (46) and the differential housing.
14. Remove the beveled gear (46) from the differential housing.
DISASSEMBLY
No-Spin Differential Unit

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

1. Assemble the no-spin unit (38, Figure 1-3), inserting the
spacer (42) and using the stay.
2. Install the no-spin unit (38) into the differential unit main
body (37).
3. Install the differential unit half-box (37) onto the main body
(37), ensuring that the coupling marks align.
4. Coat the screws (36) with Loctite 270 and install them into
the differential unit half-box (37). Tighten the screws (36)
using the criss-cross method and torque them to 86 to 89
N.m (63 to 66 lb-ft.).
5. Remove the stay from the differential carrier (37).
INSTALLATION
E14.13 1. Position the differential carrier (37) under a press and, using
an appropriately-sized driver, install the first bearing cone
(41).
2. Turn the unit upside down and position the differential carrier
(37) under a press. Using an appropriately-sized driver,
install the second bearing cone (41).
3. Using a suitable press, install a bearing cone (41) into each
of the intermediate covers.
4. Install the beveled gear (46) into the differential housing.
5. Install the differential carrier (37) into the differential housing.
6. Install the beveled gear (46) onto the differential carrier (37),
and fasten it to the flange. Ensure that the holes of the
differential carrier flange (37) match those of the beveled
gear (46). Figure 1-3
7. Install the spring washers (39) onto the screws (40).
DIFFERENTIAL
8. Coat the screws (40, Figure 1-3) with Loctite 270 and install
the them hand tight into the beveled gear (46).
9. Position the stop block between the differential housing and
the toothed portion of the beveled gear (46). While holding
the beveled gear (46) resting on the stop block, tighten the
screws (40), using the criss-cross method, to a torque of 135
to 138 N.m (100 to 102 lb-ft.).
10. Lubricate and install a new O-ring (30) onto the intermedate
cover, then install the intermediate cover on the side of the
differential housing nearest to the beveled gear (46).
11. Install the stud screws (24) and torque them to 129 to 143
N.m (95 to 105 lb-ft.).
12. Ensure that the differential carrier (37) is tightly engaged in
the intermediate cover. Lubricate and install a new O-ring
(30) onto the remaining intermedate cover, then install the
intermediate cover on the side of the differential housing
E14.14 opposite the beveled gear (46).
13. Install the stud screws (23) and torque them to 129 to 143
N.m (95 to 105 lb-ft.).
14. Remove the bolt (35) and locking plate (34) from one of the
intermediate covers. Using a suitable wrench, remove the
ring nut (33) from the intermediate cover and remove any
residue of thread locking substances.
15. Apply Loctite 242 to the ring nut (33), then re-install the ring
nut (33) into the intermediate cover.
16. Repeat steps 14 and 15 for the intermediate cover on the
opposite end of the differential housing.
17. Remove the spring ring (21) and cap (22) from the rear of the
differential housing to allow checking of the clearance
between the pinion (46) and the beveled gear (46) to take Figure 1-3
place.
DIFFERENTIAL
18. Coat the mounting surface of the differential housing with
Loctite 510 and install the reduction gear assembly and
pinion assembly (46, Figure 1-3).
19. Coat the bolts (5 and 7) with Loctite 242 and install the bolts
(5 and 7) into the reduction gear assembly. Tighten the bolts
(5 and 7), using the criss-cross method, to a torque of 129 to
143 N.m (95 to 105 lb-ft.).
20. Screw the ring nut (33) on the side of the differential housing
nearest the beveled gear (46) until the clearance between
the pinion (46) and beveled gear (46) equals zero, then
unscrew the ring nut (33) by approximately 1/4 turn.
21. Allow the pinion (46) to turn a few times in both directions to
allow the bearings to set. Pre-load the bearings through the
ring nut on the side of the differential housing opposite the
beveled gear (46) to increase pinion torque up to a value of
140 to 210 N.cm (12 to 18 lb-in.), checked using a torque
meter.
E14.15
CAUTION:
If bearings are old, check static torque. If new, check continuous
torque.
22. Introduce a dial indicator through the rear cap (22) hole.
23. Position the dial indicator on the center of one of the beveled
gear teeth (46), pre-set it to 1 mm and reset it to zero.
24. Manually move the beveled gear (46) in both directions to
check the existing clearance between the pinion (46) and the
beveled gear (46).
25. Mark the position of the ring nuts (33) in relation to the
intermediate covers.
26. Using a suitable wrench, adjust the clearance between the
pinion (46) and the beveled gear (46) crown by loosening Figure 1-3
one ring nut (33) and tightening the opposite ring nut (33)
proportionally. Normal clearance is 0.18 to 0.23 mm (0.007
to 0.906 in). DIFFERENTIAL
NOTE:
The difference between the MINIMUM and MAXIMUM clearance
for the entire circumference of the beveled gear (46, Figure 1-3)
should not exceed 0.09 mm (0.004 in).
27. Install the locking plates (34, Figure 1-3) on the ring nuts (33)
and secure them with the screws (35). Torque the screws to
10 to 11 N.m (7 to 8 lb-ft.).
28. Using a suitable driver, install the cap (22) into the rear of the
differential housing and position it in its seat with the snap
ring (21).
29. Using a driver and a plastic hammer, install the driving gear
(2) into the reduction gear housing. Apply Loctite 510 to the
mounting surface of the reduction gear housing and install
the cover.
30. Secure the cover in place with the spring washers (8) and the
screws (1 and 9). Torque the screws (1 and 9) to 82 to 91
E14.16 N.m (60 to 67 lb-ft.).
31. Install the vent (4) into the reduction gear housing and tighten
the vent to a torque of 35 to 50 N.m (26 to 37 lb-ft.).
32. Complete the assembly of the axle by installing the axle
arms.
Figure 1-3
DIFFERENTIAL
DISASSEMBLY
1. Remove the axle arms from the differential unit.
2. Loosen and remove the screws (1 and 9, Figure 1-4) and
spring washers (8) securing the cover to the reduction gear
housing. Remove the plugs (10 and 11) for oil fill and oil
drain, then remove the vent (4).
NOTE:
While removing the cover, leave two of the screws (9, Figure 1-
4) in position for safety.
3. Using a plastic hammer, loosen the cover, then remove the
two remaining screws (9) and remove the cover.
NOTE:
If operations on the differential unit need to be performed,
remove the complete reduction gear unit from the differential unit
(remove screws [5 and 7, Figure 1-4]).
4. Place a stop block of soft metal (aluminium, etc.) between
E14.17 the reduction gear housing and the gear (6) of the pinion.
5. Loosen and remove the pinion locking nut (30).
6. Remove the pinion gear (6) and the driving gear (2),
complete with bearing (3). Use a lever to remove the driving
gear (14).
7. Use a suitable puller to remove the bearing (3) from the
driving gear (2).
8. Loosen all screws (5 and 7) and remove the upper screws
(7) securing the reduction gear housing to the differential
unit. Leave the two lower screws (5) in position for safety.
9. Connect the reduction gear housing to a suitable lifting
device and remove the screws (5) previously left in place for
safety.
10. Using a plastic hammer, tap the reduction gear housing to Figure 1-4
remove it from the differential unit.
REDUCTION GEAR AND PINION
11. Position the reduction gear housing under a press and, using
a driver, remove the pinion (46, Figure 1-4), complete with
the shim (32), bearing cone (31), shim (43) and spacer (44).
The bearing cone (31) on the inside of the reduction gear
housing should come off the pinion (46) as the pinion is
pressed out of the reduction gear housing.
12. Remove the spacer (44) and shim (43) from the pinion (46).
13. Position the pinion (46) under a press and remove the
bearing cone (31) and shim (32) from the pinion (46).
14. With the help of a suitable driver, remove the bearing cups
(31) and seal (45) from the reduction gear housing. Note the
orientation of the seal (45).
E14.18
Figure 1-4

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

7. Turn the reduction gear housing upside down and insert shim
“S,” then install the countermarked bearing cup (31, Figure 1-
4) into the reduction gear housing.
8. Install special tool T12 (see below) onto tool T11 (see below),
then install the bearing cones (31) onto tool T11 so that they
are opposed to each other and separated by the spacer (44).
9. Position a depth comparator in one of the four radial holes of
tool T11. Preset the comparator to 3 to 4 mm, then set it to
zero.
Tool T11 Tool T12
E14.20
Figure 1-4

10. Remove the bearing cones (31, Figure 1-4) from tool T11
and fit them in the bearing cups (31) installed in reduction
gear housing. Ensure that the countermarked bearing cone
is fitted into the countermarked bearing cup already installed
in the centering hub of the reduction gear housing.
11. Install tool T11 into the gear reduction housing and tighten it
manually to obtain a safe rolling torque. While tightening the
tool, perform a few rotations to set the bearings.
12. Introduce the previously reset depth comparator, in one of
the four radial holes and measure. The deviation from zero
indicates the nominal value “H” relative to the shims that are
to be inserted.
13. The deviation found is to be added to a fixed value of 0.13
divided by 0.15 mm in order to obtain the correct size for
shim “S1” (43), which is to be inserted between the bearing
(31) and the spacer (44). This will produce the specified
bearing pre-load.
E14.21
NOTICE:
Perform accurate measurements. A variation of 0.001 mm
causes a variation in the torque by 20 to 40 N.m (15 to 30 lb-ft.).
14. Install the shim (32) onto the pinion (46), then press the
countermarked bearing cone (31) onto the pinion (46).
NOTICE:
Lubricate the pinion (46, Figure 1-4) with oil.
15. Install the pinion (46), the shim (43), the spacer (44) and the
remaining bearing cone (31) into the reduction gear housing
and assemble the components with a press.
16. Install the reduction gear housing (11) onto the differential
housing without the differential unit. Secure in place
temporarily with the two lower screws (5). Figure 1-4

17. Install the bearing (3, Figure 1-4) into the reduction gear
housing.
18. Install the gear (6) onto the pinion (46). Coat the nut (30)
with Loctite 242 and hand-tighten it onto the end of the
pinion (46).
19. Between the reduction gear housing and the gear (6) of the
pinion, place the stop block used for disassembly, then
tighten the nut (30) to a minimum tightening torque of 500
N.m (369 lb-ft.).
20. Allow the pinion to rotate a few times in both directions to
enable bearings to set.
21. Using a torque meter, check the torque of the pinion (46).
The proper torque should be 140 to 150 N.cm (198 to 212
oz-in.).
NOTICE:
If the torque exceeds the maximum value, then the shim “S1”
E14.22 (43, Figure 1-4) placed between bearing (31) and the spacer
(44) needs to be increased.
22. If the torque does not reach the set value, increase the
tightening torque setting of the nut (30), in different stages,
until a maximum value of 700 N.m (516 lb-ft.) is obtained.
NOTICE:
If the torque does not reach the minimum value, then the shim
“S1” (43, Figure 1-4) needs to be reduced.
NOTICE:
In order to be able to calculate the increase or reduction of shim
“S1”, it is necessary to bear in mind that a 0.01 mm variation in
the size of the shim (43, Figure 1-4) results in the torque of the
pinion (46) varying by 20 to 40 N.cm (28 to 57 oz-in.).
Figure 1-4
23. Remove the reduction gear unit from the differential
housing. Install the differential unit into the differential
housing, then install the reduction gear unit and the axle REDUCTION GEAR AND PINION
arms onto the differential unit.
SD-116 TF SERIES AXLE MOTOR
TABLE OF CONTENTS...........................................E15.1
LIP SEAL AND SHAFT............................................E15.2

Disassembly .......................................................E15.2
Inspection ...........................................................E15.2
Assembly............................................................E15.3
LOOP FLUSHING VALVE .......................................E15.4
Disassembly .......................................................E15.4
Inspection ...........................................................E15.4
Assembly............................................................E15.4
CONTROL SUPPLY ORIFICE AND
Axle Drive Motor
ORIFICE CHECK VALVE ........................................E15.5
Disassembly .......................................................E15.5
Inspection ...........................................................E15.5
E15.1
Assembly............................................................E15.5
ORIFICE CHECK VALVE AND
ELECTRIC 2-POSITION CONTROL VALVE ...........E15.6
Disassembly .......................................................E15.6
Assembly............................................................E15.7
TABLE OF CONTENTS
NOTICE:
Prior to performing repairs on this component, contact a service
representative concerning issues of warranty.
DISASSEMBLY
1. Position the motor with the shaft end facing up.
2. Remove the screws (1, Figure 1-1) securing the retainer
plate (2).
3. Remove the retainer plate (2) and the seal carrier (3) from
the housing (4).
4. Remove and discard the O-ring (5) from the seal carrier (3).
5. Press out and discard the lip seal (6) from the seal carrier
(3).
6. If necessary, remove the shaft (9) and the bearing assembly
(8) from the housing (4).
WARNING:
E15.2 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
bearing assembly (8) as required.
Figure 1-1
LIP SEAL AND SHAFT

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

DISASSEMBLY
1. Remove the plugs (1, Figure 1-2) from both sides of the
valve orifice.
2. Remove and discard the O-rings (4) from each plug (1).
3. Remove the springs (2), the spring guides (3), and the
flushing valve shuttle spool (5) from the valve orifice in the
housing (6).
4. Note the orientation of the spring guides (3). Remove the
springs (2) and the spring guides (3) from the flushing valve
shuttle spool (5).
INSPECTION
1. Inspect the parts for damage or foreign material.
ASSEMBLY
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

DISASSEMBLY
1. Remove the control supply orifice (26, Figure 1-3) from the
housing (6).
2. Remove and discard the O-rings (13 and 15) and the backup
rings (14) from the control supply orifice (26).
3. Remove the orifice check valve (12) from the housing (16).
4. Remove and discard the O-rings (13 and 15) and the backup
rings (14 and 16) from the orifice check valve (12).
INSPECTION
1. Inspect the filter screen (17) and the control supply orifice
(26). Make sure they are not plugged or contain foreign
material.
2. Inspect the orifice check valve (12) and make sure it is not
plugged.
3. Inspect that the orifice check valve seat is secure in the
E15.5 orifice check valve (12) and that the check ball is free.
NOTICE:
Do not interchange control supply orifice (26, Figure 1-3) with
orifice check valve (12).
ASSEMBLY
1. Install the new backup rings (14) and the new O-rings (13
and 15) on the control supply orifice (26).
2. Install the control supply orifice (26) into the housing (6).
3. Torque the control supply orifice (26) to 37 N·m (27 lb-ft.).
4. Install the new backup rings (14 and 16) and the new O-
rings (13 and 15) on the orifice check valve (12).
5. Install the orifice check valve (12) into the housing (6). Figure 1-3
6. Torque the orifice check valve (12) to 37 N·m (27 lb-ft.).
CONTROL SUPPLY ORIFICE AND
ORIFICE CHECK VALVE
NOTE:
Remove the orifice check valve (20, Figure 1-4), before
removing the electric 2-position control.
DISASSEMBLY
1. Loosen and remove the seal nut (18, Figue 1-4) from the
orifice check valve (20).
2. Remove the orifice check valve (20) from the housing (6).
3. Remove and discard the O-ring (19) from the orifice check
valve (20).
4. Disconnect the electrical connection (23).
5. Remove the nut (24) and the solenoid (25) from the solenoid
valve (22).
6. Remove the solenoid valve (22) from the housing (6).
7. Remove and discard the O-rings (21) from the solenoid valve
(22).
E15.6
Figure 1-4
ORIFICE CHECK VALVE AND ELECTRIC

2-POSITION CONTROL VALVE
NOTE:
Install the orifice check valve (18, 19, and 20, Figure 1-4)
AFTER installing the electric 2-position control.
ASSEMBLY
1. Install the new O-rings (21, Figure 1-4) on the solenoid valve
(22).
CAUTION:
Do not over torque the solenoid valve. Over torquing may result
in the valve spool sticking.
2. Install the solenoid valve (22) and torque the solenoid valve
(22) to 47 N·m (35 lb-ft.).
3. Install the solenoid (25) and the nut (24) on the solenoid
valve (22).
4. Torque the nut (24) to 5 N·m (44 in-ft.).
5. Install the orifice check valve (20) into the housing (6).
E15.7 6. Torque the orifice check valve (20) to 15 N·m (11 lb-ft.).
7. Install a new O-ring (19) and the seal nut (18) onto the orifice
check valve (20).
8. Torque the seal nut (18) to 34 N·m (25 lb-ft.).
Figure 1-4
ORIFICE CHECK VALVE AND ELECTRIC

2-POSITION CONTROL VALVE
SD-116 TF SERIES LOOP FLUSH VALVE
TABLE OF CONTENTS...........................................E16.1
LOOP FLUSHING VALVE .......................................E16.2

Disassembly .......................................................E16.2
Inspection ...........................................................E16.2
Assembly............................................................E16.2 Loop
Flush
CHARGE RELIEF VALVE........................................E16.3 Valve
Disassembly .......................................................E16.3
Inspection ...........................................................E16.3
Assembly............................................................E16.3
E16.1
TABLE OF CONTENTS
NOTICE:
DISASSEMBLY
1. Remove the plugs (1, Figure 1-1) from both sides of the
valve housing (6).
2. Remove and discard the O-rings (2) from each plug (1).
3. Remove the springs (3), spring guides (4), and flushing valve
shuttle spool (5) from the valve housing (6).
NOTE:
Note the orientation of the spring guides (3, Figure 1-1).
INSPECTION
1. Inspect the parts for damage or foreign material.
E16.2 ASSEMBLY
1. Install the shuttle spool (5) into the valve housing (6).
2. Install the spring guides (4) with the shoulders facing out and
springs (3) on each side of the shuttle spool (5).
3. Install new O-rings (2) on each plug (1).
4. Install plugs (1) into both sides of the valve housing (6) and
torque the plugs (1) to 41 N·m (30 lb-ft.).
Figure 1-1
LOOP FLUSHING VALVE

DISASSEMBLY
NOTE:
To maintain original adjustment, mark the plug (10, Figure 1-2),
locknut (7), and the housing (6).
1. Loosen the locknut (7, Figure 1-2) and remove the plug (10)
by unscrewing the plug (10) from the housing (6).
2. Remove and discard the O-ring (8) from the plug (10).
3. Remove the spring (11) and charge relief valve (9) from the
plug (10).
INSPECTION
valve housing for damage or foreign material.
ASSEMBLY
NOTICE
E16.3 Do not interchange parts with another valve.
plug (10).
made at disassembly and torque the locknut (7) to 52 N·m
(38 lb-ft.).
Figure 1-2
CHARGE RELIEF VALVE

SD-116 TF SERIES
Table of Contents Settings and Specifications - Vibration* 116D 116F

Engine RPM (Hi/Low) 2457/950 X X
Overview ...........................................F2 Flow at Input Speed 90.5 l/m 23.9 g/m X X
Neutral - No Vibration .......... F3 System Relief Pressure (psi/bar) 5000/345 X X
Charge Relief Pressure (psi) 285 X X
Clockwise - High AmplitudeF4
Counterclockwise - personnel.
Low Amplitude................. F5
VIBRATION
Hydraulic Tank Vibration
Motor
Oil Cooler
F1
Suction Filter
Thermal Bypass Valve
Vibration Pump
EFF. W/ ALL S/N

HYDRAULIC TANK
SUCTION STRAINER
SD-116 TF SERIES
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
HYDRAULIC TANK
SUCTION STRAINER
SD-116 TF SERIES
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
HYDRAULIC TANK
SD-116 TF SERIES
SUCTION STRAINER
VIBRATION
SUCTION L E G E N D
FILTER
OIL
COOLER
140 F CRACKING
THERMAL
BYPASS
VALVE
25 PSI
dashed lines
indicate
low pressure
VIBRATION PUMP
M3
F4 M4
A
VIBRATION MOTOR
M1 M1
M5
M2
M2 L2
L1 S
CLOCKWISE - HIGH AMPLITUDE

HYDRAULIC TANK
SD-116 TF SERIES
SUCTION STRAINER
VIBRATION
SUCTION
FILTER L E G E N D
OIL
COOLER
165 F OPEN
THERMAL
BYPASS
VALVE
25 PSI
dashed lines
VIBRATION PUMP indicate
low pressure
M3
F5 M4
A
VIBRATION MOTOR
M1 M1
M5
B
M2
M2 L2
L1 S
COUNTERCLOCKWISE -
LOW AMPLITUDE
SD-116 TF SERIES VIBRATION PUMP
TABLE OF CONTENTS .............................................F6.1 FORWARD - NEUTRAL - REVERSE
CONTROL (SD-116D 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-116DX/F Only) .................................F6.7
Disassembly .........................................................F6.7
Inspection .............................................................F6.7
Assembly..............................................................F6.8
TABLE OF CONTENTS
NOTICE:
DISASSEMBLY
1. Remove the retaining ring (1, Figure 1-1) from the housing
(2).
2. Carefully remove the lip seal (3) from the housing (2) bore. A
slide type hammer may be used to remove the lip seal (3).
INSPECTION
necessary.
ASSEMBLY
F6.2 with Loctite High Performance Sealant #59231.
CAUTION:
To prevent damage to the lip seal (3, Figure 1-1), wrap the spline
or key end of the shaft (4) with thin plastic.
2. Slide the new lip seal (3) over the shaft (4) and press it into
the housing (2) bore.
3. Install the retaining ring (1).
Figure 1-1
LIP SEAL
DISASSEMBLY
1. Remove the bypass valve (5, Figure 1-12) from the housing
(2).
2. Remove and discard the O-ring (6) and backup ring (7) from
the bypass valve (5).
INSPECTION
1. Inspect the bypass valve (5) and mating seat for damage or
foreign material. Use new parts as required.
ASSEMBLY
1. Install a new backup ring (7) and O-ring (6) onto the bypass
valve (5).
2. Lubricate the new O-ring (6) with clean hydraulic fluid and
install the bypass valve (5) into the housing (2).
3. Torque the bypass valve (5) to 9.5 to 13.6 N·m (7 to 10 lb-ft.).
F6.3
Figure 1-2
BYPASS VALVE
DISASSEMBLY
1. Remove the charge check and high pressure relief valve
plug (8, Figure 1-3).
2. Remove and discard the O-ring (9) from the charge check
and high pressure relief valve plug (8).
3. Remove the spring (10) and poppet or valve cartridge (11)
from the housing (2).
INSPECTION
1. Inspect the poppet or valve cartridge (11) and mating seat in
the housing (2) for damage or foreign material. If the seat in
the housing (2) is damaged, a new vibration pump must be
used and the original must be returned to the manufacturer
for warranty repair or replacement.
NOTE:
Always replace ball type check valves with the poppet type.
F6.4 ASSEMBLY
1. Install a new O-ring (9) on the charge check and high
pressure relief valve plug (8).
2. Install a new poppet or valve cartridge (11), new spring (10),
and charge check and high pressure relief valve plug (8) into
the housing (2).
3. Torque the charge check and high pressure relief valve plug
(8) to 41 to 95 N·m (30 to 70 lb-ft.).
CAUTION:
The high pressure relief valves are factory set and should not be
tampered with except for replacing the entire poppet or valve
cartridge. Disassembly may change the setting and cause
system malfunctions or premature failure. Figure 1-3
CHARGE CHECK AND HIGH

PRESSURE RELIEF VALVE
DISASSEMBLY
1. Remove the charge relief valve plug (12, Figure 1-4).
2. Remove and discard the O-ring (13) from the charge relief
valve plug (12).
3. Remove and discard the shims (14) from the charge relief
valve plug (12).
4. Remove the spring (15) and poppet (16) from the housing
(2).
INSPECTION
1. Inspect the poppet and mating seat in the end cap for
damage or foreign material. Use new parts as required.
ASSEMBLY
1. Install a new O-ring (13) on the charge relief valve plug (12).
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

DISASSEMBLY
1. Remove the screws (1, Figure 1-5) from the housing (19).
2. Remove the filter adapter (2) and gasket (3) from the housing
(19).
ASSEMBLY
1. Install a new gasket (3) and filter adapter (2) onto the
housing (19).
2. Install the screws (1) to secure the filter adapter (2) onto the
housing (19).
3. Torque the screws (1) to 22 to 28 N·m (16 to 21 lb-ft.).
F6.6
Figure 1-5
FILTER ADAPTER
NOTICE: (SD-116DX/F Only)
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, 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

ASSEMBLY (SD-116DX/F Only)
1. Install a new gasket (16, Figure 1-6) for each servo piston
cover (15 and 17).
2. Install the servo piston covers (15 and 17) and secure each
with screws (14).
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, Figure 1-6), the pump
neutral adjustment MUST be performed before the machine is
put back into service.
F6.8 Performance of the pump neutral adjustment may adjust the
position of the displacement limiter.
Figure 1-6
ELECTRICAL DISPLACEMENT CONTROL

DISASSEMBLY (SD-116D Only)
1. Remove the screws (4, Figure 1-7).
2. Remove the control (6) from the gasket (7).
3. Remove the screws (5) from the gasket (7).
4. Remove the gasket (7) from the housing (19). Discard the
gasket.
5. Remove and discard the O-rings (8 and 9) from the gasket
(7).
6. Remove the screws (14) from each side of the housing (19).
7. Remove the servo piston covers (15 and 17).
8. Remove and discard the gaskets (16).
INSPECTION
1. Clean all parts in a suitable solvent and allow to air dry.
2. Clean all sealing surfaces.
F6.9 3. Inspect all machined surfaces for burrs and sharp edges.
Remove any burrs or sharp edges as required.
Figure 1-7
FORWARD - NEUTRAL -
REVERSE CONTROL
ASSEMBLY (SD-116D Only)
1. Install a new gasket (16, Figure 1-7) for each servo piston
cover (15 and 17).
2. Install the servo piston covers (15 and 17) and secure each
with screws (14).
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, Figure 1-7), the pump
neutral adjustment MUST be performed before the machine is
put back into service.
Figure 1-7
FORWARD - NEUTRAL -
REVERSE CONTROL
SD-116 TF SERIES VIBRATION MOTOR
TABLE OF CONTENTS............................................. F7.1
SHAFT SEAL............................................................. F7.2

Disassembly ......................................................... F7.2
Inspection ............................................................. F7.2
Assembly.............................................................. F7.3
Vibration Motor
F7.1
TABLE OF CONTENTS
NOTICE:
DISASSEMBLY
1. Remove the retaining ring (6, Figure 1-1) located on the
shaft end of the motor (8).
2. Remove the support washer (10) and lip seal (7) from the
motor housing (8).
3. Remove the second retaining ring (6) from the motor housing
4. Remove the O-rings and ball bearing from the motor
housing. Discard the O-rings.
5. If necessary, remove the shaft from inside the motor
housing.
6. Turn the vibration motor over with the motor shaft end facing
down. Locate and loosen the screws that connect the end
F7.2 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
ASSEMBLY
1. Place a new needle bearing (1, Figure 1-1) and a new
gasket (2) on the motor end cap (9).
2. Place the motor end cap (9) on the motor shaft (8). Make
sure that the screw hole are line up perfectly on both the end
cap (9) and the motor shaft (8).
3. Using the screws provided, fasten the end cap motor (9) to
the motor shaft (8).
4. Lubicate the new O-rings (4) with petroleum jelly and in them
along with the ball bearing (5) on the motor shaft .
5. Place the first retaining ring (6) on the motor shaft.
6. Lightly lubricate the outside of the diameter of the new lip
seal (7) with Loctite High Performance Sealant #59231.
7. Install the new lip seal (7) into the shaft end of the motor
housing (8).
8. Install the support washer (10) and retaining ring (6).
F7.3
Figure 1-1
SHAFT SEAL
SD-116 TF SERIES
Table of Contents Settings and Specifications - Steering* 116D 116

F
Overview...............................G2 Engine RPM (Hi/Low) 2457/950 X X
Neutral ..................................G3 Flow at Input Speed 24.2 l/m 6.4 g/m X X
System Relief Pressure (psi/bar) 2610/180 X X
Steer Right........................... G4
Steer Left ..............................G5 personnel.
STEERING
Steering Cylinders
G1
Return Filter
Hydraulic Tank
Steering Valve
Steering Pump
EFF. W/ ALL S/N

SD-116 TF SERIES
STEERING
STEERING CYLINDERS
HYDRAULIC TANK
SUCTION STRAINER
RETURN FILTER
G2
STEERING PUMP V
STEERING VALVE
OVERVIEW
SD-116 TF SERIES
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
SD-116 TF SERIES
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
SD-116 TF SERIES
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
SD-116 TF SERIES STEERING PUMP
TABLE OF CONTENTS ............................................ G6.1
SEAL KIT .................................................................. G6.2

Disassembly ........................................................ G6.2
Inspection ............................................................ G6.3
Assembly............................................................. G6.3
G6.1 Steering Pump
TABLE OF CONTENTS
NOTICE:
DISASSEMBLY
1. Place the pump in a vise from the flange side. Be careful not
to damage the pump housing (1, Figure 1-1) or flange (2).
2. Loosen and remove the screws (3) from the pump housing
(1) and flange (2).
3. Place the pump on a table with the shaft end facing up.
4. Remove the flange (2) and dowel pins (4) from the pump
housing (1).
5. Clean up any oil left on the work surface after removing the
flange (2).
6. Carefully remove and discard the anti-extrusion ring (5) then
the seal (6) from the flange (2).
G6.2 WARNING
Safety glasses must be worn when removing the retaining ring
(7, Figure 1-1).
7. Place the flange (2) down on the work surface with a shop
towel beneath the flange. Remove the retaining ring (7) and
shaft seal (8) from the flange (2).
8. Remove the cover (9) and dowel pins (10) from the pump
housing (1).
9. Clean up any oil left on the work surface after removing the
cover (9).
10. Carefully remove and discard the anti-extrusion ring (5) then
the seal (6) from the cover (9).
11. Carefully remove and discard the O-ring seal (11) from both
ends of the pump housing (1). Figure 1-1
SEAL KIT
INSPECTION
1. Carefully clean and dry all machined surfaces thoroughly.
2. Inspect all machined surfaces for burrs and sharp edges.
Remove burrs and sharp edges as required.
ASSEMBLY
1. Lightly lubricate the new O-ring seals (11, Figure 1-1) and
seals (6) with petroleum jelly.
2. Install the new O-ring seals (11) on both ends of the pump
housing (1).
3. Install a new seal (6) in the cover (9).
4. Secure the seal (6) in the cover (9) by installing a new 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).
WARNING
G6.3 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
CAUTION:
Be careful not to damage the shaft seal (8) on the splined shaft
when installing the flange (2, Figure 1-1).
10. Carefully install the flange (2, Figure 1-1) over the shaft and
down onto the pump housing (1).
11. Place the pump in a vise from the flange side. Be careful not
to damage the pump housing (1) or flange (2).
12. Install the screws (3) to secure the cover (9) and the pump
housing (1) to the flange (2).
13. Torque the screws (3) to 50 to 55 N·m (36.9 to 40.5 lb-ft.).
Follow the pattern shown in Figure 1-1.
G6.4
Figure 1-1
SEAL KIT
SD-116 TF SERIES STEERING VALVE
TABLE OF CONTENTS............................................ G7.1
STEERING VALVE ................................................... G7.2

Disassembly ........................................................ G7.2
Inspection ............................................................ G7.4
Assembly............................................................. G7.4
Steering Valve
G7.1
TABLE OF CONTENTS
NOTICE:
DISASSEMBLY
1. Clean the exterior of the steering valve thoroughly.
2. Fasten the edges of the port face sides in a vise. Use
protective material on the vise jaws to prevent damage to the
housing (10, Figure 1-1).
3. Loosen and remove the screws (1), special screw (2) and
washers (3) from the housing (10).
4. Remove the end cap (4).
5. Carefully remove the gerotor assembly (5) from the spacer
plate (6).
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
14. Press the spool (14, Figure 1-1) inward and the sleeve (15),
bearing races (16 and 17), needle bearing (18), and ring (19)
will be pushed out of the housing (10) together. Take care to
keep the pin (20) in the sleeve (15) and spool (14) horizontal.
15. Remove the ring (19), bearing races (16 and 17), and the
needle thrust bearing (18) from the spool (14) and sleeve
(15) assembly.
NOTE:
The outer bearing race (16, Figure 1-1) can sometimes “stick” in
the housing (10), therefore check that the outer bearing race
(16) has come out.
16. Push the pin (20) from the spool (14) and sleeve (15)
assembly.
17. Carefully press the spool (14) out from the control end of the
sleeve (15), then carefully remove the centering springs (21)
from the spool (14) using only your hands.
G7.3 18. Remove the dust seal (22) and the O-ring (23) from the
housing (10). Be careful not to damage the housing (10).
19. Remove the pressure relief valve assembly from the housing
(10).
NOTE:
The pressure relief valve assembly consists of a plug (25, Figure
1-1), seal washer (26), set screw (27), spring (28), and a piston
(29).
20. Loosen and remove the plug (25) and seal washer (26) from
the housing (10).
21. Remove the set screw (27) from the pressure relief valve
port.
22. Shake out the spring (28) and piston (29) from the housing Figure 1-1
(10).
STEERING VALVE
INSPECTION
1. Inspect all mating surfaces for burrs and sharp edges.
Replace parts as required. Do not use grit paper or file or
grind these parts.
2. Clean all metal parts in a cleaning solvent. Blow dry all metal
parts. Do not wipe dry with cloth or paper towel.
ASSEMBLY
1. Install the two flat centering springs (21, Figure 1-1) in the
centering springs slots of the spool (14).
2. Place the curved centering springs (21) between the flat
centering springs (21) that are already installed in the spool
(14).
3. Align the centering springs (21) within the spring slots of the
spool (14).
G7.4 4. Install the spool (14) and sleeve (15) carefully so that the
spring slots line up at the same end. Make sure the three
slots in the end of the spool (14) align with the three holes in
the sleeve (15) opposite to the end with the centering springs
slots.
5. Press the centering springs (21) together and push the
centering springs (21) into place in the sleeve (15).
6. Align the centering springs (21) and center them in the spool
(14) and sleeve (15) assembly.
7. Install the ring (19) over the spool (14) and on the sleeve
(15). Make sure the ring (19) can rotate smoothly over the
centering springs (21).
8. Insert the pin (20) through the spool (14) and sleeve (15)
assembly until the pin is flush on both sides of the sleeve Figure 1-1
(15).
STEERING VALVE
NOTE:
The inside chamfer on the inner bearing race (17, Figure 1-1)
must face the splined end of the spool (14).
9. Install the inner bearing race (17, Figure 1-1), needle bearing
(18), and the outer bearing race (16) on the splined end of
the spool (14).
10. Place the housing (10) on the work surface with the bore in a
horizontal position. Guide the outer part of the assembly tool
into the bore for the spool (14) and sleeve (15) assembly.
11. Lightly lubricate the new O-ring (23) with clean hydraulic oil
and place the O-ring (23) on the inner part of the assembly
tool.
12. Hold the outer part of the assembly tool in the bottom of the
housing (10) and guide the inner part of the assembly tool
into the bottom of the housing (10).
G7.5 13. Press and turn the O-ring (23) into position in the housing
(10).
14. Remove the inner and outer parts of the assembly tool out of
the housing (10) bore, leaving the guide from the inner part
in the bore.
15. Install the spool (14) and sleeve (15) assembly splined end
in the gerotor end of the housing (10). Make sure the parts
do not tilt out of position.
16. Push the spool (14) and sleeve (15) assembly gently into
place with slight rotating action, keeping the pin (20) nearly
horizontal.
17. The spool (14) and sleeve (15) assembly will push out the
assembly tool guide. The O-ring (23) is now in position.
18. Test for free rotation by turning the spool (14) and sleeve Figure 1-1
(15) assembly with fingertip force at the splined end.
STEERING VALVE
19. Place the housing (10, Figure 1-1) on a clean, lint free cloth
with the bore in a vertical position.
20. Install the check valve (8) in the housing (10), refer to Figure
1-1.
21. Install the check ball (13) in the check valve port of the
housing (10).
22. Install the threaded bushing (12) in the check valve port of
the housing (10). The top of the threaded bushing (12) must
lie just below the surface of the housing (10).
23. Lightly lubricate the new seal (11) with clean hydraulic oil
and install the seal (11) in the housing (10).
24. Align the bolt holes in the spacer plate (6) with the bolt holes
in the housing (10) and install the spacer plate (6) on the
housing (10).
25. Install the drive (9), making sure the drive (9) is engaged with
G7.6 the pin (20). Use the mounting fork tool to hold the drive (9)
in position.
26. Lightly lubricate the seals (7) with clean hydraulic oil and
install the seals (7) on both sides of the gerotor assembly (5).
NOTE:
The gerotor assembly (5, Figure 1-1) and the drive (9) must fit
together so that a tooth base in the gerotor assembly (5) is
positioned in relation to the slot of the drive (9), refer to Figure 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 Figure 1-1
assembly (5) from the drive (9).
STEERING VALVE
29. Install end cap (4, Figure 1-1) on the gerotor assembly (5),
aligning the bolt holes.
30. Remove the mounting fork tool from the drive (9).
31. Install the special screw (2) and washer (3) in the check
valve port bolt hole in the end cap (3).
32. Install the screws (1) and washers (3) in the end cap (4).
33. Cross tighten the screws (1) and special screw (2) and
torque the screws (1) and special screw (2) to 30 ± 6 N·m (22
± 4.4 lb-ft).
34. Install the pressure relief valve assembly in the housing (10).
NOTE:
The pressure relief valve assembly consists of a plug (25, Figure
1-1), seal washer (26), set screw (27), spring (28), and a piston
(29).
35. Install the piston (29) and spring (28) into the pressure relief
G7.7 valve port.
36. Install the set screw (27) in the pressure relief valve port and
adjust the set screw (27) to 95 to 100 bar (1380 to 1450 psi).
37. Install the seal washer (26) and plug (25) into the pressure
relief valve port.
38. Torque the plug (25) to 50 ± 10 N·m (36 ± 7 lb-ft.).
39. Press the dust seal (22) into housing (10).
Figure 1-1
STEERING VALVE
SD-116 TF SERIES STEERING CYLINDER
(S/Ns 169494, 169572)
SEAL KIT .................................................................. G8.2
Disassembly ........................................................ G8.2
Inspection ............................................................ G8.3
Assembly............................................................. G8.4
Steering Cylinders
G8.1
TABLE OF CONTENTS
NOTICE: (S/Ns 169494, 169572)
DISASSEMBLY
1. Clean the outside of the cylinder. If the hoses were removed
with the cylinder, remove the hoses from the cylinder.
2. Fasten the tube (1, Figure 1-1) in an acceptable repair stand
or other holding equipment., Be careful not to damage the
tube (1).
3. Extend the piston rod (2) until the piston (3) bottoms out on
the head (4).
4. Loosen and remove the set screw (5) and nylon plug (16)
from the headcap (6).
5. Insert a spanner wrench into the holes provided. Remove the
headcap (6) from the tube (1) by turning the headcap (6)
counterclockwise. If the headcap (6) is sruck or moves
G8.2 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
9. Loosen and remove the locknut (7, Figure 1-1) from the (S/Ns 169494, 169572)
piston rod (2).
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
ASSEMBLY (S/Ns 169494, 169572)
1. Install a new lip seal (10, Figure 1-1) in the middle groove in
the inside diameter of the head (4).
2. Install a new wiper (9) in the front groove in the inside
diameter of the head (4).
3. Install new wear rings (11) in the back groove in the inside
diameter of the head (4).
4. Install a new backup ring (13) in the groove on the outside
diameter of the head (4) closest to the headcap (6).
5. Install a new O-ring (12) in the groove on the outside
diameter of the head (4) next to the backup ring (13).
6. Install a new glyd-ring (15) and wear ring (14) in the grooves
on the outside diameter of the piston (3).
7. Lubricate the inside and outside diameters of both the piston
(3) and head (4) with clean hydraulic oil.
8. Place the piston rod (2) on a clean work surface.
G8.4 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
14. Install the piston rod (2, Figure 1-1) assembly into the tube (S/Ns 169494, 169572)
(1) until the headcap (6) engages the threads of the tube (1).
Turn the headcap (6) counterclockwise until the first thread
just passes the engagement point, then turn the headcap (6)
clockwise until it is hand-tight or fully seated.
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
(All Other S/Ns)
SEAL KIT .................................................................. G9.2
Disassembly ........................................................ G9.2
Inspection ............................................................ G9.3
Assembly............................................................. G9.3
Steering Cylinders
G9.1
TABLE OF CONTENTS
NOTICE:
(All Other S/Ns)
representative concerning warranty issues.
DISASSEMBLY
1. Clean the outside of the cylinder. If the hoses were removed
with the cylinder, remove the hoses from the cylinder.
2. Fasten the tube (1, Figure 1-1) in an acceptable repair stand
or other holding equipment. Be careful not to damage the
tube (1).
3. Extend the cylinder rod (4) until the piston (3) bottoms out on
the head (2).
4. Gently tap the piston (3) against the head (2) to drive the
cylinder rod (4) from the tube (1).
5. Place the cylinder rod (4) assembly on a suitable work
surface to prevent damage.
G9.2 6. Loosen and remove the locknut (25) from the cylinder rod
(4).
7. Remove the piston (3) and head (2) from the cylinder rod (4).
8. Remove and discard the rod seal (11) and the rod wiper seal
(13) from the inside diameter of the head.
9. Remove and discard the O-ring (10) and backup washer (40)
from the outside diameter of the head (2).
10. Remove and discard the seal (14) and wear ring (15) from
the piston (3).
Figure 1-1
SEAL KIT
INSPECTION
1. Clean all parts in cleaning solvent. Use only lint-free cloths
(All Other S/Ns)
for cleaning and drying.
2. If the cylinder rod (4, Figure 1-1), piston (3), head (2), or tube
(1) is damaged in any way, a new cylinder assembly must be
used.
ASSEMBLY
1. Install a new O-ring (11) and a new rod wiper seal (13) in the
inside diameter of the head (2).
2. Install a new backup washer (40) in the groove on the
outside diameter of the head (2).
3. Install a new O-ring (10) in the groove on the outside
diameter of the head (2) next to the backup washer (40).
4. Install a new seal (14) and a new wear ring (15) in the groove
on the outside diameter of the piston (3).
G9.3 5. Lubricate the inside and outside diameters of both the piston
(3) and head (2) with clean hydraulic oil.
6. Place the cylinder rod (4) on a clean work surface.
7. Install the head (2), followed by the piston (3), onto the
cylinder rod (4), noting the proper orientation of each
component.
8. Secure the piston (3) onto the cylinder rod (4) with the
locknut (25).
9. Torque the locknut (25) to 407 N·m (300 lb-ft.).
10. Install the cylinder rod (4) in the tube (1).
Figure 1-1
SEAL KIT
SD-116 TF SERIES
Table of Contents
Battery....................................H2
Grid Heater Relays
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

POWER RELAY
87A
SD-116 TF SERIES
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
SD-116 TF SERIES
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
SD-116 TF SERIES
ELECTRICAL
TO HORN SWITCH
34 - BN
HORN
RD/BE CLOSES AT 180 F
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
32 - WE RD
A
B
WE THROTTLE
BK
C
BK
SOLENOID IGNITION
SD-116 TF SERIES
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

34 - BN SD-116 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
SD-116 TF SERIES
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
SD-116 TF SERIES
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
23 - RD/DGN
27 - DPE/WE
H8 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
SD-116 TF SERIES
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
SD-116 TF SERIES
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
SD-116 TF SERIES
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
SD-116 TF SERIES
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
27 - DPE/WE
B B
H12 20 - YW/BK
NEUTRAL SWITCH
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
SD-116 TF SERIES
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
SD-116 TF SERIES
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
23 - RD/DGN
H14
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
SD-116 TF SERIES
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
SD-116 TF SERIES
ELECTRICAL
SPEEDOMETER
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 GY / GN ANTI - SPIN
H16 F10 1/A
X
A
X
A1 CONTROL MODULE
F2 10A
IGN LBE / BK
F3 10A SENSOR POWER
BK / WE
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
SD-116 TF SERIES
Table of Contents
Anti-Spin Control -
Travel............................. H18
Speedometer
ELECTRICAL
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
SD-116 TF SERIES
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
F10 1/A A A1 CONTROL MODULE
H18 F2 10A
F3 10A
IGN LBE / BK
BK / WE SENSOR POWER
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
SD-116 TF SERIES
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 1250 1650 2025

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
SD-116 TF SERIES
SPEEDOMETER
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
SD-116 TF SERIES
Table of Contents
Anti-Spin Control -
Wheel Spin ................... H22
ELECTRICAL
Speedometer
1625
27.1
1450
1425 1825
238
. 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
SD-116 TF SERIES
SPEEDOMETER
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
SD-116 TF SERIES
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
SD-116 TF SERIES
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
SD-116 TF SERIES
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
SD-116 TF SERIES
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
SD-116 TF SERIES
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
SD-116 TF SERIES
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
SD-116 TF SERIES
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
SD-116 TF SERIES
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 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 MACHINE IN MOTION AUTO VIBRATION & IMPACT METER
BK CONTROL MODULE
REAR SPEED SENSOR
METER - MANUAL/LOW AMPLITUDE
SD-116 TF SERIES
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
SD-116 TF SERIES
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
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 CONTROL MODULE
REAR SPEED SENSOR
METER - MANUAL/HIGH AMPLITUDE
SD-116 TF SERIES
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
SD-116 TF SERIES
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 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
H34 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 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 AUTOMATIC VIBRATION / IMPACT
METER - AUTOMATIC/
LOW AMPLITUDE
SD-116 TF SERIES
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
SD-116 TF SERIES
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
H36
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 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
SD-116 TF SERIES
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
SPEEDOMETER VPM METER IMPACT METER
SD-116 TF SERIES
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
SD-116 TF SERIES
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

SD-116 TF SERIES
ELECTRICAL
SEAT TIMER
ENGINE RUN CONDITION
+ N/C
COM
N/O
47- WE / BN
INIT
FUEL 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
H40 START IN
N/A
GN
BN
E
F
53- LGN WE
GRID HEATER
51- RD
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
SD-116 TF SERIES
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
SD-116 TF SERIES
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
SD-116 TF SERIES
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
SD-116 TF SERIES
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
H44 INDICATOR COOLANT
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
SD-116 TF SERIES
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

SD-116 TF SERIES
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
SD-116 TF SERIES / ROPS/FOPS REPLACEMENT
TABLE OF CONTENTS............................................. J1.1
ROPS/FOPS.............................................................. J1.2
Tools Required ..................................................... J1.2
Safety ................................................................... J1.2
Removal ............................................................... J1.3
Inspection ............................................................. J1.4
Installation ............................................................ J1.4
ROPS/FOPS
J1.1
032503AA
TABLE OF CONTENTS
SD-116 TF SERIES/ ROPS/FOPS REPLACEMENT
TOOLS REQUIRED:
• Safety glasses
• Torque multiplier • Loctite number 271
• Sockets and wrenches for these models
• Lifting device with straps and chains, and sufficient
capacity for lifting weight specified on ID tag located on the
ROPS/FOPS
SAFETY
Appropriate safety practices should be observed at all times.
Refer to the AEM Safety Manual for safety instructions.
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)
REMOVAL
NOTE
To ensure the safe removal and installation of your ROPS/
FOPS, refer to and view the service video which is available
from your distributor.
WARNING:
Use care when attaching and securing the lifting device to
avoid risk of accidents. Use a lifting device that is in perfect
condition and with sufficient capacity for lifting components
being serviced or repaired. Check for overhead obstructions.
1. Attach the straps or chains of the suitable lifting device to
the ROPS/FOPS (1, Figure 1-1).
2. Once the lifting device is attached, take out the slack so the
straps or chains are fully supporting the ROPS/FOPS (1).
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)
INSPECTION
1. Check the ROPS/FOPS (1, Figure 1-1) for signs of fatigue
or cracks. If cracks are found, the machine should be
placed out of service and the ROPS/FOPS and all
mounting hardware replaced.
2. Check all mounting hardware for damage and wear.
Replace as necessary.
INSTALLATION
1. Attach a suitable lifting device with straps or chains to the
ROPS/FOPS.
WARNING:
All assisting personnel should stay clear of pinch points and
avoid standing under the suspended ROPS/FOPS at all times.
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 capscrews (2).
4. Install the capscrews (2), hex nuts (4), and flatwashers (3)
and secure the ROPS/FOPS.
5. Torque the capscrews (2) to 637 N·m (470 lbs-ft.).
6. Install the plastic plugs (10).
7. Remove the lifting device from the ROPS/FOPS (1).
Figure 1-1
ROLLOVER PROTECTIVE
STRUCTURE (ROPS)
SD-116 TF SERIES / SWIVEL BEARING REPLACEMENT
TABLE OF CONTENTS............................................. J2.1
SWIVEL BEARING .................................................... J2.2

Tools Required ..................................................... J2.2
Safety ................................................................... J2.2
Removal and Disassembly................................... J2.4
Cleaning and Inspection....................................... J2.7
Assembly.............................................................. J2.7
J2.1
032503AA
TABLE OF CONTENTS
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.
032503AA
No unauthorized person should be allowed to operate, service,

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

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
insulating adjacent live parts and elements. 032503AA
NOTE:
Clean the machine, especially connections, of any traces of oil,
fuel, or preservatives before carrying out maintenance or
repair. Never use aggressive detergents. Use lint free cleaning
rags.
Figure 1-1

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. Refer to Figure 1-2.
3. Block the drum frame in such a manner that it can be
moved back when the articulation joint is unbolted.
WARNING: Block Drum Frame
pressure is relieved from the system before disconnecting
hydraulic lines and performing maintenance.
4. Tag and disconnect the hydraulic lines to the propulsion,
vibration, and blade systems that are routed between the
drum frame and rear frame. Cap or plug all lines and
Figure 1-2
openings.
5. Tag and disconnect any electrical harnesses connected
between the two frames. JACK AND BLOCK PLACEMENT
SD-116 TF SERIES SWIVEL BEARING REPLACEMENT
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, Figure 1-3) and scraper
from the drum frame (2). Refer to the Drum and Drum Drive
Teardown and Rebuild Procedure J3.
WARNING:
7. Attach an adequate lifting/supporting device to the drum
J2.5 frame (2).
8. Remove the capscrews (27) and washers (28) from the
lock plate (26) on the drum frame and swivel horizontal
oscillating pin (5).
9. Remove the lock plate (26).
10. Loosen the stop nut (6) on the drum frame oscillating pin
(5).
11. Remove the pin (5), washer (7) and nut (6) from the swivel
and drum frame.
12. Remove the hitch pin (16) and remove the lock pin (9).
13. Move the drum frame clear of the swivel.
14. Remove and discard the bearings (4) and dust seals (24
and 25) from the drum frame (2). Figure 1-3
DRUM FRAME AND SWIVEL BEARINGS

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).
19. Remove and discard the bushings (10) from the top of the Refer to Figure 1-3 for rod
frame swivel (3). end attaching hardware.
20. Repeat steps 15 through 19 for the other steer cylinder.
J2.6
Figure 1-4
REAR FRAME AND STEER CYLINDERS

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

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

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 lb-ft.).
12. Install the new O-ring (41).
13. Install the lock plate (26).
14. Apply Loctite #271 to the capscrews (27).
15. Install the washers (28) and capscrews (27) into the lock
plate (26).
16. Torque the capscrews (27) to 61 N·m (45 lb-ft.).
17. Apply a coat of grease to the new bushings (10).
18. Install the new bushings (10) into the top of the swivel (13).
Figure 1-7

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

NOTICE:
During installation of the horizontal swivel oscillating pin (5.
Figure 1-7), and ensure the weight of the drum frame (2) is off
of the pin so as not to cause damage to the pin.
31. Install the horizontal swivel oscillating pin (5, Figure 1-7)
into the drum frame (2) and swivel (3).
32. Ensure the pin (5) is centered in the drum frame (2).
33. Install the washer (7) and stop nut (6) onto the pin (5).
34. Torque the pin (5) to 340 N·m (250 lbs-ft.).
35. Install the lock plate (26).
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.

SD-116 TF SERIES DRUM AND DRUM DRIVE
TABLE OF CONTENTS ............................................. J3.1
DRUM AND DRUM DRIVE........................................ J3.2

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

Carrier Assembly......................................... J3.14
Drive Side Assembly and Installation
.................................................................... J3.15
Drum Drive Assembly and Installation
.................................................................... J3.17
Assembly and Installation ........................... J3.19
032503AA
TABLE OF CONTENTS
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
032503AA
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
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
insulating adjacent live parts and elements. 032503AA
NOTE:
Clean the machine, especially connections, of any traces of oil,
fuel, or preservatives before carrying out maintenance or
repair. Never use aggressive detergents. Use lint free cleaning
rags.
NOTE: Figure 1-1
Take extra care when working around or on the hydraulic
system to ensure its complete cleanliness.
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

7. Remove the capscrews (42, Figure 1-3), flatwashers (21),
shims (19 and 20), and nuts (23) from the scraper and
drum frame (2).
8. Tag and wire the shims (19 and 20) together so that they
can be reinstalled at the same locations.
9. Using the lifting device, remove the scraper from the drum
frame (2).
WARNING:
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 1-6) (left side of the drum).
11. Remove the capscrews (37) and flatwashers (36) securing
the vibration motor (27) to the carrier assembly (23).
12. Remove the vibration motor (27) and O-ring (28) from the
carrier assembly (23).
13. Tag and disconnect the hydraulic lines and the electrical
line to the drum drive motor (1, Figure 1-5). Cap or plug all
lines and openings.
Figure 1-3
DRUM, DRUM FRAME AND SCRAPER

14. Remove the capscrews (22, Figure 1-4), flatwashers (21),
shims (19 and 20) and hex nuts (23), securing the drum
assembly (1) to the drum frame (2).
15. Tag and wire the shims (19 and 20) together so that they
can be reinstalled at the same location.
16. Carefully roll the drum assembly (1) out of the drum frame
(2) and block into position for further maintenance.
J3.6
Figure 1-4
DRUM, DRUM FRAME AND SCRAPER

DRUM DRIVE REMOVAL AND DISASSEMBLY
WARNING:
1. Use an adequate lifting/supporting device to support drive
motor (1, Figure 1-5) and drive plate (2).
2. Remove the nuts (35, Figure 1-6) flatwashers (34) and
washers (39) securing the drive plate assembly (33) to the
shock mounts (16).
3. Using the lifting device, remove the drive motor (1), drive
plate (2) and mounting plate (3) from the drum.
4. Remove the capscrews (30, Figure 1-6) 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 1-5) and flatwashers (4)
from the drive plate (2) and drive motor (1).
7. Remove the capscrews (5), flatwashers (4), and hex nuts
(6) from the mounting plate (3) and drive motor (1).
8. Separate the drum drive motor (1) from the drive plate (2)
and mounting plate (3).
9. If maintenance of the drum drive motor (1) is required, refer
to the Drum Drive Motor service information for this model.
Figure 1-5
DRUM DRIVE
DRUM DRIVE SIDE DISASSEMBLY
1. Remove the capscrews (12, Figure 1-6) from the cover
(11).
2. Remove the cover (11) from the bearing housing drive (2).
3. Remove and discard the O-ring (9).
WARNING:
Safety glasses must be worn when removing the retaining ring.
4. Remove the retaining ring (19) from the eccentric (5).
WARNING:
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 1-6
DRUM ASSEMBLY
CARRIER DISASSEMBLY
WARNING:
1. Attach an adequate lifting/supporting device to the shock
mounting plate (10, Figure 1-7).
2. Remove the nuts (12). flatwashers (11) and washers (9)
securing the shock mount plate (10) to the shock mounts
(6).
3. Using the lifting device, remove the shock mount plate (10).
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 1-7
CARRIER ASSEMBLY
VIBRATION SIDE DISASSEMBLY
1. Remove the coupling (24, Figure 1-8) and splined shaft
(26) from the drum (1).
WARNING:
housing spindle (3, Figure 1-8).
3. Remove the bolts (10) and flatwashers (8) from the bearing
housing spindle (3).
4. Using the lifting device, remove the bearing housing
spindle (3) from the drum (1).
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 1-8
model.
DRUM ASSEMBLY
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, Figure 1-8) onto the bearing
J3.11
2. Apply petroleum jelly to the new V-ring seal (17).
3. Install the new V-ring seal (17) onto the bearing housing
spindle (3).
4. Heat the bearings (15) to 107° C (225° F) for 15 to 30
minutes before installation.
WARNING:
Wear protective heat resistant gloves when handling heated
parts. Contact with hot bearings will cause severe burns.
NOTE:
Bearings are to be cooled to -18°C (0° F) for 2 to 4 hours
before installation.
5. Lower the temperature of the new bearings (15).
Figure 1-8
6. Apply a coat of grease to the new bearings (15).
7. Install the new bearing (15) and the spacer (4) onto the
bearing housing spindle (3). DRUM ASSEMBLY
WARNING:
Safety glasses must be worn when installing the retaining
rings.
8. Install a new bearing (15, Figure 1-8) and the retaining ring
(18) onto the bearing housing spindle (3).
9. Apply petroleum jelly to the new O-ring (20).
10. Install the new O-ring (20) into the bearing housing spindle
(3).
WARNING:
housing spindle (3 Figure 1-8).
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 lb-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 1-8
bearing housing spindle (3).
DRUM ASSEMBLY
17. Support the eccentric assembly (5, Figure 1-8) until the
bearing housing drive (2) is installed.
18. Coat the contact areas of both ends of the splined shaft
(26) with Dow Corning Moly-Kote grease prior to
installation into the coupling (24) and eccentric (5).
19. Install the splined shaft (26) and coupling (24) into the drum
(1).
20. Check the eccentric oil. Refer to the Operation and
Maintenance Manual for this model.
J3.13
Figure 1-8
DRUM ASSEMBLY
CARRIER ASSEMBLY
1. Install new oil seal (5, Figure 1-9) 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 lb-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 1-9
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
DRIVE SIDE ASSEMBLY AND INSTALLATION
1. Install a new O-ring (20, Figure 1-10) into the bearing
housing drive (2).
2. Heat the bearings (6) to 107° C (225° F) for 15 to 30
minutes before installation.
WARNING:
Wear protective heat resistant gloves when handling heated
parts. Contact with hot bearings will cause severe burns.
NOTE:
Bearings are to be cooled to -18°C (0° F) for 2 to 4 hours
before installation.
3. Lower the temperature of the new bearings (6).
4. Install new bearings (6) into the bearing housing drive (2).
WARNING:
J3.15 Safety glasses must be worn when installing the retaining
rings.
5. Install the retaining rings (7).
6. Attach an adequate lifting device to the bearing housing
drive (2).
7. Install the bearing housing drive (2) into the drum (1).
8. Apply Loctite #271 (red) to the bolts (10).
9. Install the bolts (10) and flatwashers (8) into the bearing
housing drive (2).
10. Torque the bolts (10) to 373 N·m (275 lb-ft.).
WARNING:
Safety glasses must be worn when installing the retaining
rings. Figure 1-10
11. Install the retaining ring (19) onto the eccentric (5).
DRUM ASSEMBLY
12. Apply petroleum jelly to the new O-ring (9, Figure 1-11).
13. Install a new O-ring (9) onto the cover (11).
14. Install the cover (11) onto the bearing housing drive (2).
15. Apply Loctite #242 (blue) to the capscrews (13).
16. Install the capscrews (12) into the cover (11).
17. Torque the capscrews (13) to 28.5 N·m (21 lb-ft.).
J3.16
Figure 1-11
DRUM ASSEMBLY
DRUM DRIVE ASSEMBLY AND INSTALLATION
1. Apply Loctite #271 to capscrews (5, Figure 1-12).
2. Install the mounting plate (3) to the drive motor (1).
3. Install the capscrews (5), flatwashers (4), and nuts (6) into
the mounting plate (3) and the drive motor (1).
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).
9. Apply Loctite #271 (red) to capscrews (30, Figure 1-11).
10. Install the shock mounts (16) to the drum (1).
11. Install the capscrews (30) and flatwashers (29) into the
shock mounts (16).
12. Torque the capscrews (30) to 149 N·m (110 lb-ft.)
WARNING:
being serviced or repaired. Check for overhead obstructions. Figure 1-12
13. Attach an adequate lifting/supporting device to the drive
motor (1, Figure 1-12), drive plate (2) and mounting plate
(3). DRUM DRIVE
14. Apply Loctite #271 (red) to the nuts (35, Figure 1-13).
15. Using the lifting device, install the drive plate (2), drive
motor (1) and mounting plate (3) to the shock mounts (16).
16. Install the nuts (35), flatwashers (34) and washers (39) into
the drum drive plate (2).
17. Torque the nuts (35) to 373 N·m (275 lb-ft.).
18. Check the drum drive and carrier oil level. Refer to the
Operation and Maintenance Manual for these models for
maintenance instructions.
J3.18
Figure 1-13
DRUM ASEMBLY
ASSEMBLY AND INSTALLATION
WARNING:
1. Attach an adequate lifting device to the drum assembly (1,
Figure 1-14).
1. Carefully roll the drum assembly into position in the drum
frame.
2. Measure the distance between the frame sides at positions
A and D (Figure 1-14). Measurement A should be no more
than 25.4 mm (1.0 in.) greater than measurement D.
Ensure the gap is consistent between the siderails along
the entire length of the siderail.
J3.19 3. Measure the scraper bar length. The difference between
the length of the scraper bar and the distance in position A
is the required shim pack thickness for the scraper bar
installation.
WARNING:
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.
Figure 1-14
5. Align scraper into the drum frame (2, Figure 1-15).
DRUM ALIGNMENT
6. Preload the drum assembly by shimming the vibration side
only. Fill gap on both sides of mounting bracket, then add
the smallest thickness 1.5 mm (0.06 in.) shim to each side
of mounting bracket.
7. Align the drum mounting holes by rocking the drum forward
and backward until the mounting capscrews can be
inserted temporarily on each side. Install capscrews (22,
Figure 1-15 ), flat washers (21) and nuts (23).
8. Take clearance measurements B and C (Fgure 1-14) on
both ends of the drum. Measure between the edge of the
drum shell and the drum frame. Shift the drum until these
measurements are equal.
9. Measure to determine the shim thickness on each end at
the drum mounting location E.
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 1-15) at each end
of the drum.
13. Alternately torque the capscrews (22) to 1780 N·m (1310
lb-ft.).
NOTE:
Scraper shim packs should result in the scraper total length to
nearly match, but not exceed the distance between the drum
frame siderails.
14. Install scraper shims (19 and 20).
15. Apply Loctite to the capscrews (42).
16. Install the capscrews (42), flatwashers (21), and nuts (23) Figure 1-15
into the scraper and drum frame.
DRUM, DRUM FRAME, AND SCRAPER
17. Torque the cappscrews (42, Figure 1-15) to 1780 N·m
(1313 lb-ft.).
18. Connect the hydraulic lines to the drum drive motor (1,
Figure 1-12).
19. Apply petroleum jelly to new O-ring (28, Figure 1-16).
20. Install the vibration motor (27, Figure 1-16) and new O-ring
(28) into the drum.
21. Apply Loctite #271 (red) to the capscrews (37).
22. Install the capscrews (37) and flatwashers (36) into the
vibration motor (27, Figure 1-16) and carrier assembly (23).
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
J3.21 and Maintenance Manual for these models for mainte-
nance instructions.
27. Operate the compactor and check for proper operation,
and ensure there are no oil leaks.
Figure 1-16
DRUM ASSEMBLY
SD-116 TF SERIES / ECCENTRIC ASSEMBLY
TABLE OF CONTENTS. ............................................ J4.1
ECCENTRIC ASSEMBLY.......................................... J4.2

Tools Required ..................................................... J4.2
Safety ................................................................... J4.2
Disassembly ......................................................... J4.2
Cleaning and Inspection....................................... J4.3
Assembly.............................................................. J4.3
Eccentric Assembly
J4.1
032503AA
TABLE OF CONTENTS
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).
4. Remove the capscrews (8) and flatwashers (7) from the
non-drive side journal (4).
5. Remove the roll pin (10) from the non-drive journal (4) and
eccentric shaft (2).
6. Pull the eccentric shaft (2) from the non-drive side journal
(4). Figure 1-1
ECCENTRIC ASSEMBLY
7. Remove the capscrews (8, Figure 1-1) and flatwashers (7)
from the drive side journal (1).
8. Remove the drive side journal (1) from the eccentric shaft
housing (2).
9. Remove and discard the oillite bearing (5) from the
eccentric shaft (3).
10. Remove the eccentric shaft (3) from the eccentric shaft
housing (2).

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

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

K1
Surge
Smoke
Stalling
ENGINE
No Lights
No Gauges
SYMPTOMS
Noise (excessive)
ELECTRICAL SYSTEMS
ELECTRICAL
Hard to start or will not start

Won't crank or cranks slowly
POSSIBLE CAUSES
8
AFC malfunction/injection pump overfueled
Air cleaner/filter plugged
3 2
3
4
4
Air in fuel system
1
1
Battery
Battery charge low
4 2
Crankshaft rotation restricted
1
Drive belt squeal
3
3
Electical circuits
2
2
Engine cranking speed too low
1
Engine drive units engaged

7 Engine running too cold
7
Fuel contaminated
Fuel filter plugged
4
7 5 6
5
2 Fuel supply restricted

2
Fuses
4
Gear train noise

1
Idle speed too low

2
1
Incorrect starting procedure

Injector nozzle malfunction
6 4
8
8
Injection pump timing incorrect

6
Injection pump malfunction

6
Intake air system restricted

2
Intake air/exhaust leaks

1
Low/No fuel
1
Lugging engine
5
Malfunctioning injectors
10
3
Malfunctioning engine shut-down

TROUBLESHOOTING
5
Multiple seal washers under injector nozzle

5
No voltage to Starter Solenoid

3
Starting aid needed

6
Solenoid or Starting motor malfunction

3
Starting Circuit connections loose or corroded

NOTE: Possible causes for each symptom are numbered in order of most likely occurance.
7
Starting motor operating but not cranking engine

3
Valve lash excessive

9
Valves incorrectly adjusted

K2
Sluggish
STEERING
No Steering
Not working
VIBRATION
Wrong Mode
SYMPTOMS
Hard to Steer
One Direction
No Propulsion
Frequency low
PROPULSION
Wander or Drift
Off and On again
One direction only
Neutral difficult to find

Neutral difficult to find
System operating "HOT"

System operating "HOT"
Steering Slip (Intermittant)

HYDRAULICS
POSSIBLE CAUSES
2
2
2
Air in system
4
8
4
Bad pump
5 11
3
6
Broken Cylinder
4
3
3
4
5
3
Bypass valve
6
4
3
4
Charge Pressure
7
Charge pump (Vibration)
6
3
3
5
4
Contaminated System
10
2
1
2
Control Cable
3
9
3
6
4
4
4
3
Control Valve
5 4
4
5
8 Cylinder by-pass
6
Drive coupling
7
9
Eccentric bearings
12 11
6
2
Eccentric oil level

1
1
2
EDC Electrical displmt cntrl (DX/F)

9
2
Electical circuit
2
2
Heat Exchanger
1
1
1
1
1
1
1
1
1
Hydraulic oil level in reservoir

5
3
3
Inlet filter
Inspect chrg relief valve/pump
7
6
6 5 8
Inspect Control orifice

3
1
2
Linkage and lever

4
Pump multi-function valve

7
5
Replace Control Valve

Replace Transmission
10
13
TROUBLESHOOTING
12 2
10 1
RPM
5
Servo Control pressure

3
Servo pressure differential

1
Settings on console
6
Loop flushing valve

NOTE: Possible causes for each symptom are numbered in order of most likely occurance.
Steering pump
8
5
3
2
5
3 2
System pressure check

2
System relief/check valves

10 9
2
8 7
System relief pressure

7 4
Traction control valve (Optional)

SD-116 TF SERIES / VIBRATION CONTROL SYSTEM
TABLE OF CONTENTS. ............................................K3.1
VIBRATION CONTROL SYSTEM .............................K3.2

Major Components ...............................................K3.2
Troubleshooting....................................................K3.4
Fault Codes ..........................................................K3.6
CHARTS
Vibration Control Components .............................K3.2
Microprocessor LED Functions ............................K3.3
Troubleshooting Chart..........................................K3.4
Fault Code Troubleshooting Chart .......................K3.6
K3.1
032503AA
TABLE OF CONTENTS
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

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
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
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
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
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
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
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
SD-116 TF SERIES / TRACTION ENHANCEMENT SYSTEM
TABLE OF CONTENTS. ............................................ 43.1
TRACTION ENHANCEMENT SYSTEM....................K4.2

Major Components ...............................................K4.2
Troubleshooting....................................................K4.4
Fault Codes ..........................................................K4.6
CHARTS
Traction Enhancement Components ....................K4.2
Microprocessor LED Functions ............................K4.3
Troubleshooting Chart..........................................K4.4
Fault Code Troubleshooting Chart .......................K4.7
K4.1
032503AA
TABLE OF CONTENTS
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.
032503AA
• A remote loop-flushing valve is located on the inside of the

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

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
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
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
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
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 should be
approximately. 6.0
ohms)
LSLS • Current supplied to rear • Check continuity of
valve coil on the the wire that runs from
traction valve is out of the B2 terminal at the
range. microprocessor to the
rear valve coil at the
traction valve.
• Check continuity of
the wire that runs from
the front valve coil to Figure 1-2
ground frame.
MICROPROCESSOR
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
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
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
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 by
cycling ignition switch
to the off position and
then restarting the
machine.
Figure 1-3

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

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

Hydraulic Symbol Quick Reference Chart
Operation Methods Motors & Cylinders Miscellaneous Symbols Pumps Valves
Fixed Displacement,
Fixed Displacement, Unidirectional Check Valve
Unidirectional, Pressure Gauge
Manual Hydraulic Pump
Rotary Hydraulic Motor
Manual Shut Off Valve
Pedal Or Treadle Temperature Gauge Fixed Displacement,

Bidirectional
Fixed Displacement, Hydraulic Pump Pressure Relief Valve
Bidirectional,
Rotary Hydraulic Motor
Push Button
Cooler
Needle Valve
Variable Displacement,
Non-Compensating,
Bidirectional
Variable Displacement, Closed Center, Three
Hydraulic Pump
Bidirectional, Position Directional
Level Rotary Hydraulic Motor Pressure Switch Control Valve
L1 Filter or Strainer
Open Center, Three
Position Directional
Pilot Pressure Double Acting Component
Cylinder Enclosure Control Valve
Line
Solenoid Tandem Center, Three

Position Directional
Control Valve
Hydraulic Lines
Working Hydraulic Line to Tank
Spring Line (Above Fluid Level)
Lines Joining Float Center,
Three Position
Pilot Line Directional
Control Valve
Servo Lines Passing
Line to Tank Two Position

Drain Line
(Below Fluid Level) Multiple Flow Path Valve
(Arrows show
Plug or Plugged
direction of flow)
Fixed Restriction Connection
Electrical Schematic Code Reference Chart
Wire Color Codes
Gray/Black GY/BK Orange/Black OE/BK
Black/Yellow BK/YW White/Violet WE/VT
White/Gray WE/GY Gray/Yellow GY/YW
Dr Blue/White DBE/WE Yellow/Brown YW/BN
Black/Orange BK/OE Dr Green/Orange DGN/OE
White/Orange WE/OE White/Blue WE/BE
Dr Blue/Yellow DBE/YW Dr Blue/Black DBE/BK
Lt Green/Black LGN/BK White/Green WE/GN
Dr Green/Red DGN/RD Gray/Red GY/RD
Dr Blue/Red DBE/RD Yellow/Red YW/RD
Purple/Red PE/RD Pink/Red PK/RD
Orange/Red OE/RD Brown/Red BN/RD
White/Red WE/RD Black/Red BK/RD
L2 White/Brown WE/BN White/Yellow WE/YW
Tan/White TN/WE Lt Green/White LGN/WE
Lt Blue/White LBE/WE Gray/White GY/WE
Dr Blue/White DBE/WE Yellow/White YW/WE
Red/White RD/WE Purple/White PE/WE
Pink/White PK/WE Orange/White OE/WE
White/Black WE/BK Brown/White BN/WE
Black/White BK/WE Dk Green DGN
Lt Green LGN Lt Blue LBE
Gray GY Dk Blue DBE
Yellow YW Red RD
Purple PE Pink PK
Orange OE White WE
Brown BN Black BK
SD-116 TF SERIES HYDRAULIC
L3
D13238902
MACHINE HYDRAULIC SCHEMATIC

SD-116 TF SERIES HYDRAULIC
L4
D13238902
MACHINE HYDRAULIC SCHEMATIC

SD-116 TF SERIES ELECTRICAL
L5
D59292995 Rev. 4
MACHINE ELECTRICAL SCHEMATIC

L6
D59292995 Rev. 4

L7
D59292995 Rev. 4

The warranty statement is provided within the manual kit shipped with the machine.
Ref. No. VOE21A1004254 English
CPN 43929439
Printed in USA 2007-12 CST
Volvo, Shippensburg

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VOLVO CONSTRUCTION EQUIPMENT

EFF. W/ ALL S/N

EFF. W/ ALL S/N

EFF. W/ ALL S/N

FEATURES OF THIS MANUAL

• Hose routing diagram w/ components labeled.

• Standard symbols are

• Colors are standard

REVERSE - BRAKES RELEASED

S ept embe r 2 002

EFF. W/ ALL S/N

Before performing any maintenance or service procedures

EFF. W/ ALL S/N

ILLUSTRATED HOSE SCHEMATIC

Steering Pump Right

Suction Filter Drum Drive Motor

EFF. W/ ALL S/N

ILLUSTRATED HOSE SCHEMATIC

Hydraulic Tank Check Valve Steering

Steering Pump Right

Traction Control Valve

Suction Filter Drum Drive Motor

EFF. W/ ALL S/N

Standard on DX, Optional on D & F ........E10

Settings and Specifications - Propulsion* 116D 116F

DUMP / BRAKE / 2 SPEED MANIFOLD

DUMP / BRAKE / 2 SPEED MANIFOLD

CHARGE FILTER TRACTION ENHANCEMENT VALVE

NEUTRAL - BRAKES APPLIED

DUMP / BRAKE / 2 SPEED MANIFOLD

FORWARD - BRAKES RELEASED

REVERSE - BRAKES RELEASED

DUMP / BRAKE / 2 SPEED MANIFOLD

FORWARD - BRAKES RELEASED

DUMP / BRAKE / 2 SPEED MANIFOLD

FORWARD - BRAKES RELEASED

DUMP / BRAKE / 2 SPEED MANIFOLD

REVERSE - BRAKES RELEASED

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

LIP SEAL AND SHAFT

LIP SEAL AND SHAFT

MULTI-FUNCTION VALVE CARTRIDGES

CHARGE RELIEF VALVE

No-Spin Differential Unit

No-Spin Differential Unit

REDUCTION GEAR AND PINION

REDUCTION GEAR AND PINION

Tool T11 Tool T12

REDUCTION GEAR AND PINION

REDUCTION GEAR AND PINION

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

LIP SEAL AND SHAFT

LIP SEAL AND SHAFT

LOOP FLUSHING VALVE

ORIFICE CHECK VALVE AND ELECTRIC

ORIFICE CHECK VALVE AND ELECTRIC

LOOP FLUSHING VALVE .......................................E16.2

LOOP FLUSHING VALVE

CHARGE RELIEF VALVE

Table of Contents Settings and Specifications - Vibration* 116D 116F

Thermal Bypass Valve

EFF. W/ ALL S/N

CLOCKWISE - HIGH AMPLITUDE