Vibromax Translated Manual

1103 ROLLER SINGLE DRUM
SERVICE MANUAL SM90001

July 1998
CALIFORNIA
Proposition 65 Notice
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
CONTENTS TABLE
SECTION A
GENERAL INFORMATION
MACHINE DESCRIPTION..........................................................................1 - 3
SERIAL NUMBER............................................................................1 - 5
IDENTIFYING MACHINE COMPONENTS......................................1 - 6
SECURITY, GENERAL...............................................................................1 - 7
ARRESTER SPARK.........................................................................1 - 7
PERSONAL SECURITY.............................................................................1 - 7
SAFETY, MACHINE OPERATION.............................................................1 - 8
SECURITY, MAINTENANCE......................................................................1 - 9
GENERAL INFORMATION.......................................................................1 - 12
CLEANING.....................................................................................1 - 12
INSPECTION.................................................................................1 - 12
BEARINGS.....................................................................................1 - 12
NEEDLE BEARINGS.....................................................................1 - 12
MARCHES.....................................................................................1 - 12
OIL SEALS, O-RINGS, & GASKETS.............................................1 - 12
BOFTS...........................................................................................1 - 12
THE SERVICE SEPARATES.........................................................1 - 12
LUBRICATION...............................................................................1 - 12
STANDARD TORQUE DATA...................................................................1 - 13
MACHINE SPECIFICATIONS...................................................................1 - 15
FLUID SPECIFICATIONS.........................................................................1 - 17
DIESEL FUEL SPECIFICATION...............................................................1 - 18
ENGINE OIL SPECIFICATION.................................................................1 - 19
TIRE BALLAST.........................................................................................1 - 20
SECTION TWO
ENGINE
CUMMINS ENGINE WARRANTY...............................................................2 - 3
ENGINE REMOVAL....................................................................................2 - 4
SECTION THREE
ELECTRICAL
GENERAL INFORMATION.........................................................................3 - 2
INSTRUMENT DASHBOARD.....................................................................3 - 4
COMPREHENSIVE ELECTRICAL SCHEMATICS.....................................3 - 7
COMPREHENSIVE RELAYS.....................................................................3 - 9
VIBROMAX RELAYS.....................................................................3 - 11
STARTER/CHARGING CIRCUIT (before JKC8302000) .........................3 - 13
STARTER/CHARGING CIRCUIT (AFTER JKC8302000) ........................3 - 15
COMPREHENSIVE BATTERIES..............................................................3 - 15
BATTERY DIAGNOSTICS.............................................................3 - 16
July 1998 3
CONTENTS TABLE
COMPREHENSIVE ALTERNATORS....................................................... 3 - 17
CHARGING SYSTEM DIAGNOSES.............................................. 3 - 18
VOLTAGE CONTROLS ON ALTERNATOR.................................. 3 - 19
EXHAUST SYSTEM....................................................................... 3 - 19
CIRCUIT WIRING TEST................................................................ 3 - 19
MEASURING ALTERNATOR PRODUCTION............................... 3 - 20
COMPREHENSIVE STARTERS.................................................... 3 - 20
STARTER SOLENOID................................................................... 3 - 21
STARTER SYSTEM DIAGNOSTICS........................................................ 3 - 21
SOLENOID CIRCUIT TEST........................................................... 3 - 21
STARTER CIRCUIT WIRING TEST............................................... 3 - 22
STARTER ENGINE TEST.............................................................. 3 - 23
INSTRUMENTATION DASHBOARD........................................................ 3 - 25
SHIFT STOP/ EMERGENCY SHIFT BRAKE........................................... 3 - 27
VIBRATION CIRCUIT............................................................................... 3 - 29
VIBRATION AFTER JKC8300700............................................................ 3 - 31
SWITCHING ON CIRCUIT........................................................................ 3 - 33
WORK LIGHTS, ACCESSORY PLUG, HEATER AND WIPERS .............3 - 35
TAXI WIRING............................................................................................ 3 - 46
CABLE HARNESS 7250/16315................................................................ 3 - 47
CABLE CHART 7250/16315..................................................................... 3 - 52
CABLE HARNESS 7250/16110................................................................ 3 - 56
CABLE CHART 7250/16110..................................................................... 3 - 59
SECTION FOUR
HYDRAULIC
TACHA PUMP SUCTION........................................................................... 4 - 2
HYDRAULIC COOLING SYSTEM.............................................................. 4 - 4
The HYDRAULIC DRAIN TACHA............................................................... 4 - 6
HYDRAULIC TEST SYSTEM...................................................................... 4 - 8
HYDRAULIC TEST STATION..................................................................... 4 - 9
CHARGE SYSTEM................................................................................... 4 - 11
Propulsion system..................................................................................... 4 - 13
MULTIFUNCTION VALVES...................................................................... 4 - 17
PROPULSION SYSTEM DIAGNOSES..................................................... 4 - 18
INTERNAL EXHAUST....................................................................4 - 18
SERVO CONTROL PUMP........................................................................ 4 - 19
VIBRATION SYSTEM............................................................................... 4 - 21
VIBRATION FREQUENCY....................................................................... 4 - 23
VIBRATION AMPLITUDE......................................................................... 4 - 25
VIBRATORY SYSTEM DIAGNOSES....................................................... 4 - 26
STEERING................................................................................ SYSTEM 4 - 27
PARKING BRAKE SYSTEM..................................................................... 4 - 30
TOWING YOUR MACHINE............................................................ 4 - 31
PARKING BRAKE DIAGNOSTICS........................................................... 4 - 31
4 July 1998
CONTENTS TABLE
DIFFERENTIAL LOCK SYSTEM..............................................................4 - 35

HYDRAULIC SCHEMATIC.......................................................................4 - 38
SECTION FIVE
FINAL RIDES
GENERAL INFORMATION.........................................................................5 - 2
OPERATION...............................................................................................5 - 3
KESSLER AXLE.........................................................................................5 - 4
SPETH STANDARD SHAFT.......................................................................5 - 5
REAR AXLE REMOVAL.............................................................................5 - 6
SHAFT INSTALLATION..............................................................................5 - 7
SHAFT TUBE DISASSEMBLY...................................................................5 - 8
DISSASSEMBLY PLANETARIUM............................................................5 - 10
DIFFERENTIAL LOCK REMOVAL...........................................................5 - 12
DIFFERENTIAL LOCK ASSEMBLY.........................................................5 - 13
SHAFT TUBE AND PLANETARY ASSEMBLY........................................5 - 14
INTERMEDIATE GEARBOX DISASSEMBLY..........................................5 - 18
INTERMEDIATE GEARBOX ASSEMBLY................................................5 - 20
DIFFERENTIAL DISASSEMBLY..............................................................5 - 22
DIFFERENTIAL ASSEMBLY....................................................................5 - 24
DRUM REMOVAL.....................................................................................5 - 29
DRUM INSTALLATION.............................................................................5 - 29
DRUM RIDE..............................................................................................5 - 30
DRUM RIDE THAT HOLDS EXTRACTION..............................................5 - 34
DRUM RIDE HOLDING INSTALLATION..................................................5 - 36
DRUM DRIVE MOTOR REPAIR...............................................................5 - 36
SECTION SIX
PARKING BRAKE SYSTEM
DESCRIPTION........................................................................................... 6 - 2
RELEASE AND TUG BOAT .......................................................................6 - 4
DRUM MOTOR BRAKE..............................................................................6 - 5
ENGINE BRAKE DISASSEMBLY....................................................6 - 6
ENGINE BRAKE ASSEMBLY..........................................................6 - 6
STANDARD AXLE BRAKE.........................................................................6 - 8
BRAKE BAND ADJUSTMENT....................................................................6 - 9
BRAKE CYLINDER BAND........................................................................6 - 10
HEAVY DUTY AXLE BRAKE....................................................................6 - 11
July 1998 5
CONTENTS TABLE
SECTION SEVEN
VIBRATION SYSTEM
VIBRATION SYSTEM.................................................................................7 - 2
VIBRATION FREQUENCY.........................................................................7 - 3
VIBRATION AMPLITUDE...........................................................................7 - 5
VIBRATORY SYSTEM DIAGNOSES.........................................................7 - 6
LIFTING DEVICE........................................................................................7 - 7
DRUM REMOVAL.......................................................................................7 - 8
DRUM INSTALLATION...............................................................................7 - 8
EXCITER HOLDING EXTRACTION...........................................................7 - 9
EXCITER HOLDING ASSEMBLY.............................................................7 - 14
SMOOTH DRUM SHAFT..........................................................................7 - 15
PADFOOT DRUM SHAFT........................................................................7 - 16
SECTION EIGHT
STEERING SYSTEM
SPECIAL TOOLS........................................................................................8 - 2
JOINT JOINT.............................................................................................. 8 - 3
DISASSEMBLY BOARD.............................................................................8 - 5
BOARD ASSEMBLY...................................................................................8 - 9
STEERING
..................................................................................................................
CYLINDER 8 - 12
SECTION NINE
CHASSIS
DRUM FRAME............................................................................................9 - 2
REAR FRAME.............................................................................................9 - 3
SIDE FRAME..............................................................................................9 - 4
ENGINE COMPARTMENT DASHBOARDS...............................................9 - 5
OPERATOR PLATFORM...........................................................................9 - 6
ROLLOVER PROTECTIVE STRUCTURE..................................................9 - 7
SECTION TEN
ANNEXES
LEVELING BLADE....................................................................................10 - 2
BLADE CONTROL....................................................................................10 - 3
HYDRAULIC LINES SHEET.....................................................................10 - 4
6 July 1998
SECTION A
GENERAL
INFORMATIO
N
CALIFORNIA
July 1998 1-1
1-2 July 1998
SECTION A GENERAL
INFORMATION
MACHINE DESCRIPTION
The 1103 Vibratory Roller

is the replacement for the
1102. Like the 1102, the
1103 is available in
smooth deck or foot drum
configuration. The 1103
What-ever is also offered
with a standard Speth axle
or a heavy duty Speth axle
for high gradeability
applications.
The 1103 uses the

Cummins 5.9-liter 6-
cylinder turbocharged
engine at 130 gross
horsepower. Chang- is On
the ride pump and
The addition of a heavy duty axle drive motor results in improved machine performance.
The vibrating drum diameter remains the same and drum width is two inches narrower. The
centrifugal force of the drum has been increased by 22%.
A Sauer Sundstrand Series 90 variable displacement, axial piston hydrostatic pump, used
for machine propulsion, is mounted to the flywheel end of the engine. Provides oil to a
Poclain LADY25 drum drive motor and a Sauer Sundstrand 2 speed shaft drive motor in a
parallel way. The Poclain motor is mounted on the left side of the drum and is isolated from
the drum by rubber buffers. The axle ride motor on the standard axle has a displacement of
80cc while the motor on the heavy duty axle displaces 110cc.
The vibration system used a Sauer Sundstrand Series 90 hydrostatic pump similar to the
propulsion pump and mounted directly behind the propulsion pump. The vibratory pump
supplies oil to a Sauer Sundstrand hydrostatic motor mounted on the right side of the drum.
Like the 1102, the 1103 smooth drum operates at frequencies of 1680 or 2160 vibrations
per minute,
July 1998 1-3
SECTION A GENERAL
INFORMATION
While the standing version of the platform
operates only at the lowest frequency.
A steering pump, mounted to the rear of
the vibration pump, provides the oil
needed for steering. The steering pump is
also a second charge pump in the
propulsion/vibration circuit. The steering oil
draws from the reservoir pump, passes it
through the steering control valve, through
the inline hydraulic filter, and to the charge
circuit. The charge pump draws oil from
the reservoir, joins the steering oil into the
filter, and passes it through the filter and
into the charge circuit.
The 1103 has brakes on both the front drum

and the rear axle. A spring-applied,
hydraulically released multi-disc brake is
part of the drum ride motor. The standard
axle machine uses a spring applied-
hydraulically-released band brake in the
intermediate gearbox while the heavy duty
axle incorporates multiple disc brakes in the
intermediate gearbox.
Pressure testing of the 1103 has been

made easier by placing all test ports in a
test station centrally located under the
operators platform on the correct side of
the machine.
The electrical system of the 1103 consists

of a 12 volt battery, starter, alternator sys-
tem, optional starting and standard
instrumentation.
1-4 July 1998

SECTION A GENERAL
INFORMATION
SERIAL NUMBERS
1 Model/Serial Number
2 Front Drum Drive Motor S/N
3 Steering Unit S/N
4 S/N axis
5 Vibrating motor S/N
6 Hydraulic pumps S/N
7 Shaft Drive Motor S/N
8 Engine S/N
July 1998 1-5

SECTION A GENERAL
INFORMATION
IDENTIFYING MACHINE COMPONENTS

1 Joint joint 13 Lifting and towing eyes
2 smooth drum 14 Fuel tank
3 lifting eye 15 air filter system
4 The position of the operator 16 The freshest hydraulic oil
5 Battery 17 I run on a protective structure
6 Hydraulic tank 18 vibration motor
7 Engine 19 Steering Cylinder
8 planetary march 20 Hydraulic bombs
9 Differential 21 Parking brake cylinder
10 drum ride motor 22 middle gear box
11 Buffer isolation 23 shaft ride motor
12 Scraper 24 Radiator
1-6 July 1998

SECTION A GENERAL
INFORMATION
SECURITY, GENERAL
The information in this manual does

not replace any safety rules and laws used A fire can cause
in your area. Before you operate this injury or death. Always have a fire
machine, learn the rules and laws for your extinguisher at the work site near the
area and make sure your machine has the machine. Safe Brand The fire
correct equipment according to these rules extinguisher is serviced according to
and controls. the manufacturer's instructions.
Your safety and the safety of other people

in the work area are dependent on your Foreign materials
correct operation of this machine. and loose objects on steps, hand
rails, and in the operator
• Know the location and function of all compartment can cause accidents
and damage. Keep steps, hand rails,
machine controls. and operator compartment clear at
• Clear other people's area before you start all times..
the engine.
• Check all controls in a safe area before Always use the
seat belt when operating the machine.
you operate the machine. Make sure the buckle so the seat is
• Understand the limits of the machine. fastened correctly.
• Don't try to do too much too quickly.

• Keep the machine under control at all Make sure the taxi
won- dows is clean and
times. unobstructed..
ARRESTER SPARK
Know and
NOTE: rules or laws in some areas may understand the arrangements for the
make it necessary for this machine to movement of trucks, machines, and
be equipped with a spark arrester or people at your workplace. Understand
spark arrester muffler. Check the and follow the instructions of
rules or laws in your area. flagmen, road signs, or signs..
PERSONAL SECURITY
Always wear
appropriate ear protection when
operating this machine. Permanent
Loose jewelry and
hearing loss can result from extended
clothing can cause an accident. Do
exposure to loud noises.
not wear jewelry or loose clothing
that could be picked up at
checkpoints, etc. wear safety shoes,
hard hat, heavy gloves, etc. when Control machine
required for your protection. checks for proper operation prior to
starting the machine.
July 1998 1-7

Holes, obstructions, Look at the
debris, and other work area hazards instruments and gauges frequently
can cause injury or death. Always when you operate. Make sure all
walk around and look for these and systems are in the appropriate
other hazards before you operate operating range.
your machine in a new work area.
This machine uses

Electrical cables, a articulating joint. Keep all persons
gas pipes, water pipes, sewers, or clear of this area pinch when the
other underground objects can cause engine is running. Machine movement
injury or death. Know the location of may cause personal injury.
underground hazards before you
operate your machine in a new work
area.
An out-of-control
machine can cause injury or death.
You have to make a judgment
Failure to do, or whether weather and ground
incorrect machine inspection and conditions will allow safe operation
maintenance can cause accidents. on a hill, ramp, or rough terrain.
Always follow the instructions in this Adjust machine operation
manual for machine inspection and accordingly.
maintenance.
SAFETY, MACHINE OPERATION Operating
your machine in, over, or approaching

Dust, smoke, fog, a trench, high bank, or overhang is
etc. It can decrease your vision and extra dangerous and can cause injury
cause an accident. Always stop or or death. You have to make a
slow down the machine until you can judgment whether your machine can
see your work area and surrounding be safely operated near any of these
traffic areas. Use wall brackets if necessary.
Operate the Sparks from the

controls from the operator's seat electrical system or engine exhaust
only, and keep your hands on the can cause a fire or explosion. Before
controls during operation. you operate this machine in an area
with flammable dust or vapors, use
good ventilation to remove the
Do not allow other flammable dust or vapors.
people to ride on the machine.
Engine exhaust
fumes can cause injury or death. If
you operate this machine in an
enclosed area, use good ventilation to
replace exhaust fumes with fresh air.
The vibrations from Operating this
this machine can cause the walls of a machine too close to High Voltage
trench or high bench to collapse. If power lines may cause injury or
you must operate this machine close death. Follow the guide lines listed
to a trench or high bench, make sure below.
the walls of the trench or bench are
braced. Failure to follow these NOTE: IF THE CLEARANCES IN THE
instructions may cause death or SPECIFICATIONS BELOW ARE LESS
personal injury to people working in THAN THE CLEARANCES GIVEN IN
these areas. THE RULES AND LAWS OF YOUR
AREA, YOU HAVE TO FOLLOW THE
RULES AND LAWS OF YOUR AREA!
Electrical Safety Rules
Minimum Minimum Cable

Clearance Of Clearance
cable voltage Cable When When
Machine Is Transporting
Working Machine
50,000 volts or less 10 feet (3 meters) 4 feet (1.2 meters)
50,000 volts at 10 feet (3m) plus 1/2 10 feet (3 meters)

345,000 volts Inch (13mm) for
Every 1000 volts
Over 50,000 volts
345,000 volts at 10 feet (3m) plus 1/2 16 feet (5 meters)

750,000 volts Inch (13mm) for
Every 1000 volts
Over 50,000 volts
SECURITY, MAINTENANCE
Motor fuel is
flammable and can cause a fire or
explosion. Do not fill the fuel tank or
service the fuel system while the
machine is running, or approach an Machine movement
open flame, welding, burning cigars without an operator can cause injury
and cigarettes, etc. or death. If you have to service this
machine with the motor running, have
another person help you and follow
Flammable clean- the instructions in the machine
ing solvents can cause injury or manuals. It locks the articulation joint
death. Use nonflammable cleaning and does not leave the machine when
solvents for cleaning purposes. the engine is running.
Improper repair or Batteries produce
service can cause injury or death. If explosive gases. Keeps sparks and
you do not understand the service flame out. Ventilate when charging.
procedures for this machine, see your Always wear eye protection when
Vibromax dealer. working near batteries. Do not wear
jewelry or watch bands when working
on batteries.
Missing shields,
guards, or access boards can cause
damage or death. Always install all When installing a
shields, guards, or access panels battery or using a battery booster,
before you start the engine. connect the negative ground cable
last. When you remove a battery or
booster battery, disconnect the
Does not make any negative ground cable first.
modifications or repairs to the ROPS
machine. If your ROPS is damaged,
replace it with new parts. Welding, I never charge or
drilling, etc. can weaken the ROPS jump a battery when the electrolyte is
structure. frozen. If you do not follow this
instruction the battery may explode.
Unauthorized
modifications to this machine can Never wear rings or
cause injury or death. Never make other jewelry when working on
modifications to this machine without machine maintenance. Severe burns
prior written approval from Vibromax. can result when jewelry is shorted
into an electrical system.
Metal chips or
debris can cause eye damage. Eye Never wear loose
protection from wear and tear when clothing which can catch on objects
you service this machine. If you use a or become entangled in moving parts.
hammer to drive hardened pins or for
other service, use a hammer with a
soft face (brass, plastic, etc.).
Use proper ground
(service) jacks and safety positions
Unauthorized when lifting the machine off the
ground.
modifications to cast iron parts can
cause injury or death. Welding can
cause cast iron parts to break. Do not
use welding to repair or fasten items
to cast iron parts on this machine.
Hydraulic oil under
pressure can penetrate the skin. If
hydraulic oil has penetrated the skin,
seek medical treatment immediately.
Don't use your hands to check for
hydraulic leaks, use a piece of card-
board or wood.
Keep your work

area clean and free of spilled grease
and oil to avoid accidentally slipping.
GENERAL INFORMATION MARCHES
Check all gears for wear and damage.
Replaces gears that are worn or damaged.
CLEANING
I clean all metal parts, except bearings, in OIL SEALS, O-RINGS, & GASKETS
mineral spirits or by steam cleaning. Does
Always install new oil seals, o-rings and
not use caustic soda for steam cleaning.
gaskets. Put petroleum jelly or the
After cleaning, dry and put oil on all parts.
specified oil in seals and o-rings.
Clean oil passages with compressed air.
Clean bearings in kerosene, dry the BOFTS
bearings completely and put oil on the
Check all stems that have wear damage.
bearings.
Check the surfaces where bearings and oil
seals operate for signs of wear.
INSPECTION
Control all parts when parts are Service parts
disassembled. Replace everything Always install genuine Vibromax service
separated that has wear or damage. Small parts. When ordering refer to the parts
scoring or grooves can be drawn with a manual for the correct part numbers.
hone or crocus cloth. Complete visual Failure to use genuine Vibromax
inspection for indications of wear and replacement parts may void your warranty.
facing. Replacing bad parts will prevent
early failure. LUBRICATION
Use the oils and lubricants specified in the
BEARINGS
Operator's or Service Manual. Failures due
Control bearings for easy movement. If
to the use of unspecified lubricants are not
bearings have a loose fit or rough action
covered by warranty.
replace the bearing. Wash bearings in ker-
osene and leave to air dry. DO NOT USE
COMPRESSED AIR to DRY BEARINGS.
NEEDLE BEARINGS
Before pressing needle bearings into a
boring always remove any metal
protrusions on the boring or edge of the
boring. Before pressing and holding,
lubricate the inner and outer diameters
when needed.
STANDARD TORQUE DATA
Where no special torque data is specified, the following torque figures should be applied. The
threads would have to be lubricated with motor oil or grease.
STANDARD TORQUE SPECIFICATIONS +/- 10%
GRADE 8.8 GRADE 10.9 GRADE 12.9
EXTENT ft-lbs Nm ft-lbs Nm ft-lbs Nm

5mm 4 5.5 5.5 7.5 6.6 9
6mm 6.6 9 9.2 12.5 11 15
8mm 16.5 22.5 23 31.5 26.5 36
10mm 32 44 45 62 55 75
12mm 57 77.5 81 110 95 130
14mm 88 120 125 170 155 210
16mm 140 190 195 265 236 320
18mm 192 260 269 365 320 435
20mm 273 370 383 520 457 620
22mm 369 500 516 700 619 840
24mm 471 640 665 900 796 1080
27mm 702 950 996 1350 1195 1620
30mm 955 1300 1328 1800 1593 2160
NUTS FOR TUBES AND HOSES

FIELD & DIAMETER M/NEWTONS FOOT/POUNDS
16MM X 1.5 20 14.5
18MM X 1.5 35 26
20MMX1.45 45 33.2
24MM X 1.5 60 44
FITTINGS, CONNECTIONS AND PLUGS
10MM X 1 20 14.5
12MM X 1.5 35 26
14MM X 1.5 45 33.2
16MM X 1.5 60 44
18MM X 1.5 70 51
22MM X 1.5 100 73
27MM X 2 200 147
33MM X 2 280 207
42MM X 2 380 281
EDGES
8MM X 1.5 28 21
10MM X 1.5 55 41
12MM X 1.75 90 67
14MM X 2 145 107
16MM X 2 230 170
MACHINE SPECIFICATIONS
Inch mm
A 112 2845
b 88.6 2250
c 62.2 1580
d1 59.8 1520
d2 59.1 1500
d3 55.1 1400
d4 63 1600
h1 123.6 3140
h2 106.3 2700
k 18.1 216.5
l 216.5 5500
either 3 75
yes 1 25
w 82.7 2100
e1 30 30
e2 40 40
ENGINE DATA
Type/Model/Brand Cummins 6BT5.9C, 6 cylinder, turbo diesel
Cooling Water
Cubicage - cu.in. (DC) 359 (5880)
HP, SAE mains (kW) @ 2500 rpm 122 (91)
air cleaner Dual Substitution Elements
Fuel filter Spin-up Cartridge
Fuel consumption gal/hr (l/hr) 5.3 (19.5)
Fuel capacity - gal (liter) 74 (280)
Electric system 12 volt
RIDE SYSTEM DATA

1103D/1103HD 1103PD/1103HPD
Propulsion - front and rear Infinitely variable hydrostatic Infinitely variable hydrostatic
Travel speed 1st. - mph (Km/hr) 0 - 3.1 (0-5) 0 - 3.3 (0-5.5)
Travel speed 2nd. - mph (Km/hr) 0 - 6 (0-9) 0 - 6.6 (0-11)
Theoretical gradeability, forward -% 45/65 45/65
Brakes, front drum hydraulic disc hydraulic disc
Brakes, rear 1103 Hydraulic drum, intermediate shaft Hydraulic drum, intermediate shaft
Brakes, rear 1103H Hydraulic disc, intermediate shaft Hydraulic disc, intermediate shaft
Steering Articulated, hydraulic powered Articulated, hydraulic powered
tire size 23.1x26 8PR diamond tread 23.1x26 8PR tractor tread
OPERATIONAL DATA
1103D/1103HD 1103PD/1103HPD
Operating Weight - lbs (kg) 24475 (11100)/25740 (11700) 25300 (11500) / 26620 (12100)
Weight, front - lbs (kg) 12789 (5813) 13668 (6212)
Static Linear Drum Load - lb/in (cm/kg) 155 (27.6) -------------------
Drum wt, unsprung - lbs (kg) 7055 (3206) 7934 (3606)
Articulation/oscillation - degrees 37/15 37/15
Turning radius, inside - ft (m) 12 (3.7) 12 (3.7)
Drum shell thickness - in. (mm) 1.0 (25) 1.0 (25)
Number of feet/foot platform height - in -------------------- 144/4.0 (100)
(mm)
Foot contact area - sq. In (sq. cm) -------------------- 14.8 (95)
1st stage 2nd stage 1st stage
Max compaction depth - in (cm) 39 (100) 23.6 (60) 39 (100)
Frequency - vpm (Hz) 1680 (28) 2160 (36) 1680 (28)
Nominal amplitude - in. (mm) .063 (1.6) .023 (0.6) .063 (1.6)
Centrifugal force - lbf (kN) 47211 (210) 24053 (107) 47211 (210)
Centrifugal Drum/Force Width - lb/in 570 (1000) 291 (510) 570 (1000)
Total applied(N/cm)
force - lb/in (N/cm) 60000 (267) 36842 (164) 60879 (271)
Total Applied Linear Force 725 (1271) 445 (781) 736 (1290)
FLUID SPECIFICATIONS
US CAPACITY
MACHINE PART SPECIFICATIONS
(Metric)
Fuel tank 74 gal (280 l) See diesel fuel
Engine 15 qts (14.2 l) Motor oil
crankcase API Classification API-CD MIL-L-2104C
multigrade motor oil (see oil graph)
Solo Grade Motor Oil (see oil graph)
Hydraulic system 29.1 gal (110 l) Cold weather HLP 46 RUPLOUS 51524/2
hot weather HLP 68 URBAN 51524/2
Reservoir only 18.5 gal (70 l) Mobil DTE 25.26
Tellus Shell OL 46.68
Amoco Rykon HD 46.68
Texaco Rando HD 46.68
vibration system 12.7 qt. (12l) CLP ALBOROTO 51517/3
Mobil Marcha 629
Omala Shell 150
Texaco Meropa 150
Battery When required Distilled water
Fat When required KP3K RUPOR 51502
Mobil Oil - Mobilux 3
Shell Oil - Alvania 3
Texaco Oil - Starplex
3
engine coolant 20 qts (19 l) 50% ethylene glycol and 50% water
tire ballast See graph Calcium chloride (77%CaCl 2 )
Middle gear SAE 90 API GL-5 gear lubricant
standard duty 1.1 qts (1 ltr)
heavy duty 1.6 qts (1.5 ltr)
axle gear
heavy duty 14.8 qts (14 ltr)
planetary march
heavy duty 1.9 qts (1.8 ltr)
DIESEL FUEL SPECIFICATION
If fuel is stored for a long time, water or foreign particles may collect in the fuel storage
tank. Many engine problems are caused by contaminated fuel. Store fuel outside and keep
the fuel as fresh as possible. Drain water from the fuel storage tank at regular intervals.
NOTE: Paraffin crystals will begin to form in fuel when the fuel temperature drops below the
fuel cloud point. These paraffin crystals clog the fuel filter and cause the engine to stop losing
power. At ambient temperatures above 32 O F (0 O C) use #2 diesel fuel. A t temperature serl
ow 32 O F (0 O C ) uses #1 diesel fuel.
Different brands of fuel may exhibit different properties. Make sure that the number 2 diesel
fuel you use meets the following minimum requirements.
MINIMUM REQUIREMENTS FOR No.2 DIESEL FUEL:
Maximum cloud point -10 ° F (-23 ° C)

Maximum pour point 42 ° F (6 ° C) is the lowest temperature at
which the engine starts
Cetane Number, min 40 (45 to 55 in winter or at high altitude)

Max. Sulfur content, by weight 0.50%
Max. Water content & sediment by volume 0.05%
Max, ash content, by weight 0.01%
Max. Carbon residue (10% point) 0.20%
DistillUnt ien temperunt ure @ 90% point 540 to 6 25 O F (282-329 O

C) Distillunt ien temperunt ure @ fin point 675 ° F (357 ° C)
Minimum flceniza point 125 ° F (52 ° C)
Viscosity at 100 O F (38 O C)

Centistokes 2.0 to 4.3.
Saybolt Universal Seconds (SUS) 32 to 40
Copper strip test, 3 hours @ 212 O F (100 O C ) No 3
UnS TM Minimum API gravity 30
ENGINE OIL SPECIFICATION
Use multigrade or single grade motor oil with API motor oil service classification “CD”. NOTE:
DO NOT use performance additives or other oil additives in your crankcase engine. See chart
below for recommended oil viscosity in the various ambient air temperature range
TIRE BALLAST
Refer to the weight chart below for the maximum weight of tire ballast you can add to the
o o
machine. Calcium choride will prevent ballast from freezing at -30 F (-34 C). Tire pressure
is set at 13 to 20 PSI (0.9 to 1.40 bar). See your Vibromax dealer for more information.
NOTE: The following information is for one tire only and for a tire
size of 23.1-26 AW 8PR.
Water Calcium chloride Total Mix Weight

Liters US Gal. kg lbs kg lbs
484.5 128 481.7 1062
412.6 109 173.3 382 585.2 1291
389.9 103 233.6 515 623.3 1374
SECTION TWO
ENGINE
CALIFORNIA
July 1998 2-1

SECTION TWO ENGINE
2-2 July 1998

SECTION TWO ENGINE
CUMMINS ENGINE WARRANTY
All Cummins engines manufactured by Cummins Diesel and installed on Vibromax

products are covered by Cummins warranty and are to be serviced by an Authorized
Cummins Servicing Dealer and/or Distributor. The motors used in Vibromax equipment
have a two (2) year warranty period.
Warranty on Cummins engines begins when any of the following conditions are known:
* A claim is submitted to Cummins.

* The engine has accumulated 50 running hours
* The unit is rented, leased, or retailed.
* Cummins Representatives perform a start-up service
Cummins Engine Warranty is transferable during its term. The deadlines are not adjustable
or reversible.
Start up service is not required at the start of warranty on the engine. Warranty service is
provided by your local Cummins Service Outlet. If you require assistance with locating a
Service Outlet, call the Cummins Customer Relations Department, 1-800-343-7357.
ENGINE DATA
Type/Model/Brand Cummins 6BT5.9C, 6 cylinder, turbo diesel
Cooling Water
Cubicage - cu.in. (DC) 359 (5880)
HP, SAE mains (kW) @ 2500 rpm 122 (91)
air cleaner Dual Substitution Elements
Fuel filter Spin-up Cartridge
Fuel consumption gal/hr (l/hr) 5.3 (19.5)
Fuel capacity - gal (liter) 74 (280)
Electric system 12 volt
It is not the intent or purpose of this manual to provide the manufacturers technical
instruction for repair or overhaul of this engine. After the warranty expires, those wishing to
do their own engine service work would need to obtain the Cummins Shop Manual for the
“B” series engine from their local Cummins dealer.
July 1998 2-3

SECTION TWO ENGINE
ENGINE REMOVAL
1. Disconnect the negative battery cable. The battery is located on the operator
platform on the right side of the seat.
2. Remove the engine compartment hood and side panels.
3. Drain the engine cooling system. A drain valve is provided and is located on the
rear side of the radiator overflow tank on the left side of the machine.
4. Drain the engine oil using the fitting provided on the left rear frame behind the tire.
After the oil has been drained disconnect the drain hose from the engine oil pan.
2-4 July 1998

SECTION TWO ENGINE
5. Remove the air intake system.
6. Loosen the four screws that secure the hydraulic pumps to the engine. Support and
lock triple pump combination. Remove the four screws and slide the pump forward
off the motor. The engine will be removed without the pumps.
7. Remove the upper radiator and lower hoses. The radiator can be left in place.
8. Disconnect the radiator overflow tank from the left side of the engine.
9. Remove the muffler motor.
10. Disconnect the following electrical wires:

Starter wire located on left side of engine
Alternator wires located on left side of
engine.
Oil pressure change cable located on the left side of
the engine temperature sensor cable located above
the engine fuel solenoid cable located on the right
side of the engine ground belt located on the right
side of the engine
11. Disconnect the throttle cable located on the correct side of the machine.
12. Disconnect The fuel supply and fuel return lines located on the correct side of
the machine.
13. Remove the follower shroud and move it forward over the follower.
July 1998 2-5

SECTION TWO ENGINE
14. Prepare the engine for lifting using a sling and the two lifting eyes provided on
the engine. Approximate engine weight is 1200 lbs. (544 kg).
15. Remove the three motor mounts and lift the motor clear of the machine. Take extra
care not to damage the radiator.
2-6 July 1998

SECTION THREE
ELECTRIC
July 1998 3-1

SECTION THREE ELECTRIC
GENERAL INFORMATION
The electrical system on the 1103 is a 12 volt, negative ground system. A solenoid
controlled, gear driven, motor starter is standard along with a belt driven alternator. The
battery is located in an enclosure to the right of the operator's seat and is accessible by
tilting the operator's front seat or by removing the enclosure.
A drop down the dash under the pinch contains a housing for the fuses and relays. The
fuses are located in front of the edge of the housing under three separate covers.
There are thirteen relays mounted above the housing for various functions. They are easily removable from
their plug-in terminals. A delay relay, mounted in front of the relays, is used in the automatic vibration circuit.
FUSE FUNCTION RELAY FUNCTION
F1 Backup & Dashboard Alarm D1 Vibration delay (before JKC8300700)
F2 Alternator K1 starter interlock (anti-Resume)
F3 park brake K2 Brake and alternator monitor
F4 Vibration K3 Brake and neutral position monitor
F5 Two speed ride K4 neutral position
F6 taxi heater K5 brake release
F7 Emergency out change K6 Vibration control
F8 Differential lock K7 Vibration control (before JKC8300700)
F9 Turning on K8 Vibration control (before JKC8300700)
F10 Accessory plug K9 Emergency outside
F11 Work lights K10 Turning on system
F12 Turn signals K11 Back up alarm
F13 Turning on system K12 Automatic vibration
F14 hazard warning lights K13 Directional flasher
F15 Side lights, left
F16 Side lights, good
F17 Lights dimmed, left
F18 dimmed lights, good
3-2 July 1998

FUSE LOCATION
AFTER S/N JKC8300700
RELAY LOCATION
AFTER S/N JKC8300700
July 1998 3-3

INSTRUMENT DASHBOARD
1 Water tank level indicator 7 Engine oil temp. Indicator

2 Hydraulic filter indicator 8 sprinkler indicator
3 brake indicator 9 Air Cleaner Gauge
4 alternator indicator 10 Fuel Level Gauge
5 Engine Oil PSI Gauge 11 Neutral position indicator
6 Eng. coolant temp. 12 Directional indicator
Indicator
3-4 July 1998

INSTRUMENT DASHBOARD, LEFT SIDE
1 ) Differential lock light

2 ) Differential lock change
3 ) Change of ride range
4 ) Engine temperature gauge
5 ) Vibratory change #1
6 ) Vibratory change #2
7 ) Equip light gear
8 ) hazard Warning slight change
9 ) High beam light shift
10) Car vibration change
11) Directional light shift
INSTRUMENT DASHBOARD, RIGHT

SIDE
1) ignition Change
2) fuel level gauge
3) Parking brake change
4) Front working light shift
5) Rear working light shift
COMPREHENSIVE ELECTRICAL SCHEMATICS
COMPREHENSIVE ELECTRICAL Another example of how ladder schemes
SCHEMATICS overcome line crossing problems is the
x1/2 connector on line 2. The connectors
European electrical schematics differ typically handle multiple cables. Rather
somewhat from US schematics in that the than drawing the X1 connector with all the
European schematic is drawn in the form wires going to and from it, a ladder
of a ladder scheme. Ladder schemes are schematic will show the connector and port
easy to draw and simple to interpret. number for each wire in the connector. In
this case, X1/2 indicates connector X1,
Ladder schematics have the B+ power wire #2. X2/4 on-line 13 means it is the X2
lines across the top of the drawing, ground connector, wire #4.
across the bottom, and all components
shown vertically between the power and There is time when it is necessary to
ground lines. Each vertical line is cross lines in the scheme. In that case, a
numbered below the ground line. horizontal line is terminated with an
arrowhead, followed by a component
Ladder Schemes rarely allow lines to number and a line number (see drawing,
cross. This keeps the outline clean and line 10). In the indicated line number, in
easy to follow. To maintain the rules of this case line 28, the component number is
lines not crossing, it is sometimes displayed, followed by line number 10 and
necessary to split the functions of a the conclusion of the circuit.
component and show these functions
separately (see drawing). K2 Relay in line All components in a ladder scheme are
5 shows terminal 86 when power to coil labeled by a letter and a number. The
while 85 is coil ground. The number shown letter markings on Vibromax schemes are
in parentheses below the line number (in standard to all Vibromax schemes and
this case, 16) indicates there is more to have the following markings:
the relay than is shown on line 16. Line 16
shows the relay again, but this time shows
terminal 87A so power to the relay
contacts and 30, power to the relay
contacts. Shown between the contacts, in
parentheses, is the number (5). This
indicates there is more to the relay than is
shown on line 5.
COMPREHENSIVE ELECTRICAL SCHEMATICS
All drawings are shown without power
D delay relay
E Item (headlight, tail lights, All components are shown in the OUT
dashboard lights, etc.) position.
F Fuse
G Battery, alternator All relay contact #87 is normally open con-
H Indicator (dashboard indicator light, tacts
horn, alarm)
K Relay All relay contact #87A is normally closed
M Engine contacts
Q Gauges (Hour meter,
temperature gauge, etc.) Relay terminal #30 is power to contacts
R Resistor (when possible)
S Change
V Diode Relay terminal #87 or #87A is power
X Connector contacts (when possible)
Y Solenoid control valve
Power to control the relay is always terminal
An identification chart on the schematic #86
lists each component, the component
description, and its location on the The earth is always terminal #85
schematic by line number.
The design of all Vibromax electric dia- COMPREHENSIVE RELAYS

grams is similar in considerations to
component placement. The battery will An electrical relay is basically a solenoid
operated shift used to turn a circuit over or
always be located on-line 1, starter on line similar to a manual shift. A relay has a
2, alternator on line 3, etc. Slight variations working circuit (A) and a control circuit (B).
may be seen on different models, but the
important components will be located in
the same general area of the schematic.
This similar layout makes locating
components easier as you become more
familiar with the drawings.
Other elements that can help you below

are the diagram:
The working circuit is switched on and off The relay working circuit contacts closed.
by the relay. Connected to the working
circuit is the equipment to be operated (a
lamp in the illustration below). A relay can
usually shorten the distance of the power
supply as it is operated. They are also
used where the working circuit operates at
a higher or lower voltage than the control
circuit.
Opening the control circuit change will

drop the magnetic holding force and cause
the work circuit contacts to open due to the
spring return.
The following control circuit uses an on/off

type manual switch to control the working
circuit contacts. This could be one of the
pinch changes on the machine to control
the sprinkler pump, emergency flashers,
etc.
In the next example, the part of the relay

that is connected to the control circuit
consists of the windings of an
electromagnet. When the changeover
control circuit is closed, a magnetic field is
produced by the electromagnet. This
magnetic force usually attracts
VIBROMAX RELAYS A variation of the simple relay just shown
is what we refer to as an either/or relay.
Most common relays are the simple on/off The control circuit in this relay is no
type which have a control circuit and a set different from that of the simplest relay.
of simple working circuit contacts. The difference is found in the working
circuit which has two sets of contacts; one
normally closed and one normally open.
Either of the two working circuits are
activated depending on the state of the
relay control circuit.
The numbering system mentioned above

will apply.
Relay terminal #30 is able to work circuit

contacts when possible.
One additional relay common to some
Relay terminals #87 or #87A are work Vibromax circuits is the delay relay. In a
circuit contacts power. relay, the working circuits will be one of the
two types mentioned above. The important
Relay contact #87 indicates a working difference is found in the relay control
normally open contact while #87A circuit. In a delay relay, one or more timers
indicates a working normally closed circuit are added to the control circuit. These
contact. timers can be fixed or adjustable depending
on the applications.
Relay terminal #86 is power to the
electromagnet control circuit. With advances in technology you could
also find what we mean by so ready
Relay terminal #85 is always ground. replenishments. These are relays with
micro-circuitry built into the relay for
various control logic.
Before
JKC8302000
STARTER/CHARGING CIRCUIT 86 and ground at terminals
(Before JKC8302000).
The important components of the starter
and charging circuit are the starter motor,
alternator, battery, ignition shift and the
neutral start shift.
The ignition switch (S1) receives power

from the battery (G1) on terminal 30 [line
1]. When the ignition shift is turned to the
UP position, power is connected to
terminals 15/54, electrifying all ignition
controlled components. The alternator
indicator light (H1) illuminates, indicating
the ignition is on but there is no alternator
output. The ground for H1 is at the
alternator regulator [line 3]. The P1 hour
meter [line 4] and the K2 brake relay [line
5] do not function because battery ground
occurs on both sides of these components.
When the engine is started and the
alternator provides output current, the
regulator produces 12 volts at ground
level. With 12 volts to the P1 hour meter
and K2 brake relay, these components
now function. The HELLO indicator
extinguishes as a result of there being 12
volts on each side of the indicator.
To start the machine, S2 neutral start

change has to be closed, electrifying the
coil of relay K4 [line 11]. This closes the
contacts of the K4 relay [line 8]. Ignition
current flows through the K4 contacts,
providing power to H2 neutral indicator
light and K1 relay coil [line 8]. K1 coil will
be electrified due to 12 volts at terminals
terminal 85 of the alternator regulator
[line 3]. K1 relay contacts [line 2] nearby,
providing a current path from the start
terminal 50 in the ignition switch to the
engine starter.
When the engine starts and the

alternator provides current, the regulator
produces 12 volts at ground level.
Without ground, K1 contacts open,
preventing a restart of a running motor.
STARTER/CHARGING CIRCUIT COMPREHENSIVE BATTERIES
(AFTER JKC8302000)
A battery is a device that stores chemical
With the use of the turbocharged engine energy and converts it to electrical power
introduced in 1997 there was a slight when required. The amount of electrical
change to the starter circuit. energy that a battery is able to supply
depends primarily on the actual size of the
battery. The capacity of a battery is
To start the machine, S2 neutral start measured in Amp/hours.
change has to be closed, electrifying the
coil of relay K4 [line 11]. This closes the
contacts of the K4 relay [line 8]. Ignition
current flows through the K4 contacts,
providing power to H2 neutral indicator
light and K1 relay coil [line 8]. Coil K1 will
be energized due to 12 volts at terminals
86 and ground at terminal 85 of the
The rate at which a battery will convert
alternator regulator [line 3]. K1 relay chemical energy to electrical energy will
contacts [line 2] nearby, providing a vary depending on temperature. The
current path to relay control coil K0 [line 0] lower the temperature, the lower the
conversion rate. This is often referred to as
and to ground at control coil terminal 85. Cold Cranking Amperage.
Relay contacts K0 [line 2] nearby,
providing a current path to the starter
engine terminal 50 and the engine fuel
Batteries can be dangerous and should
shut-off solenoid engagement coil Y6 [line be handled carefully. Battery acid
6]. causes severe burns; Avoid contact
with skin, eyes or clothing.
When the engine starts and the alternator
provides current, the regulator produces
12 volts at ground level. Without ground on
the K1 control coil K1 contacts open, pre-
discharging a restart of a running motor.
Contacts K0 [line 2] opens power to the
starter and the single-noid Y6 engagement
coil. Holding power for Y6 is provided
through fuse F1.
BATTERY DIAGNOSTICS
Batteries can be tested to determine

charge status and battery condition. In
Batteries produce explosive gases. nonsealed batteries, a hydrometer can
Keeps out open flames, sparks, or usually measure the specific gravity of the
smoking materials and provides good electrolyte to determine the state of
ventilation, especially when recharging. charge.
On top of sealed batteries (or if a

hydrometer is not available), turn on the
headlights for 5 minutes or apply a 300
amp charge for 15 seconds to remove
the charge from the surface. Let the
battery sit for 30 seconds to recover from
charge then carefully measure the voltage
across the battery with a voltmeter.
The simple steps to battery care are:

1) Keep the battery clean and dry.
2) Keeps terminals free of corrosion.
3) Keeps the battery secured tightly.
4) Keep the electrolyte level topped off.
5) Keep the alternator belt tight. I use the following readings
As a guideline to determine the status of
the charging battery.
Apply a load of approximately 1/2 of the
cold crank amperage titrating for 15
STATE OF CHARGE
seconds. Measure the voltage just before
VOLTAGE CONCRE % removing the load.
READING TE POST
GRAVITY If your measurement is less than that
12.66 1.260 100 shown in the table below, the battery
needs replacing.
12.60 1.250 91
12.54 1.240 83 Temp C 21 16 10 4 -1
12.48 1.230 75 Temp F 70 60 50 40 30
12.42 1.220 62* Min-Voltage 9.6 9.5 9.4 9.3 9.1
12.36 1.210 58
12.30 1.200 0**
COMPREHENSIVE ALTERNATORS
* = WILL FREEZE AT -31F.
** = WILL FREEZE AT +20F. The purpose of the charging circuit is to
maintain the battery in a fully charged
condition. The alternator, which usually
performs this function, has two main parts;
the rotor which is attached to the shaft,
A battery has to be load tested to and the stator which is fixed in the
determine the overall condition of the housing. The stator normally has three
battery. To perform a load test, the battery windings.
has to be at least 80% charged prior to
conducting the test.
Using a heavy flow tester, apply a load of

300 amps for a 15 second period.
Wait 30 seconds for the battery to recover.

The rotor (Un), when supplied with a small Terminal to the positive terminal of the
amount of current, will produce an starter solenoid.
electromagnetic field (C). The power to the
rotor is On a machine the sequence will be so fol -
lows. When the ignition key is turned on
but the engine is still off, current is left to
flow from the battery, through the
instrument cluster alternator light, rotor
brush, rotor, regulator and ground, causing
the warning lamp to illuminate..
When the motor is started, alternating cur-

rent is generated in the separate stator
windings. Each winding has a pair of
diodes to change the alternating current to
direct current which is sent out of the B+
terminal to the battery.
Controlled through the ignition switch to
pre-vent battery drain when the engine is When the engine is started and the
not running. alternator starts to produce output, the
regulator is no longer grounded but is at 12
When the rotor is rotated by the shaft, the volts. This causes the warning indicator
magnetic field of the rotor (C) will pass lamp on the instrument panel to go out..
through the windings of the stator (B) and
produce an electric current in the stator
windings. The amount of current produced CHARGING SYSTEM DIAGNOSES
will vary depending on the speed of the
rotor and the strength of the magnetic field. Normal warning lamp operation.
CLUE ENGINE LAMP

OUT OUT OUT
ON OUT ON
ON ON OUT
Abnormal warning lamp operation and

probable cause:
The stator output will be an AC sine wave Key (Out); Engine (OUT); Lamp
and has to be rectified to obtain a DC (ABOVE) short on wiring to energize
output. The stator output rectification is rotor
accomplished by a pair of diodes for each
stator winding. The DC output is then con- Key (UP); Engine (OUT); Bad
trolled by the regulator/brush assembly on alternator diode lamp (OUT)
the alternator. The actual battery that
charges output from the alternator flows Key (UP); Engine (OVER); Lamp
out of the B+ (UP) regulator problem
VOLTAGE CONTROLS ON source
ALTERNATOR
With the engine OFF, connect the positive

lead of a voltmeter to the B+ terminal and
connect the negative lead to a good
engine ground. The meter would have to
read the system
(12) volts.
If no voltage is indicated, move the

positive lead to the starter solenoid. If the
proper voltage is stamped on the starter
solenoid, the wire between alternator B+
and the tan-lenoid is defective.
If there is still no voltage indicated, move

the positive lead of the voltmeter to the
battery positive terminal. If the voltage is
stagnant, the wire to the starter solenoid is
defective or the wire connection is
corroded. If no voltage is indicated, check
the battery negative ground cable.
To determine if current is available from

the ignition switch to the alternator rotor
field circuit, turn on the ignition switch,
connect the positive lead voltmeter to the
switch wire and connect the negative
voltmeter to a good engine ground. The
voltmeter should read system voltage.
EXHAUST SYSTEM
Remove the battery ground cable. Make

sure the ignition shift is in the OUT
position. Connect a test lamp between the
negative battery post and the battery
cable. The lamp must not illuminate with
the key in the OFF position. If the lamp
illuminates, this is an indication of a power
Going ashore. This will finally discharge
the battery.
CIRCUIT WIRING TEST
To determine if there is excessive

resistance in the alternator wiring or
connectors, perform the following two
tests:
I ran the engine at half throttle with the
lights on. Place a voltmeter carefully at
the location shown as “V1” and measure
the voltage. Do not have to exceed 0.5
volts. Place the voltmeter in the location
shown as “V2” and measure the voltage.
Do not have to exceed 0.25 volts.
Excessive voltage at any location is an
indication of resistance in the cables or
connectors.
MEASURING ALTERNATOR COMPREHENSIVE STARTERS
PRODUCTION All starter engines work similarly and serve
the same purpose in the engine.
The maximum current output can be
determined by replacing the B+ to solenoid
wire with an ammeter.
A heavy cable connects the battery to a
derailleur (1). When the shift is “ON”,
current flows from the battery, through the
shift and to the starter (2). Current flows
through the field coils (3) and then to the
armature
(4) using insulated brushes (5). Cur-
Rental flows through the armature coils
and the ground brushes (6) to ground.
The passage of current through the field
and armature coils generates magnetic
forces which oppose each other causing
the armature to rotate..
With a charging device, apply a load that is
larger than the specified output of the Pre-Committed starters are used on most
alternator. Start the engine and increase engines. They provide a positive
the speed to maximum. The ammeter engagement by not leaving full battery
reading must equal the alternator rating. power to the starter motor until the drive
pinion is fully engaged to the flywheel.
The output voltage can be determined with
the ammeter still in the circuit and by plac-
ing a voltmeter across the battery. Run the
motor at medium speed until the ammeter
is less than 10 amps. The battery
voltmeter reading should measure
between
13.6 and 14.4 volts for a 12 volt system.
STARTER SOLENOID When the plunger (3) moves to full stroke
and the drive pinion is fully engaged, the
A starter solenoid has two coils. They are tan-lenoid contacts (5) are closed, leaving
the “control-in coil” (1) which connects to full power to the starter motor.
ground, and the “enclosure coil” (2) which
is connected to ground through the starter
motor windings.
STARTER SYSTEM DIAGNOSTICS

When the shift is “ON”, current passes
through the control-in coil (1), creating a
SOLENOID CIRCUIT TEST
magnetic field around the plunger (3).
Current also passes through the enclosure
WARNING: Fasten the manual lever
coil (2), creating a second field.
closed on the injection pump in the
"OUT" position prior to this test.
The current that flows from the enclosure
coil to the starter motor windings causes
Connect a test light or voltmeter to test point
the motor to rotate slowly. The combined
(1) and the other advantage to a good
magnetic fields of the two coils cause the
land. Return the key shift to the starting
plunger to engage. This moves the arm (4)
position.
causing engagement of the drive pinion to
the flywheel.
The test light should illuminate or the volt-

meter should indicate system voltage. If
not, there is a problem in the current
supply to the solenoid.
Then, connect the test light or voltmeter to Connect the positive lead of a voltmeter to
the starter terminal (1). Connect the other the positive battery terminal (1) and the
lead to ground. Return the key to the start negative lead to the starter supply terminal
position. (2). Return the key to the home position
and measure the voltage on the meter. If
the reading is less than 0.2 volts there is
high resistance in the battery supply cable
or the contact plate inside the solenoid is
corroded and worn.
Connect the positive voltmeter lead to the

starter case (1) and the negative lead to
the negative battery terminal (2). Turn the
key shift to start and read the voltmeter.
The test light should indicate system volt-
age. If not, it indicates the solenoid is at
fault.
NOTE: A click of the solenoid indicates the

following:
1) Badly charged battery
2) Corroded cables
3) Bad connection
4) poor land
5) Bad solenoid
If the reading was 0.5 or less, the soil is

STARTER CIRCUIT WIRING TEST satisfactory. If the reading is more than 0.5
volts, the starter is poorly grounded.
WARNING: Fasten the manual lever on
the fuel injection pump to the "OFF"
position .
STARTER ENGINE TEST
WARNING: Fasten the manual lever on

the fuel injection pump to the "OFF"
position.
Connect the positive voltmeter lead to the

starter motor supply terminal (1) and the
negative lead to a good ground (2). Return
the key shift to the home position and read
the meter. The voltmeter should read 8.5
a
10.0 volts.
If the reading is less than 8.5 volts or more

than 10.0 volts it indicates a problem with
the armature, field or brushes.
INSTRUMENTATION The current.
DASHBOARD
The instrument panel receives power from

terminal 15/54 of the ignition switch. Power
flows from Fuse F1 and is available to the
dash when the ignition shift is in the UP
position.
Power is available to backup alarm [line

14] if the direction control lever is placed in
the reverse direction, electrifying the relay
coil K11 [line 13] causing the relay
contacts K11 [line 14] to close . Plac- ing
The steering control lever in neutral or
forward draws power from relay K11 and
the contacts open.
Light brake indicator H3 [line15] illuminates

if Shift S3 [line15] is closed due to
insufficient brake pressure. When brake
pressure is sufficient, the gearbox opens
and the light goes out.
Horn H4 [line 17] will sound if Shift S4 [line

17] is depressed. The horn also provides a
warning signal if (1) the running machine is
placed in forward or reverse when brake
pressure is insufficient, or (2) engine
coolant temperature is excessively high.
The current path when brake pressure is
sufficient is through the horn, through K2
reset [lines 16 & 5] (closed contacts if the
alternator has output), Diode V2, K3 relay
[lines 16 & 10 ] (opens when the neutral
light continues on) and through the change
of brake pressure S3 [line 15] to ground.
The way when the engine temperature is
excessive is through the horn, through
Diode V1 and Temperature change S5
[line 18]. Di- Odes V1 and V2 prevents
illumination of H3 or H5 when the horn
button is depressed.
The light indicator H9 [line 19]

illuminates whether the hydraulic oil filter
differential pressure change S18 closes.
H6 Light Engine Oil Pressure Gauge

[line 20] illuminates if oil pressure is not
high enough to open S6 oil pressure
change.
Dashboard gauges P2 [line 21] and P3

[line 22] indicate engine coolant
temperature and fuel level. These
gauges function whenever the ignition
is ON.
BRAKE CIRCUIT / EMERGENCY STOP
SHIFT STOP/ EMERGENCY SHIFT
BRAKE A second set of contacts on the S17 Brake
Shifter [line 27] closes when the brake
The Emergency Stop Shift S23 [line 24] shifter is depressed to apply the brakes.
receives power from the ignition switch, This portion of the shift sends current to
terminal 15/54, when the ignition switch is the Y4 differential lock solenoid, closing
in the UP position. Ignition current shift the differential, improving brake holding
passes through Fuse F7, through the capabilities.
normally closed Emergency Shutdown
Switch S23, through the Emergency
Shutdown Relay Coil K9, and to ground.
Power through the K9 relay coil causes the
K9 relay contacts [line 25] to close,
providing power to the brake circuit [line
26] as well as the vibration, two-speed,
and differential lock circuits.
When the emergency stop change is

depressed, power to the K9 relay is drawn
causing the contacts to open. This re-
power of brake movements, vibration, two
speed and differential lock circuits.
Brake solenoid Y5 [line 26] receives power

to release the brakes provided the ignition
shift is in the UP position, the nimally
closed Brake shift contacts S17 is closed,
and the normally closed brake contacts the
K5 relay is closed. The brakes will apply if
(1) the ignition is off, (2) Shift Brake S17 is
depressed, (3) there is insufficient brake
pressure in Shift S3 [line 15] causing the
shift to close, energizing the coil of the
Relay K5 [line 16] causing the contacts of
relay K5 [line 26] to open.
VIBRATION CIRCUIT BEFORE S/N JKC8300700
VIBRATION CIRCUIT Through the switch, through the closed D1
Contacts, through the K8 Relay coil to
Power to the vibration control circuit is ground. The normally closed contacts of
available through Fuse F4 [line 29] if the the K8 Relay [line 33] now open, causing
ignition shift is in the UP position and the the coil of the K7 Relay to lose power,
emergency stop shift is not depressed. opening the K7 Contacts. This causes
Solenoids Y1 and Y2 [lines 29 and 30] Relay Coil K6 to lose power, opening the
provide vibration at any high or low fre- K6 Contacts [line 29].
quency and are controlled by Shift Selector
S7 or S7Un. S7B selector change provides Diodes V4 and V5 are isolation diodes. V4
the option of manual vibration (started and prevents current flow to Switch Relay Coil
stopped by the operator) or automatic K6 S24, while V5 prevents current flow
vibration (vibration will stop when the from Contacts K7 to Circuit D1/K8.
machine enters neutral).
When Shift S7B is placed in the automatic
With Shift Selector S7B in manual mode shift mode, it passes current through the
and Shift S7 or S7Un selected, Relay automatic shift contacts, through nimally
Contacts K6 must close to provide current closed K12 Relay Contacts, and through
flow to one of the two solenoids. K6 relay the rest of the circuit. When the machine is
is controlled by the Momentary Contact placed in neutral, the Relay K12 coil
Change S24 [line 33] on the [line28] is energized, opening the K12
para-ward/reverse control lever. The shift Relay Contacts
contacts are closed only when the button
is depressed. When depressed, current
from Fuse F4 passes through the switch,
through the V5 Diode, through the
normally closed contacts of the K8 Relay,
through the coil of the K7 Relay to ground.
The Relay K7 contacts [line 32] close,
creating a current path through the Relay
K6 coil to ground, causing the Relay K6
contacts [line 29] to close. With the
contacts closed, the vibration circuit is
activated.
When the Shift push button S24 is

released, the contacts open, however,
nothing changes because with the K7
Contacts closed, still current flows through
the K6 Relay Coil, the K7 Relay Coil and
the D1 Delay Relay. . After a time delay,
D1 Contacts [line 35] close but with
Change S24 open, nothing happens.
When Cambio S24 is momentarily

depressed to stop vibration, current flows
VIBRATION AFTER JKC8300700. independent work-
The smooth drum 1103D and 1103HD
models are equipped with a high and low
frequency vibrating system. Models with
the padfoot drum are setup to operate at
the lowest frequency only. The padfoot
(PD models) ships with the extra gears
and solenoids needed for high/low
frequency operation but not all
connections are made. This configuration
allows for easily changing the machine
drum between smooth and padfoot. Never
run the padfoot drum with the high
frequency vibration circuit. - ing So it
will shorten your lifespan.
Power to the vibration control circuit is

available through Fuse F4 [line 29] if the
key is on and the emergency stop shift is
not depressed. Fuse power is available
on both Cambio S7B and S24. In manual
mode the manual/auto selector switch S7B
current passes through the manual mode
contacts [S] to terminal 2 of the K6 latching
relay [line 33]. When the momentary push
button, shift S24 [line 33] on the
forward/reverse lever, is depressed and
released, K6 latches contact 2 and 5,
letting current flow to S7 (high frequency)
and S7A (low frequency) vibration control
changes. Activating shift S7 or S7Un
energizes solenoids Y1 or Y2 on the
vibration control valve. When switching
S24 is depressed and released a second
time K6 unlatches, drawing power from
terminal 5 of the K6 relay, and closes from
vibration. S7 and S7 changesAn
pendently Once K6 relay is latched, it is
still recommended that the vibration
system on smooth drum machines be
closed by using S24 before switching
between high and low frequency with S7
and S7Un shifts.
In automatic vibration mode, current

passes through switch S7B [line 29],
through relay contacts K12 [line29], and
then switches S7 and S7Un to terminal
30. Shift S24 and relay K6 is not
separate from the active circuit so the
button on the para- ward/reverse lever
has no effect on vibration operations in
automatic mode. The automatic vibration
off in neutral is controlled through relay
K12. K12 contacts open whenever the
backhand/forward lever is moved to the
neutral position.
SWITCHING ON
CIRCUIT
SWITCHING ON CIRCUIT occurs.
The lighting circuit on the 1103 includes

instrument panel lighting, optional parking
and taillights, optional turn signal and
beam lighting, and optional work lights.
The instrument panel ignition receives

power from the ignition switch UP position
through Fuse F9. When depressed, Shift
S11 [line 52] illuminates lights on the fuel
gauge and engine temperature gauge, as
well as the Light H13 indicator on the Shift
S11 button [line 53].
If the optional park and taillight circuit is

provided, changing the instrument panel
also energizes the coil of Relay K10 [line
54]. The optional circuit receives power
from Terminal 30 of the ignition switch and
does not need the ignition to be on to
provide power from Fuse F13 and Switch
25, provided the K10 Relay Contacts are
closed.
Separate fuses are used for each pair of
park/tail lights.
Fuse F12 [line 63] receives power from the

ignition shift UP position and provides
power to the optional turn signal circuit.
Current introduces Change S27 in terminal
15, passes through Relay K13 and
introduces Directional Change S26,
Terminal Un. When the lever is moved left
or right, it energizes the appropriate lights.
When the current passes through the K13
Flasher Relay, end-termittent production
Fuse F14 [line 62] receives power from
Terminal 30 and does not need the
ignition switch over. Provides power to
the optional Hazard Light Change S27,
Terminal 30. When the shift is activated,
power is passed through the K13 Relay
as well as to all four turn signals.
ACCESSORY PLUG / WORK LIGHTS / HEATER / WIPERS
July 1998 3 - 34
WORK LIGHTS, ACCESSORY

PLUG, HEATER AND WIPERS.
The optional work light circuit is an ignition

controlled circuit, protected by Fuse F11
and controlled by Shift S28 [line 70] for the
front work lights and Shift S28un [line 73]
for the rear work lights. Indicator lights H17
[line 71] and H18 [line 74] illuminate light
changes when activated.
The accessory plug circuit [line 76] is an

ignition controlled circuit, protected by
Fuse 10.
The optional heater/wiper circuit [line 78] is

not ignition controlled. Power is available
at Fuse F6, supplying current to Wiper
Cambio S12 and front wiper motor [line
80], to Wiper Cambio S13 and rear wiper
motor [line 81], to Abancar Cambio S15
and heater follower [line 82] and to Heater
Change S16 and heater [line 78].
July 1998 3 - 35
ELE LINE DESCRIPTION ELE LINE DESCRIPTION ELE LINE DESCRIPTION
MEN MEN MEN
T T T
E1 51 LIGHT, TEMPERATURE GAUGE H12 35 INDICATOR LIGHT, 2 AXIS SPEED S6 20 CHANGE, ENGINE OIL PRESSURE
E2 52 LIGHT, FUEL GAUGE H13 53 INDICATOR LIGHT, LIGHTS S7 29 CHANGE, HIGH FREQ VIBRATION.
E3 69 LIGHT, FRONT WORK LEFT H14 64un INDICATOR LIGHT, DIRECTIONALS S7Un 29 CHANGE, LOW VIBRATION FREQ.
E4 70 LIGHT, CORRECT WORK FRONT H15 65 INDICATOR LIGHT, HAZARD LIGHTS S7B 29 SHIFT, CAR/MANUAL VIBRATION
E5 72 LIGHT, LEFT REAR WORK H16 68 INDICATOR LIGHT, DIRECTION ARROW S8 35 GEARBOX, TWO SPEED AXIS
E6 73 LIGHT, FRONT WORK LEFT H17 71 INDICATOR LIGHT, LIGHT FRONT WORK S9 46 CHANGE, DIFFERENTIAL LOCK
E7 55 LIGHT, IN FRONT OF LEFT PARK H18 74 INDICATOR LIGHT, WORK REAR LIGHT S10 46 CHANGE, JOINT POSITION
E8 56 LIGHT TAIL, LEFT H19 77 INDICATOR LIGHT, HEATER S11 52 CHANGE, SWITCHING ON SYSTEM
E9 57 LIGHT, CORRECT PARK FRONT H21 63 LIGHT, FRONT LEFT DIRECTIONAL S12 79 GEARBOX, FRONT WIPER
E10 58 LIGHT TAIL, CORRECT H22 64 LIGHT, REAR LEFT DIRECTIONAL S13 80 SHIFT, REAR WIPER
E11 59 LIGHT, LEFT DIM H23 65 LIGHT, CORRECT FRONT DIRECTIONAL S15 82 CHANGE, FOLLOWER
E12 60 LIGHT, RIGHT DIM H24 66 LIGHT, REAR CORRECT DIRECTIONAL S16 77 CHANGE, HEATER
F1 2 FUSE, INSTRUMENTATION S17 26 SHIFT, HYDRAULIC BRAKE
F2 3 FUSE, ALTENATOR K0 0-2 RELAY, AUXILIARY START S18 19 CHANGE, PSI HYDRAULIC FILTER.
F3 26 FUSE, BRAKE K1 2-8 RELAY, ANTI-RESET S19 13 SHIFT, BACK UP ALARM
F4 29 FUSE, VIBRATION K2 5-16 RELAY, BRAKE MONITOR, ALTENATOR S23 24 CHANGE, EMERGENCY OUT
F5 35 FUSE, TWO SPEED K3 10-16 RELAY, BRAKE MONITOR, NEUTRAL S24 33 SHIFT, THUMB, VIBRATION ON/OFF
F6 78 FUSE, TAXI FUNCTIONS K4 8-11 RELAY, NEUTRAL POSITION S25 56 CHANGE, SWITCHING ON
F7 24 FUSE, EMERGENCY OUT K5 16-26 RELAY, BRAKE RELEASE S26 65 SHIFT, DIRECTIONAL LIGHTS
F8 46 FUSE, DIFFERENTIAL LOCK K6 32-33 RELAY, VIBRATION MANUAL CONTROL S27 65 CHANGE, HAZARD LIGHTS
3 - 36
F9 52 FUSE, IGNITION K9 24-25 RELAY, EMERGENCY OUT S28 70 SHIFT, FRONT WORK LIGHTS
F10 76 FUSE, PLUG CAP K10 54-56 RELAY, SYSTEM ON S28Un 73 SHIFT, REAR WORK LIGHTS
F11 70 FUSE, WORK LIGHTS K11 13-14 RELAY, BACK UP ALARM Y1 29 SOLENOID, HIGH VIBRATION FREQ.
F12 63 FUSE, TURN SIGNAL LIGHTS K12 28-29 RELAY, AUTOMATIC VIBRATION Y2 30 SOLENOID, LOW VIBRATION FREQ.
F13 56un FUSE, IGNITION K13 64 RELAY, DIRECTIONAL FLASHER Y3 35 SOLENOID, 2 SPEED AXIS
F14 62 FUSE, HAZARD LIGHTS M1 2 ENGINE, STARTER Y4 46 SOLENOID, DIFFERENTIAL LOCK
F15 56 FUSE, PARK LIGHTS LEFT M2 79 ENGINE, FRONT WIPER Y5 26 SOLENOID, BRAKE/SERVO
F16 57 FUSE, PARK LIGHTS OK M3 80 ENGINE, REAR WIPER Y6 6 SOLENOID, ENGINE CLOSED
F17 59 FUSE, LIGHT DIM LEFT M4 81 MOTOR, WASHER PUMP V1 17 DIODE, INSULATION
F18 60 FUSE, RIGHT LIGHT DIM M5 82 MOTOR, FOLLOWER V2 16 DIODE, INSULATION
G1 1 BATTERY M6 78 ENGINE, HEATER V3 7 DIODE, INSULATION
G2 2 ALTENATOR M7 78un ENGINE, HEATER PUMP V4 46 DIODE, INSULATION
H1 3 INDICATOR LIGHT, ALTENATOR P1 4 HOUR METER
H2 9 INDICATOR LIGHT, NEUTRAL P2 21 GAUGE, ENGINE TEMPERATURE
H3 15 INDICATOR LIGHT, BRAKE P3 22 GAUGE, FUEL LEVEL
H4 17 HORN R1 21 SENSOR, ENGINE TEMPERATURE
July 1998
H5 18 INDICATOR LIGHT, ENG. TEMP. R2 22 SENSOR, FUEL LEVEL

H6 20 INDICATOR LIGHT, ENG. PSI OIL. S1 1 CHANGE, KEY
H7 45 INDICATOR LIGHT, DIFFERENTIAL LOCK S2 11 CHANGE, NEUTRAL POSITION
H8 14 BACK UP ALARM S3 15 SHIFT, BRAKE RELEASE PRESSURE
H9 19 INDICATOR LIGHT, HYDRAULIC FILTER S4 17 SHIFT, HORN BUTTON
H11 30 INDICATOR LIGHT, CAR VIBRATION S5 18 CHANGE, HIGH TEMP. ENGINE
July 1998 3 - 37
MEN MEN MEN
3 - 38
July 1998

July 1998 3 - 39
MEN MEN MEN
3 - 40
July 1998

July 1998 3 - 41
MEN MEN MEN
3 - 42
July 1998

July 1998 3 - 43
MEN MEN MEN
3 - 44
July 1998

July 1998 3 - 45
TAXI WIRING
3 - 46 July 1998
CABLE HARNESS 7250/16315
July 1998 3 - 47
3 - 48 July 1998
July 1998 3 - 49
3 - 50 July 1998
July 1998 3 - 51
CABLE CHART 7250/16315
WIRE COLOR OF TO
1 Red Battery + terminal Change key (S1) terminal 30
2 Red Change key (S1) terminal 30 Fuse (F6) terminal 1
3 red/black Change key (S1) terminal 15 Fuse (F1) terminal 1
4 red/black Change key (S1) terminal 54 Fuse (F7) terminal 1
5 Black Change key (S1) terminal 50un Relay (K1) terminal 30
6 Black Relay (K1) terminal 87 Plug connector (X1) terminal 1
6un Black Relay (K1) terminal 87 Plug connector (X1) terminal 2
7 red/black Fuse (F1) terminal 2 Plug connector (X1) terminal 6
8 red/black Fuse (F1) terminal 2 Relay (K4) terminal 30
9 red/black Relay (K4) terminal 30 Relay (K5) terminal 86
10 red/black Relay (K5) terminal 86 Relay (K11) terminal 30
11 red/black Relay (K11) terminal 30 Horn (H4) + terminal
12 red/black Fuse (F1) terminal 2 Fuel gauge (P3) + terminal
13 red/black Fuel gauge (P3) + terminal Engine temp. gauge (P2) + terminal
14 red/black Engine temp. gauge (P2) + terminal Plug connector (X14) terminal 13
15 red/black Fuse (F1) terminal 2 Plug connector (X2) terminal 1
16 Blue Plug connector (X1) terminal 3 Fuse (F2) terminal 1
17 Blue Fuse (F2) terminal 2 Plug connector (X14) terminal 7
19 Blue Fuse (F2) terminal 2 Relay (K2) terminal 86
20 Blue Relay (K2) terminal 86 Diode (V3)
21 Violet Diode (V3) Relay (K1) terminal 85
22 Violet Relay (K1) terminal 86 Relay (K3) terminal 86
25 Violet Relay (K12) terminal 86 Plug connector (X14) terminal 9
26 Violet Relay (K4) terminal 86 Plug connector (X2) terminal 2
27 Brown Green Relay (K11) terminal 86 Plug connector (X2) terminal 4
28 White Brown Relay (K11) terminal 87 Plug connector (X1) terminal 4
29 Black/yellow Relay (K3) terminal 30 Plug connector (X14) terminal 6
30 Black/yellow Relay (K3) terminal 30 Brake change (S3) terminal 3
31 Black Relay (K5) terminal 85 Relay (K3) terminal 87un
32 Black Relay (K3) terminal 87un Diode (V2)
33 Black Diode (V2) Relay (K2) terminal 30
34 Brown yellow Relay (K2) terminal 87 Horn button change (S4) S terminal
35 Brown yellow Horn (H4) - terminal Relay (K2) terminal 87
36 Brown yellow Horn button change (S4) S terminal Diode (V1)
37 White Red Diode (V1) Plug connector (X14) terminal 3
3 - 52 July 1998
WIRE COLOR OF TO
38 White Red Diode (V1) Plug connector (X1) terminal 7
39 Red Green Plug connector (X14) terminal 12 Plug connector (X4) terminal 1
40 Green Plug connector (X14) terminal 8 Plug connector (X1) terminal 8
41 Black Engine temp gauge (P2) G terminal Plug connector (X1) terminal 9
42 White Fuel gauge (P3) G terminal Plug connector (X1) terminal 10
43 Black/yellow Fuse (F7) terminal 2 Plug connector (X6) terminal 1
45 red/black Fuse (F7) terminal 1 Relay (K9) terminal 30
46 red/black Relay (K9) terminal 87 Fuse (F3) terminal 1
47 Black/yellow Fuse (F3) terminal 2 Brake change (S17) terminal 15
48 Black/yellow Brake change (S17) terminal 15 Brake change (S17) terminal 30
49 Black/yellow Brake change (S17) terminal 49 Relay (K5) terminal 87un
51 White yellow Diode (V6) Brake change (S17) terminal 30b
52 White yellow Brake change (S17) terminal 30b diff. Lock solenoid (Y4) terminal 1
56 Grey Fuse (F4) terminal 2 Car vib shift (S7B) + terminal
57 Grey Car vib shift (S7B) terminal S Relay (K6) terminal 85
58 Grey High freq. vib Change (S7) terminal 30 Relay (K6) terminal 87
59 Grey High freq. vib Change (S7) terminal 30 Low freq. vib Change (S7Un) terminal
30
60 Green/gray Relay (K6) terminal 87 Relay (K12) terminal 30
61 Green/gray Car vib change (S7B) terminal S2 Relay (K12) terminal 87un
62 White grey Low freq. vib Change (S7Un) terminal High freq. vib Change (S7) terminal
15 30b
63 White grey Low freq. vib Change (S7Un) terminal Plug connector (X1) terminal 11
49
64 red/gray Low freq. vib Change (S7Un) terminal High freq. vib Change (S7) terminal
30b 15
65 red/gray High freq. vib Change (S7) terminal 49 Plug connector (X1) terminal 12
67 Grey Fuse (F4) terminal 2 Plug connector (X2) terminal 5
73 Grey Relay (K9) terminal 86 Plug connector (X2) terminal 6
77 Blue yellow Fuse (F5) terminal 2 Two speed change (S8) + terminal
78 Blue yellow Two speed change (S8) terminal S2 Plug connector (X1) terminal 13
79 Yellow Fuse (F8) terminal 2 diff. Lock change (S9) terminal S
80 White yellow diff. Lock change (S9) terminal S1 Plug connector (X1) terminal 14
81 White yellow Plug connector (X1) terminal 15 Light (H7) + terminal
82 White yellow Light (H7) + terminal Diode (V6)
83 Black/gray Fuse (F9) terminal 2 Light shift (S11) + terminal
84 Black/gray Light shift (S11) terminal S2 temp. gauge Light (E1) + terminal
85 Black/gray temp. gauge Light (E1) + terminal Fuel gauge light (E2) + terminal
86 Black/gray Light shift (S11) terminal S1 Relay (K10) terminal 86
90 Red Fuse (F6) terminal 1 Fuse (F13) terminal 1
91 Red Fuse (F13) terminal 2 Relay (K10) terminal 30
July 1998 3 - 53
WIRE COLOR OF TO
92 Red Relay (K10) terminal 87 Light shift (S25) + terminal
93 Red Light shift (S25) terminal 1 Fuse (F15) + terminal
94 White yellow was (F15) terminal 2 Plug connector (X7) terminal 1
95 White yellow Fuse (F15) terminal 2 Plug connector (X1) terminal 20
96 Yellow Fuse (F16) terminal 2 Plug connector (X7) terminal 2
98 Black White Light shift (S25) terminal 3 Fuse (F17) terminal 1
100 Red Yellow Fuse (F18) terminal 2 Plug connector (X7) terminal 4
101 Red Fuse (F14) terminal 2 hazard Change (S27) terminal 30
102 red/black Fuse (F12) terminal 2 hazard Change (S27) terminal 15
103 Black hazard Change (S27) terminal 49 Relay (K13) terminal 49
104 Black hazard Change (S27) terminal 49 hazard Change (S27) terminal 30b
105 Black/yellow Relay (K13) terminal C Plug connector (X14) terminal 5
106 Black/yellow Relay (K13) terminal 49un hazard Change (S27) terminal 49un
107 Black/yellow hazard Change (S27) terminal 49un Directional change (S26) terminal A
108 Black White hazard Change (S27) terminal L Directional change (S26) terminal B
109 Black White Directional change (S26) terminal B Directional change (S26) terminal E
110 Green/black hazard Change (S27) terminal R Directional change (S26) terminal C
111 Green/black Directional change (S26) terminal C Directional change (S26) terminal F
112 Black White hazard Change (S27) terminal L Plug connector (X7) terminal 5
113 Black White hazard Change (S27) terminal L Plug connector (X1) terminal 22
114 Green/black hazard Change (S27) terminal R Plug connector (X7) terminal 6
115 Green/black hazard Change (S27) terminal R Plug connector (X1) terminal 23
120 Black/gray Fuse (F11) terminal 2 Light shift (S28) + terminal
121 Black/gray Light shift (S28) + terminal Light shift (S28Un) + terminal
122 Black/gray Light shift (S28) terminal S2 Plug connector (X9) terminal 1
123 Black/gray Light shift (S28Un) terminal S2 Plug connector (X1) terminal 24
125 Black/gray Fuse (F10) terminal 2 Accessory plug (X3) + terminal
127 Red Fuse (F6) terminal 2 Plug connector (X5) terminal 1
160 Brown ground terminal ground terminal
161 Brown Fuel gauge (P3) - terminal gound Cable 160
162 Brown Engine temp. gauge (P2) - terminal Fuel gauge (P3) - terminal
165 Brown Plug connector (X14) terminal 15 Engine temp. gauge (P2) - terminal
166 Brown Light shift (S28Un) terminal 31 Ground wire 160
167 Brown Light shift (S28) terminal 31 Light shift (S28Un) terminal 31
168 Brown Horn change (S4) terminal S1 Light shift (S28) terminal 31
169 Brown Indicator (H7) - terminal Ground wire 160
170 Brown Light shift (S11) terminal 31 Indicator (H7) - terminal
3 - 54 July 1998
WIRE COLOR OF TO
171 Brown Car vib change (S7B) terminal 31 Light shift (S11) terminal 31
172 Brown Two speed change (S8) terminal 31 Car vib change (S7B) terminal 31
173 Brown Plug connector (X9) terminal 2 ground terminal
179 Brown Brake change (S3) terminal 4 ground terminal
181 Brown Relay (K2) terminal 85 ground terminal
182 Brown Relay (K2) terminal 85 Relay (K3) terminal 85
186 Brown Relay (K6) terminal 86 ground terminal
195 Brown diff. Lock solenoid (Y4) terminal 2 ground terminal
196 Brown Plug connector (X7) terminal 7 Plug connector (X7) terminal 8
200 White yellow Fuse (F15) terminal 2 Plug connector (X5) terminal 6
203 Red Yellow Fuse (F18) terminal 2 Plug connector (X5) terminal 9
204 Black White Plug connector (X7) terminal 5 Plug connector (X5) terminal 10
205 Green/black Plug connector (X7) terminal 6 Plug connector (X5) terminal 11
206 Black/gray Plug connector (X9) terminal 1 Plug connector (X5) terminal 2
July 1998 3 - 55
CABLE HARNESS 7250/16110
3 - 56 July 1998
July 1998 3 - 57
3 - 58 July 1998
CABLE CHART 7250/16110
WIRE COLOR OF TO
1 Red starter Motor (M1) terminal 30 alternator (G2) terminal B+
2 Black Plug connector (X1) terminal 1 starter Motor (M1) terminal 50
2un Black Plug connector (X1) terminal 2 starter Motor (M1) terminal 50
3 Blue Plug connector (X1) terminal 3 alternator (G2) terminal D+
4 White Plug connector (X1) terminal 10 Fuel level sensor (R2)
5 Grey Plug connector (X1) terminal 7 Engine temp. Change (S5)
6 Grey Plug connector (X1) terminal 6 Engine closed off solenoid (Y6)
7 Green Plug connector (X1) terminal 8 Engine oil PSI change (S6) terminal 4
8 Black Plug connector (X1) terminal 9 Engine temp. Sensor
9 White Brown Plug connector (X1) terminal 4 Backup alarm connector (X11) +
10 Brown Plug connector (X1) ground terminal Backup alarm connector (X11) -
11 Blue yellow Plug connector (X1) terminal 13 Two speed solenoid (Y3) terminal 1
12 Brown Plug connector (X1) ground terminal Two speed solenoid (Y3) terminal 2
13 White yellow Plug connector (X1) terminal 14 Joint change (S10) terminal 3
14 White yellow Plug connector (X1) terminal 15 Joint change (S10) terminal 4
15 White grey Plug connector (X1) terminal 11 High vib solenoid (Y1) terminal 1
16 Brown Plug connector (X1) ground terminal High vib solenoid (Y1) terminal 2
17 red/gray Plug connector (X1) terminal 12 Low vib solenoid (Y2) terminal 1
18 Brown Plug connector (X1) ground terminal Low vib solenoid (Y2) terminal 2
19 Brown Plug connector (X1) ground terminal Plug connector (X10) terminal 2
20 Black/gray Plug connector (X1) terminal 24 Plug connector (X10) terminal 1
21 Green Plug connector (X1) terminal 17 Engine fuel heater (M7) terminal 1
22 Green Plug connector (X1) terminal 18 Engine fuel heater (M7) terminal 2
23 Brown Plug connector (X1) ground terminal Engine oil PSI change (S6) terminal 3
25 Green/black Plug connector (X1) terminal 23 Plug connector (X8) terminal 4
26 Black White Plug connector (X1) terminal 22 Plug connector (X8) terminal 3
27 Yellow Plug connector (X1) terminal 21 Plug connector (X8) terminal 2
28 White Plug connector (X1) terminal 20 Plug connector (X8) terminal 1
29 Brown Plug connector (X1) ground terminal Brake solenoid (Y5) terminal 2
30 Black/yellow Plug connector (X1) terminal 16 Brake solenoid (Y5) terminal 1
31 Brown Plug connector (X1) ground terminal Plug connector (X8) terminal 6
32 Brown Plug connector (X8) terminal 6 Plug connector (X8) terminal 5
July 1998 3 - 59
3 - 60 July 1998
SECTION FOUR
HYDRAULIC
July 1998 4-1

SECTION FOUR HYDRAULICS
PUMP SUCTION LINES
4-2 July 1998

July 1998 4 - 11
HYDRAULIC COOLING SYSTEM
4-4 July 1998

July 1998 4-5

HYDRAULIC DRAIN
LINES
4-6 July 1998

DRAIN LINES
July 1998 4-7

TEST SYSTEM
HYDRAULICS
4-8 July 1998

HYDRAULIC TEST STATION
A hydraulic pressure test station is located on the right side of the machine, under the
operator platform. All hydraulic pressures can be measured from this location by using
either a VT8002 gauge set or a VT8004 adapter that fits.
July 1998 4-9

4 - 10 July 1998
CHARGE SYSTEM
Charge oil is supplied by two separate pumps. A gerotor type charge pump is mounted
inside the propulsion pump housing. Flow from the gerotor pump is combined with return oil
from the steering system to fill the necessary charge oil requirements. Supply oil for the
propulsion charge pump is drawn from the reservoir. Production of the charge pump leaves
the drive pump and connects the steering oil back into the inlet to the filter. The oil released
from the hydraulic filter returns to the propulsion and vibratory pumps, brake pump and
control systems, and the differential lock system.
Charge oil used to servo control the drive pump swash plate, it is controlled by a small
solenoid valve on the drive pump. This valve is sometimes referred to as the brake release
valve due to its dual functions of brake and servo control. When activated, this solenoid
valve supplies oil to release the brakes and operate the pump servo system. When
deactivated oil brake release and pump servo control is locked. This causes the brakes to
be spring applied and the servo pump to return to neutral. Filter charge oil also feeds the
vibrating pump and its servo control. Charge pressure can be checked at test station port
#1
July 1998 4 - 11
4 - 12 July 1998
Propulsion system
The propulsion, or ride system, consists of an engine driven Sauer Sundstrand 90 series
variable displacement axial piston pump with bi-directional flow. This pump supplies oil to a
drum drive motor and a shaft drive motor in a parallel flow path. The drum ride motor is a
Poclain model MS25 radial piston type. Some early model 1103s used a Rexroth MCR20
engine. The drum ride motor can also be equipped with an optional drum ride brake. The
shaft drive motor is a Sauer Sundstrand 51V axial piston type with a two speed
characteristic.
Charge oil used to servo control the drive pump swash plate, it is controlled by a small
solenoid valve on the drive pump. This valve is sometimes referred to as the brake release
valve due to its dual functions of brake and servo control. When activated, this solenoid
valve supplies oil to release the brakes and operate the pump servo system. When
deactivated oil brake release and pump servo control is locked.
The oil from the propulsion pump flows to the front drum motor and the rear axle motor in a
parallel path. The front drum motor is a fixed displacement motor while the rear axle motor
is a variable displacement motor controlled by a solenoid valve to obtain two driving speeds
for the machine. Multifunction Valves, located on the bottom side of the pump and set at
450 bar (6500 psi), protect the system from overloading.
July 1998 4 - 13
4 - 14 July 1998
July 1998 4 - 15
4 - 16 July 1998
MULTIFUNCTION VALVES
Two multifunction valves are located in the high pressure circuit of the Series 90 propulsion
pump. Each valve contains a charge control valve, high pressure relief valve, and an
adjusting-capable closed loop servo controlled pressure limiting characteristic. The
pressure-limiting characteristic shocks the pump when the pressure approaches the high
pressure relief point.
Charge pressure enters the valve near the valve council, passes through the control valve
and flows out of the council, provided the charge pressure is greater than system pressure.
This function maintains the charge pressure in the hydrostatic loop. As high pressure
reaches the limiting point, the pressure limiting valve opens and flows oil to the dis-
placement control valve. Pressure offsets the stroked position of the control valve,
destroking the pump, maintaining system pressure. Servo pressure relief valves limit the
pressure of the oil release to 750 PSI. In the event of a cold oil start up, the pressure
limiting functions in the control valve could see quite a delay. In that case, the main relief
valve would open, releasing oil through the charge control port to the charge circuit.
Pressure limiter adjustments can be made by inserting a 5mm Allen wrench into the end of
the valve and loosening the jam nut. Rotating the Allen wrench clockwise will increase the
limiting pressure point while rotating the wrench counter clockwise will lower the limiting
pressure point. One revolution of the wrench is equal to approximately 1350 PSI. After
adjustment is complete, torque the jam nut to 12 ft./lbs. Don't over torque!
The tug pass function is accomplished by unscrewing the middle section of the valve three
full revolutions. I use a 1 5/8'' wrench to hold the valve in place. I use a 1 1/16'' wrench to
unscrew the pass-through. After towing is completed, tighten the by-pass and torque to 30
ft./lbs. Don't over torque!
July 1998 4 - 17
PROPULSION SYSTEM DIAGNOSES

INTERNAL EXHAUST
All hydrostatic systems require charge pressure to function correctly. This is because a
hydrostatic system cannot operate at a negative pressure. The charge pump provides
positive pressure to the hydrostatic pump inlet. On the model 1103, normal charge pressure
is approximately 290 PSI and can be checked at port #1 at the test station located on the
right side of the machine. Hydrostatic systems are designed to leak a small amount of oil
from pumps and motors for lubrication of parts and cooling, and in some cases, the leak is
strictly due to operating clearances. The larger the system pressure the higher this exhaust
rate. Fresh charge oil will make up for normal system losses.
When components fail, exhaust under pressure increases tremendously and is noted by a
drop in charge pressure (the charge pump is not able to keep up with the hydrostatic
system's exhaust rate). The condition of a hydrostatic motor/pump circuit can be
determined by a simple charge pressure test at maximum engine RPM and normal
operating temperature. Under the previously mentioned conditions (RPM and temperature),
compare the pressure readings of the charge with the hydrostatic system at no load and
maximum load. If these two charge pressure readings show a difference of more than 10%,
between the loaded and unloaded conditions, the hydrostatic system has higher than
desired exhaust.
After determining that the hydrostatic closed loop system has a higher than desired leak
rate, it is necessary to determine what component is leaking and causing the pressure to
drop.
One method of isolating the component is to measure the engine case drain flows with the
hydrostatic system at no load and maximum load at high engine idle. The component with
high internal exhaust will have a significantly higher drain flow rate when the system is
loaded - ed. When using a flow meter in the case drain line, be sure it is correctly sized to
avoid excessive case drain pressure.
A second method is to cap the pressure lines at the front and rear engines and determine
if charge pressure increases to normal. A normal charge pressure reading under these
conditions would eliminate the pump as the problem. A low charge pressure reading with
the engines locked indicates a pump or charge relief problem. With the pump isolated and
in a no-shock condition, there should be normal charge pressure. If the pressure is low, the
first place to look is at the charge relief valve.
4 - 18 July 1998
The next step is to reconnect one drive engine and rerun the charge pressure test. A
normal charge pressure reading would eliminate that engine as the source of exhaust. A
low charge pressure reading would indicate that the engine has high internal exhaust.
Reconnect the second ride motor and repeat the test. If a cruiser engine has an exhaust
problem, it must have been isolated by this test.
Remember, the failure of one component in a hydrostatic system can cause contamination
throughout the entire system. Prior to installing the new or rebuilt component, the entire
system must be disassembled and cleaned. This includes all pumps, motors, valves,
coolers, hoses, and reservoirs.
SERVO CONTROL PUMP

Charge system oil is supplied to the servo controlled pump through a solenoid valve
located on the upper rear of the pump assembly. A control cable to the operator's platform
usually blows the pump's internal servo control valve. Small holes are installed in the servo
valve to help control the stroke rate.
If the machine moves in the neutral position, check the adjustment of the control cable. If
the cable is adjusted correctly the machine could be having brake problems.
If the machine does not move forward or reverse when the operator control lever is moved,
check for a problem (possibly electrical) in the solenoid valve. As a quick check, see if the
brake release pressure, which is also controlled by this solenoid valve, is at 290 PSI. For
more information on troubleshooting electrical problems refer to the electrical section of this
manual.
If the machine does not move or moves slowly and charge pressure is at its normal level, it
is possible that leakage in the servo control cylinder is larger than the amount of oil left
through the servo valve holes. Servo gauge Ports M4 and M5 on the pump can be used to
test the servo pressure in the servo cylinder.
July 1998 4 - 19
4 - 20 July 1998
VIBRATION SYSTEM
The vibration circuit consists of a Sunstrand Sauer Series 90 pump that provides oil to a
Sunstrand Sauer SF4 vibration motor. The pump is a variable displacement axial piston
design with bi-directional flow, while the motor is a fixed displacement, bi-directional piston,
axial style.
Machines with smooth drums have two frequency ranges while the padfoot drum operates
with just the lowest frequency. When high frequency is desired, the solenoid controlled
pump is stroked to provide oil at a 42 cc per revolution rate to the vibration motor. This
results in a vibration frequency of 2160 vibrations per minute, rotating the vibration shaft
clockwise with a centrifugal force of 24053 lbs. When the low frequency is desired, the
solenoid controlled pump is stroked in the opposite direction, to provide oil at a 32 cc per
revolution rate to the vibration motor. This results in a vibration frequency of 1680 vibrations
per minute, rotating the shaft in a counter clockwise direction with a centrifugal force of
47211 lbs.
July 1998 4 - 21
4 - 22 July 1998
Push button shifts on the operators control panel provide frequency options as well as
automatic vibration off into neutral. A thumb shift on the top of the front reverse control
handle enables the operator to start and stop vibration.
Two multifunction valves on the vibration pump, set at 350 bar (5075 PSI), protect the
vibration circuit from excessive pressure, in the same way as in the propulsion circuit. The
upper valve controls the pressure when operating at the 2160 VPM frequency, low
amplitude. The 1680 VPM low frequency, high amplitude pressure is controlled through the
bottom valve. Home up pressure can be as high as 350 bar (5075 PSI) but will drop
between 100 bar (1450 PSI) and 150 bar (2200 PSI) once the operating vibration speed is
obtained.
VIBRATION FREQUENCY
This drawing illustrates a typical exciter shaft and the two overturning weights used to
change the amplitude on a vibrating roller.
Stem rotation may be faster in one direction and slower in the other direction. These two
speeds create the two frequencies available on some models. The amplitude is changed by
the use of overturning weights. In one direction the overturning weights are opposite the
shaft counterweight and create a low amplitude vibration. When the shaft is rotated in the
opposite direction the overturning weights are transferred to the same side as the shaft
counterweight causing an increase in amplitude. This design allows for a LOW amplitude
when the frequency is HIGH and a HIGH amplitude when the frequency is LOW.
July 1998 4 - 23
Models that offer only one frequency do not reverse the direction of shaft rotation nor do
they use the overturning weight design. For additional information on this contact your
Vibromax dealer.
Model freq#1 freq#2 ampl#1 ampl#2
1103D 28Hz 36Hz 1.6mm 0.6mm

1103PD 28Hz N/A 1.6mm N/A
1103HD 28Hz 36Hz 1.6mm 0.6mm
1103HPD 28Hz N/A 1.6mm N/A
LOW FREQUENCY
HIGH FREQUENCY
4 - 24 July 1998
VIBRATION AMPLITUDE
HIGH AMPLITUDE LOW FREQUENCY
AMPLITUDE
h1
TIME in seconds
h2
LOW AMPLITUDE HIGH FREQUENCY
h1 and h2 above = Jumping Height

1/2 of h1 or h2 = Width
One half the vertical distance that

the drum travels is called the
amplitude. The amplitude for any
given machine will vary depending
on ground conditions. The breadth
and height the machine lifts it of the
JUMPING HIGH ground gradually increase as the
AMPLITUDE
ground becomes denser or more
compacted.
July 1998 4 - 25
VIBRATORY SYSTEM DIAGNOSES

The 1103PD (padfoot) models have a vibration frequency of 1680 vibrations per minute (28
Hz). Padfoot models also use a single offset shaft without overturning weights. The
vibration motor only rotate in one direction due to machine control settings.
The 1103D (smooth drum) models are equipped with two overturning weights. The vibration
shaft is bi-directionally rotated to obtain a vibration frequency of 1680 vibrations per minute
(28 Hz) in one rotational direction and 2160 vibrations per minute (36 Hz) with the opposite
direction of rotation.
Vibration frequency is related to the speed at which the vibration shaft is rotated and can be
measured with a frequency meter. Low frequency problems will typically appear as
machine rough riding (often referred to as tan bucking). Operation at higher than
recommended frequency will manifest as shortened vibratory sustaining life.
Vibromax No. on
VT9013 behalf
To increase or decrease the shaft speed requires more or less flow from the vibration
pump. Before making adjustments to the pump displacement controls, always check that
the engine operating speed is set to maximum (2500 rpm) and pressure test the system to
ensure that the system is operating correctly. Hydraulic pressures can be tested at taps #3
and #4 of the hydraulic test station. Start up pressure can be as high as 350 bar (5075 PSI)
but would have to drop between 100 and 150 bar (1400 and 2200 PSI) once operating
speed has been obtained.
vibration system from excessive pressure. The upper valve controls the pressure when
operating at high frequency and low amplitude. The low frequency high amplitude circuit is
controlled through the lower valve.
4 - 26 July 1998
STEERING SYSTEM
The steering circuit consists of a fixed displacement drive pump mounted behind the
vibration pump, a steering control valve (steering orbitrol) and two steering cylinders in the
knuckle joint. The oil is supplied from the reservoir to the steering pump. The oil from the
pump is directed to the steering control valve at Port P. If a steering correction is not
required, oil will pass through the valve and flow out of Port T, flow through the filter and
enter the propulsion and vibration circuits when charging oil. Oil in the L and R steps as
well as oil in the steering cylinders is trapped and cannot flow, which is why the machine
maintains its steering direction. When a steering correction is required as dictated by
rotation of the steering wheel, the control valve meters a portion of the oil from the P port to
the L or R port (dependent on the direction the wheel is rotated) and to the steering
cylinders. The resulting stroking of the cylinders causes the machine to rotate. When oil is
admitted to one end of the cylinders, oil discharges from the opposite end and returns to
the valve, flows out of port T to the filter and over charge pressure.
Three relief valves are designed into the steering system. Working pressure is controlled at
140 bar (2030 PSI) by the port P relief. This pressure can be checked at port #2 of the
hydraulic test station. Two port safety reliefs, set at 200 bar (2900 PSI), are built into L and
R cylinder ports. These port relief valves protect the steering cylinder and working lines
from being over pressurized while the oil is trapped by the steering hand valve (orbital
engine).
July 1998 4 - 27
4 - 28 July 1998
STEERING SYSTEM
July 1998 4 - 29
PARKING BRAKE SYSTEM
A spring applied, hydraulically released, multi-disc brake is built into the drum drive motor.
Pilot pressure usually releases the brake. Without pilot pressure, the spring keeps the
brake applied.
The standard rear axle uses a band brake in the intermediate gear boxes which is activated
by a spring loaded cylinder. The cylinder is stroked by the application of pilot pressure,
releasing the brake. The heavy duty rear axle has a shoe and drum brake on each end of
the axle, or a multi-disc brake on the intermediate gear case.
The brakes are controlled by a push button on the pinch or by the emergency stop button
on the steering console. When the brake shift on the brake pedal is depressed, hydraulic
pressure is removed from the brake circuit and the brakes become applied through spring
force. The brake shift also activates the differential lock solenoid for enhanced brake
holding. When the emergency stop shift is activated, the brake pressure is released and the
springs apply the brakes, the vibration circuit is off, the two-speed motor is placed in low
range, the differential lock is applied and the stops of ride system.
4 - 30 July 1998
TOWING YOUR MACHINE
A tow valve, located under the operators seat, usually releases the brakes on a machine
that needs to be moved when the engine is not running. Place the valve in the tow position
and turn the steering wheel to the right. The mechanical effort of turning the steering
wheel will create enough pressure to release the brakes. That, together with unscrewing
the multifunction valves, will allow the machine to be towed. WARNING! Operating the
machine with the tow valve in the tow position will cause brake system damage.
Multifunction
Valves
PARKING BRAKE DIAGNOSTICS

The parking brake is spring pressure applied and hydraulic released. When the brake/servo
valve is activated pressure is applied to release the brake and operate the pump controls.
When the pump control is compromised the brake should release. If the machine makes an
effort to move after engaging the forward/reverse lever (the engine seems to load down),
the solenoid valve should be working. This would be an indication of a mechanic hanging
on the brake. If you are able to drive the machine but the parking brake does not engage
with the brake but- the ton activated this could indicate a mechanical hang-up, or worn
brake discs. To get the actual brake pressure reading requires teeing the line to the
pressure change located at the tow valve. It should be mentioned here that this change in
pressure usually controls the brake indicator light on the instrument panel.
July 1998 4 - 31
4 - 32 July 1998
July 1998 4 - 33
4 - 34 July 1998
DIFFERENTIAL LOCK SYSTEM
The differential lock is a spring applied, hydraulically released clutch that allows the
operator to close the differential. These results in both wheels rotating as a unit, which
provides an improvement in machine traction.
Normal operation of the machine is conducted with the differential lock in the hydraulically
reset position. This allows for a differential action on the shaft when turning the machine.
When increased traction is required, depressing the push button on the instrument panel
activates a solenoid that releases hydraulic pressure from the differential lock, allowing the
lock to engage.
A zero angle shift, mounted on the knuckle joint, renders the solenoid useless if the
machine is not traveling in a straight forward direction. The differential lock cannot
compromise if the machine is rotating.
July 1998 4 - 35
4 - 36 July 1998
July 1998 4 - 37
HYDRAULIC SCHEMATIC
SECTION FIVE
FINAL RIDES
July 1998 5-1

SECTION FIVE FINAL RIDES
GENERAL INFORMATION
The rear drive axle consists of a hydraulic drive motor, intermediate gear box, differential
gears, differential lock, and planetary drive. Three types of axles have been used in the
1103 model. The standard axle on the 1103 is the same Speth design used on the later
model 1102. This axis is common to 1103D and 1103PD. The 1103HD and 1103HPD are
equipped with a Speth heavy duty or a Kessler heavy duty axle. The Speth heavy duty is
new to the model 1103 but the Kessler design has previously been used by Vibromax in the
model 1402.
To identify a Speth the axis looks for the Speth name cast to the planetary end caps. The visible differences
between the standard and heavy duty Speth axles are the larger ride motor on the heavy duty axle and the
change in brakes. The standard Speth axle is equipped with a band type brake on the intermediate input
shaft gearbox which is activated by a small hydraulic cylinder. The Speth heavy duty axle brake is a self
contained hydraulic disc type also in the intermediate gearbox input shaft.
The Kessler heavy duty axle is easily identified by the large wheel brakes on the axle ends.
The major housing is also made from welded parts while the Speth axles use cast parts.
All 1103 models use a Sauer Sundstrand Series 51 dual-axial hydraulic drive motor,
although heavy-duty models have a larger displacement motor for added torque and better
abilty. These ride motors come with a standard two speed feature which allows the
machine to have two travel speeds. The normal position for the two speed characteristic is
low range. A change in the instrument panel usually activates high range.
5 - 10 July 1998
OPERATION
The shaft drive motor is driven in a parallel flow path with the front drum motor. The output
shaft of the drive axle motor is connected to the input shaft of the rear axle intermediate
gear box. The intermediate gear box drives the differential through the differential pinion
shaft. Torque is transferred via the axle shaft and gear from the axle shaft to the planetary
gears.
The three planetary gears turn into a fixed internal ring gear and drive the wheel hub.
The left hand axle tube is equipped with a differential locking mechanism. This mechanism
is a spring pressure applied and hydraulic released device. As soon as the engine is
started, hydraulic charge pressure is ported to the differential lock cylinder to release the
lock. The differential lock can be compromised by a change in the instrument panel which
changes a valve to block the charge pressure and port the differential lock cylinder to the
tank. Once the hydraulic pressure is released, spring force is allowed to close the
differential. It should be noted that the differential will not close if the machine is rotating.
July 1998 5-3

KESSLER AXLE
This manual will not go into detail on the disassembly or assembly procedures for the
Kessler heavy duty axle. Very few model 1103H machines were produced with this axle.
Repair procedures for these units are available in sections 6001 and 7001 of the 1402
service manual. Copies of these sections of the 1402 service manual are available from
Vibromax.
5-4 July 1998

SPETH STANDARD SHAFT
The remainder of this section of the manual will discuss the disassembly and assembly of
the standard Speth shaft. The main items of concern are also applicable to the Speth heavy
duty axle.
July 1998 5-5

REAR AXLE REMOVAL

1. Place the machine on a level surface, lock the hinge joint, and lock the front drum.
2. Drain the hydraulic reservoir by removing the return hose from the bottom of the
vibration ride motor and collecting the oil in a clean container. Hydraulic tank capacity
is approximately 18.5 gallons (70 liters).
3. Loosen the lock nut and turn the parking brake adjustment screw out as far as possible..
4. Remove the break pin from the brake cylinder rod pin and stretch the pin out of the
cylinder yoke. NOTE: The cylinder is under spring load.
5. Remove the electrical connector from the two-speed valve shaft ride motor.
6. Label, remove, and cap the hydraulic lines of the drive axle motor and differential lock.
7. Loosen the rear wheel lug nuts.
8. Lift the rear of the machine until the rear wheels are clear of the ground.
9. Support the machine rear frame with jack positions.
10. Remove the wheel lug nuts and stretch the wheels from the axle.
WARNING: the tires are liquid and the approximate filled weight is 1294 lbs. (587
kg.). Use appropriate lifting equipment to remove tires.
11. Support the axle in the center with a flat jack and take out the axle mounting screws
from both sides of the frame. More under the axle completely..
5-6 July 1998

REAR AXLE INSTALLATION

1. Position the axle under the machine frame rails. Install and torque the axle bolts to 295 ft
lbs. (400 Nm.).
2. Install both wheels with snug wheel lug nuts.
3. Remove the jack support positions from under the machine and let the machine sit on the
ground.
4. Tighten and torque wheel nuts to 288 ft lbs. (390 Nm.).

NOTE: Re-tighten wheel nuts every 8 hours until nut torque stabilizes.
5. Reconnect the hydraulic lines to the drive shaft motor. Use tie straps to bundle hoses.
NOTE: Be sure to fill the hydraulic motor case with oil!
6. Reconnect the electric plug on the two speed valve.
7. Install the brake lever to the brake cylinder yoke and install the cotter pin. Secure the
pin with a new breakaway pin.
8. Adjust the brake using the framing screw. Proper clearance is measured between the
end cap of the cylinder and the end of the cylinder rod. This measurement would have
to be 1.0 inch (25.4 mm).
9. Replace the hydraulic reservoir with 18.5 gallons (70 liters) of filtered hydraulic fluid.
10. Fill the planetary rides with SAE 90 API GL-5 oil until it flows from the filler plug hole in
the planetary ride hub. Be sure the drain plug on the hub is located at the bottom of
rotation during filling.
July 1998 5-7

11. Remove the breather tube from the axle and fill with SAE 90 API GL-5 oil until it flows
from the plug hole in the differential housing.
12. Remove the middle gear case breather and fill with SAE 90 API GL-5 oil until it flows
from the plug hole in the middle gear case cover.
SHAFT TUBE DISASSEMBLY

NOTE: The hub and planetary wheel can be removed and serviced without axle removal but
the following instructions assume the final drive is removed from the machine.
1. Mark the axle tubes and differential housing to ensure correct alignment
during assembly.
2. Remove the screws that hold the axle tubes to the differential housing and remove the
tube and planetary assemblies from the differential. Note that the left axle tube contains
the differential locking mechanism.
3. Remove the differential lock compression spring, changing ring, and changing washer
ring from the left axle tube assembly.
4. Place the tube and hub assembly on a bracket with the planetary facing.
5-8 July 1998

July 1998 5-9
DISSASSEMBLY PLANETARIUM
1. Remove the planetary cover screws (32) and remove the cover (30).
2. Remove the axle shaft. The shaft shaft gear and holding can now be removed from the
shaft by removing the retaining ring (29) and support ring (26). An external puller is
required to remove the holding (28).
3. Take out the planetary carrier capscrews (14). Use two M12 jacking screws in the two
holes provided on the planetary carrier (22) to loosen and remove the planetary carrier.
4. After removing the planetary carrier (22), press the planetary gear pins (18) out of the
gears (21).
5. Move each planetary gear to the opening center and pull it down out of the carrier.
6. Remove the two driven planetary gear washers (17), the needle that supports rollers
(19), and separating washers (20) from the planetary gears.
7. Returning to the wheel hub and axle tube assembly remove the old o-ring (7) from
the wheel hub (6).
8. Remove the locking screw (12) from the large slotted nut (11) which holds the wheel hub
to the axle tube (1). Loosen the slotted nut and take out the inner ring gear (16) with the
ride gear (10) still installed.
9. Remove the snap rings (9) from the internal gear and remove the driving gear (10).
10. An external gear puller can now be used to remove the tapered holding roller (8) from
the drive gear.
11. Install two 12mm eye bolts to the wheel hub 180 degrees apart. Install a puller to the
eye bolts and stretch the wheel hub from the axle tube.
12. The holding cup, holding cone (5), and seal (4) can now be driven off the wheel hub.
13. Remove any damaged wheel lug screws (2) from the hub (6).
5 - 10 July 1998
July 1998 5-
11
DIFFERENTIAL LOCK REMOVAL
1. Remove the hydraulic differential lock fitting.
2. Using the appropriate tooling, compress the piston (9) and internal compression spring
(6).
3. Remove the snap ring (3) with an internal snap ring pliers.
4. Carefully release the pressure applied by the compression spring allowing the piston
to push outward.
5. Use an internal puller to stretch the differential lock cylinder bushing (8) out of the axle
tube.
6. The piston can now be removed for seal replacement.
7. Remove the inner compression spring (6).
8. Remove the flanged bushing (5)
5 - 12 July 1998
DIFFERENTIAL LOCK ASSEMBLY

1. Install new inner and outer seals on the differential lock cylinder bushing (8).
2. Install new seals on the piston (9).
3. Lubricate the piston seal and install the piston to the cylinder bushing so that the notch
in the piston is aligned exactly in the center of the hole in the cylinder bushing.
4. Install the flanged bushing (5) to the axle tube.
5. Install the inner compression spring (6).
6. Lubricate the cylinder seals and install the cylinder unit to the axle tube making sure
that the hole in the cylinder, which shows the piston groove, is aligned with the
threaded fitting hole in the axle tube.
7. Using the appropriate tooling apply a force to the piston in order to compress spring (6)
while maintaining the alignment of the piston notch in the threaded hole.
8. Install the hydraulic fitting (10).
9. Install the snap ring (3).
10. Pull force against the piston and allow the snap ring to seat properly.
11. Conduct an air leak down test at 85 PSI (6 bar) by applying air pressure to the
hydraulic fitting port. The pressure trapped in the cylinder must not decay from the 85
PSI level during a one minute decay test.
12. With air pressure still applied to the piston you should be able to easily push the piston
in with hand pressure applied to the piston.
13. Remove the air line.
July 1998 5 - 13
SHAFT TUBE AND PLANETARY ASSEMBLY

1. Install the holding cup for the tapered holding roller (6) to the wheel hub (5). Press the
shoulder cup into the hub.
2. Install the tapered cone holding roller (6) to the wheel hub.
3. Apply Permatex sealant to the outer edge of seal ring (7) and press the seal to the
wheel hub.
4. Turn the wheel hub over. Install the holding cup to taper the holding roller (4) to the wheel
hub (5). Press the shoulder cup onto the wheel hub.
5. Coat the bearing surface on the axle tube (8) with Molycote grease.
6. Guide the hub wheel over the axle tube.
7. Press the wheel hub to the axle tube until holding (6) is seated on the axle tube. Use of
a driving hold tool is recommended. Rotating the hub during installation will help to
keep the tapered holding up.
8. Pour some SAE 90 oil into the hub wheel to lubricate the bearing.
9. Press the holding cone to taper the holding roller (4) to the drive ring gear (10).
10. Install the drive ring gear (10) to the inner ring gear (11) and retain it with the two
large snap rings.
11. Install the inner ring gear and drive ring gear assembly to the axle tube splines.
12. Apply Loctite 592 to the threads of the slotted nut and axle tube.
13. Install the slotted nut (3) and tighten it to 140 ft lbs (190 Nm). After tightening, slot the
nut back approximately 22 degrees and install the locking screw to 7.5 ft lbs (10 Nm.)
5 - 14 July 1998
July 1998 5 - 15
5 - 16 July 1998
14. Install o-ring (7) on the wheel hub.
15. Coat the inside of the planetary gear (21) with grease and install the needle bearings
(19) on one side of the planetary gear.
16. Install the two separating rings (20) to the planetary gear on the opposite side. Coat the
rest of the inside of the planetary gear with grease and install the needle bearings.
17. After preparing the three planetary gears apply grease to the thrust washers (17) and
install the planetary gear.
18. Carefully install the planetary gear to the planetary carrier (22) from the bottom side of
the loader by moving it up into the center position then sliding it to the side position.
Make sure the thrust washers and needle bearings stay in position.
19. Align the planetary gears with the holes in the carrier. Install the planetary pins with the
tapped holes facing up toward the cover plate (30). The threaded holes should face the
outside of the carrier.
Note: The threaded holes in the pins usually secure the cover (screw 34) and have
to be aligned with the screw pattern of the other cover holes touched to the
automotive- rier.
20. Install the planetary loader assembly onto the axle tube. Install the planetary screws
(14) and washers (13) and tighten to 89 ft. lbs (120 Nm).
21. Install the bushing (24) on the axle shaft.
22. Install the axle gear (25) on the axle shaft.
23. Install two spacer washers (26) to the axle shaft.
24. Install the snap ring (27) to the supporting shaft (28). Heat holding to 145 0 F and install
to the stem with the snap ring facing outwards. Make sure you hold it against your
shoulder and leave to cool.
25. Install a washer spacer (26) to the shaft and install the snap ring (29).
26. Install the axle shaft to the axle tube.
27. Install a new o-ring cover. Apply Permatex 300 to the exterior load-bearing surface.
Install the cover. Apply Permatex 300 to the deck screws. Tighten the 12mm screws
to 88 ft lbs (120 Nm) and the 10mm screws to the planetary pins to 51 ft lbs (69 Nm).
July 1998 5 - 17
INTERMEDIATE GEARBOX DISASSEMBLY

1. Disconnect the drive motor from the intermediate gearbox shaft.
2. Remove the brake drum retaining capscrew (10) and remove the brake drum with an
external puller.
3. Disconnect the brake release springs from the brake shoes and remove the brake shoes.
4. Remove the snap ring and washer from the brake lever and remove the brake lever from
the toggle pin.
5. Remove the capscrews from the intermediate gearbox cover. Use two 10x80mm jack
screws to pry open the gearbox housing cover.
6. Remove the plate intermediate gear shaft lock (31).
7. Using a piece of wood or hard plastic, lock the gears and remove the neck nut into
the spur gear. The spur gear is the large gear mounted on the differential input shaft.
8. Using a soft driving pin ride off the intermediate drive shaft and input pinion shaft.
You have to work alternately between the two shafts when you are leading them
outside. When you stretch the two shafts watch for any shims which could be
installed.
9. Remove the spur gear from the differential input pinion shaft with an internal puller.
10. Press the inner and outer bearings out of the intermediate gearbox input pinion shaft.
11. Press the middle gear of the middle gear shaft.
12. Take out the intermediate gear that holds cones and spacer shim.
13. Remove both cups from holding the middle gear with an internal puller.
14. Remove the middle gear ring click.
5 - 18 July 1998
July 1998 5 - 19
INTERMEDIATE GEARBOX ASSEMBLY

1. Press the two new ball bearings onto the intermediate gearbox input pinion shaft.
Remember to install the snap ring on the outboard holding ring (8) and press the
holding ring on top in order to have snap ring towards the gear teeth.
2. Install the snap ring to the middle gear and press on the two cup holders.
3. Install the two cone holders in the middle gear with the shim spacer between the two
cones. These parts are offered as matched listed under part number V40128.
4. Press the intermediate gear shaft to the gear with the end knurled shaft.
Press the shaft in until it protrudes 0.8 inch (2cm) across the fly. This measurement is
from the marching face to the end of the shaft.
5. It applies pressure to the inside holding bearings and control the intermediate gear
stroke freely. The end play of the intermediate gear should be 0.0008 inch (0.02 mm).
End play is set by grinding the shim spacer to size..
6. After seating the intermediate gear shaft and bearings, install a new o-ring in the
groove of the intermediate gear shaft.
5 - 20 July 1998
7. Replace the old input pinion shaft seal in the gearbox housing.
8. Install the large production shaft drive by driving it to the shaft with a plastic hammer.
9. It is necessary to check the input pinion gear for proper end play of 0.008 to 0.012 inch
(0.2 to 0.3 mm). To check end play, measure the distance from the sealing surface of
the housing to the pinion shaft that supports the contact surface in the housing
(measurement “un”). Measure the distance from the sealing face of the intermediate
gearbox cover to the contact groove - face of the pinion bearing snap ring
(measurement “b”). Using a caliper, measure the length of the pinion shaft from the
bottom of one pinion bearing to the outer edge of the second bearing ring
(measurement “c”).
Pinion shaft clearance = (a + b) - c

If needed, shims can be added under the sprocket that holds which seats to the
intermediate gearbox housing.
10. Install the pinion and intermediate gears that make sure the gear teeth are engaged.
Care has to be taken not to damage the input pinion shaft seal or the intermediate
shaft O-ring.
NOTE: Make sure the orientation of the intermediate gear shaft is correct. The slot
in the shaft must be aligned for the lock plate to be installed.
11. Use a suitable tube driver on the inner race holding to seat the intermediate drive
shaft then seat the pinion shaft with a plastic hammer.
12. Install the lock plate in the groove in the intermediate drive shaft.
13. Install the neck nut to the production shaft using Loctite 271. I use a piece of wood or
plastic to hold the gear and tighten the neck nut to 332 ft lbs (450 Nm). Secure the neck
nut by driving the edge of the nut into the shaft groove.
14. Apply Permatex 300 sealer to the sealing surfaces of the gearbox intermediates and
install the cover using a plastic hammer to seat the cover. Install the capscrews
cover and torque to 51 ft lbs (69 Nm).
15. Install the brake lever and washer. Safe with the ring snap.
16. Install the brake shoes and shoe return springs.
17. Install the key parallel to the pinion shaft and install the brake drum. Secure the drum
with the washer, washer lock, and retaining capscrew. Torque capscrew at 93 -112 ft
lbs (125 - 150 Nm).
18. Install a new o-ring on the ride motor flange and install the ride motor.
July 1998 5 - 21
DIFFERENTIAL DISASSEMBLY
1. Remove the axle tubes.
2. Take out the intermediate gears.
3. Mark an alignment marking between the axle housing (19) and the intermediate
gearbox housing. Remove the capscrews that hold the intermediate gearbox housing to
the shaft housing and remove the intermediate gearbox.
4. Remove the old shaft seals from the intermediate gearbox housing.
5. Press the bearing flange (27) out of the axle housing (19) using two 12x120mm jacking
screws into the threaded holes provided in the flange.
6. Remove the shims (26) from the retaining flange.

NOTE: Write below the number and measurement of these shims. Install the same
number of shims during assembly.
7. Press the differential pinion shaft out of the tapered roller bearings (22) onto the
bearing shoulder (27). Press the holding cone of the pinion shaft. Watch for the
spacer (24) and any shims (23) during disassembly.
NOTE: The pinion shaft and ring gear are matched sets and must be replaced as
such.
8. Remove the exterior holding cup and shaft seal from the holding rim.
9. Remove the capscrews (11) from the gear cover (15) and remove the gear cover.
10. Remove the holding cup and shims from the gear cover.
NOTE: Write below the number and measurement of these shims. Install the same
number of shims during assembly.
11. Install two 12mm eyebolts to the tapped holes provided in the differential housing (1)
and remove the differential.
12. Remove the remaining snap ring (33), ring (32), shims (16), and holding cup from the
axle housing. NOTE: Write below the number and measurement of these shims.
Install the same number of shims during assembly.
13. I use an external puller to remove the two cone holders from the differential housing.
14. Remove the capscrews holding the ring gear (20) to the differential housing. Use two
12x40mm jacking screws to separate the gear ring from the housing.
NOTE: Only remove the differential if repairs are needed.
5 - 22 July 1998
July 1998 5 - 23
15. Remove the capscrews which hold the two parts of the differential housing together.
Before separating the two housing parts note that there would need to be alignment
markings on the parts.
16. Take out the differential bevel gears and pushed washers.
DIFFERENTIAL ASSEMBLY
1. Apply oil to the contact area for the thrust washers on the differential housing halves
(1) and install the thrust washers (2).
2. Install the bevel gears (3) into the differential halves.
3. Install the bevel spider gears (6) into the bevel gear shafts (4) with thrust washers (6).
4. Install the first set of spider gears from the bezel and shaft to the housing.
5. Install the second set of spider gears from the shafted bezel to the first set.
6. Assemble the second half of the differential housing to the middle containing the
spider gears. NOTE: Align the housing markings .
7. Install the differential capscrews using Loctite 271 and torque to 51 ft lbs (69 Nm).
8. Install the ring gear that ensures alignment of the capscrew and ring pin holes.
NOTE: If a new ring gear is installed the pinion shaft must also be replaced. Make
sure the ring and pinion have the same identification numbers.
9. Install the two ring pins (9 and 10) with the smaller one fitting the larger one.
10. Install the gear ring capscrews using Loctite 271 and torque to 88 ft lbs (120 Nm).
11. Preheat the differential holding cones to 175 0 F (80 0 C) and install into the
differential halves.
12. Install the snap ring (33) to the groove in the shaft housing (19).
13. Install the support ring (32) and the same number of shims (16) that were removed
during disassembly.
14. Install the exterior holding cup.
15. Apply a marking agent to three areas of the gear ring and install the differential
assembly to the axle housing using two 12mm eyebolts.
16. Install the shims and holding cup to the gear cover (15).
5 - 24 July 1998
July 1998 5 - 25
17. Install the gear cover and tighten the capscrews to 50 ft lbs (69 Nm). NOTE: do not
apply any sealant until the shimming has been applied.
18. Press the new tapered holding cone (22) to the pinion shaft (21).
NOTE: If a new pinion gear is installed the ring gear also needs to be replaced.
Make sure the ring and pinion have the same identification numbers.
19. Install the bushing spacer (24) and shim (23) to the pinion shaft.
20. Install lip seal (25) to bearing flange (27) until it is seated 1.9 inch (49mm) below the
face of the flange. Apply a sealant to the bearing lip prior to installing the seal.
21. Install the exterior and interior holding cups to the holding lip.
22. Install the pinion shaft to the bearing flange and install the outer bearing cone. With a
10 ton load applied to the bearing cone bearing flange torque would have to be 7 ft lbs
(10 Nm). A thicker shim will lower roll torque and a thinner shim will increase roll torque.
A new shim spacer (23) will normally need to be ground to size.
23. Install a suitable spacer on the pinion shaft (in spur gear position 28) and secure in
place with neck nut (29). In preparation for differential installed torque the neck nut to
327 ft lbs (450 Nm).
24. Install two 12x20mm guide bolts to the axle housing and install the shims (26) and
pinion assembly. Secure the flange to hold with four capscrews torqued to 88 ft lbs
(120 Nm).
25. Rotate the pinion shaft several rotations in both directions then remove the
shoulder from holding and note the contact area in the ring gear.
5 - 26 July 1998
July 1998 5 - 27
26. Change shims (16) on the left or right side of the differential or shim (23) on the input
pin-ion shaft to make corrections to the tooth contact area.
27. When differential setup is complete, apply a sealing medium to the sealing surfaces of
the gear cover (15) and the axle housing (19) and drive cover arrival installation.
Tighten the capscrews to 50 ft lbs (69 Nm).
28. When differential setup is complete, apply a sealing medium to the contact surfaces of
the bearing flange (27), shims (26), and axle housing (19) and install the bearing
flange.
29. Apply sealant to the shaft seal (25) and install into the intermediate gearbox housing.
30. Install the intermediate gearbox housing using the alignment marks previously
made. Tighten the capscrews to 88 ft lbs (120 Nm).
5 - 28 July 1998
DRUM REMOVAL
1. Disconnect, tag, and cap the hydraulic lines for the drum drive motor on the left side
of the machine. Plug the engine ports.
2. Disconnect, tag, and cap the hydraulic lines to the vibration motor on the correct side of
the machine. Plug the engine ports.
3. Block and support the front frame of the machine.
4. Remove the drive motor adapter (89) to frame screws (102) on the left side of the machine.
5. Take out the front and rear buffer brackets (10) on the right side of the machine.
6. Remove the scraper bar from the front of the machine.
7. I run or lift the drum out of the front frame. Smooth drum weight = 9,372 lbs (4,250
kg) Padfoot drum weight = 10,197 lbs (4,625 kg)
DRUM INSTALLATION
1. I run or lift the drum into position on the front frame of the machine. The drum has to
be posi- tioned for alignment of the ride motor bracket to the left side frame screw
holes.
2. Install the screws on the front and rear buffer brackets on the correct side of the
machine. This will allow the machine frame to be lowered or raised as needed to
complete alignment of the ride motor bracket on the left side of the machine.
3. Install the front scraper bar and torque the screws to 313 ft lbs (425 Nm).
4. Tighten and torque the motor bracket and buffer bracket screws to 313 ft lbs (425 Nm).
5. Install the hydraulic hoses on both the vibration and ride motors. NOTE: Fill all engine
ports with clean hydraulic oil prior to hose installation.
6. Start the machine engine and let the hydraulic systems develop charge pressure. Let
the engine run at low idle for several minutes without loading to fill and flush the
system.
7. On machines that have a brake on the drum drive motor it may be necessary to bleed
the brake system at the brake port of the motor.
July 1998 5 - 29
DRUM RIDE
LEFT SIDE
5 - 30 July 1998
July 1998 5 - 31
RIGHT SIDE
5 - 32 July 1998
July 1998 5 - 33
DRUM RIDE THAT HOLDS EXTRACTION

1. Remove the drum from the machine and drain the exciter oil from the shaft.
2. Position the drum at its end with the vibration motor facing upwards. Note: The bear
ride- ings cannot be removed without the drum being on end. This is necessary to
avoid damage to the exciter shaft and exciter bearings.
3. Remove the vibration motor (21) and motor coupling (33).
4. Remove plate (9) from holding rim (8).
5. Remove capscrews (44) from the holding housing (7) and use two jacking screws to
remove the housing from the drum. NOTE: care should be taken not to damage the
exciter shaft. The exciter holding the cone will come out with the housing.
6. Remove snap ring (31) and stretch the exciter holding cone (5) with an external puller.
7. Remove snap ring (29) from the shaft holding flange (8) and press the holding shaft out of
the housing.
8. Use an external bearing puller to remove the inner drum bearing bearing (25) and
spacer.
(28) of the accommodation.
9. Remove the old face seal (26) then remove the retaining snap ring (27) for the
holding outer drum ride (24).
10. Use an external holding puller to remove the holding drum drive (24).
5 - 34 July 1998
July 1998 5 - 35
DRUM RIDE HOLDING INSTALLATION

1. Press drive bearing (24) to bearing housing (7) and install snap ring (27).
2. Install seal halves (26) to bearing housing (7) and bearing flange (8).
3. Press the holding lip (8) into the holding housing (7).
4. Flip the housing over and install the spacer (28).
5. Walk bearing press drum (25) to flange shaft (8) and install snap ring (29).
6. Press the exciter shaft holding cone into the holding housing (7) and install snap ring
(31).
7. Replaces o-ring seal (64) in bearing housing.
8. If the exciter oil was drained prior to disassembly, pour the appropriate amount and
type of oil into the exciter shaft tube (refer to the oil specification chart in section A).
9. Install the drive that holds the housing to the drum and install capscrews (44) using
Loctite 271 and torque to 471 ft lbs (640 Nm).
10. Install plate (9) using capscrews (58), washers (59), and Loctite 271. Torque
capscrews at 155 ft lbs (210 Nm).
11. Installs vibration motor ride coupling (33).
12. Install a new vibration motor o-ring (23) and assemble the vibration motor using
capscrew
(56) and washer (57).
DRUM RIDE MOTOR REPAIRS

This manual is not intended to supersede or replace Poclain Hydraulic repair instructions
for the model LADY25 drum ride motor. We strongly recommend that those wanting to
rebuild the ride motor, obtain a copy of Poclain Hydraulic repair manual IMG4/25125
(677777 666R) from your local Poclain dealer or from Vibromax under part number
V40108.
NOTE: During the machine's warranty period, the Poclain drum ride motor has to be
serviced by a certified Poclain repair center to receive warranty claim reimbursment.
5 - 36 July 1998
SECTION SIX
PARKING BRAKE
SYSTEM
July 1998 6-1

SECTION SIX PARKING BRAKE SYSTEM
DESCRIPTION
The 1103 model comes standard with a parking brake on the rear axle. The 1103D with the
standard Speth axle will have a hydraulic deactivated drum type brake on the intermediate
input shaft gearbox. The heavy duty Speth axle is equipped with a hydraulic disc type brake
on the intermediate input shaft gearbox. Some early production 1103s were equipped with
a Kessler heavy duty axle which had hydraulic deactivated drum brakes in the axle shaft.
This Kessler axle was also common to the model 1402.
As an option the model 1103 also offers a disc type brake built into the drum drive motor.
Both the axle and drum motor brakes are designed as parking brakes but have enough
braking power to stop the machine in emergency situations. It is important to note that
after such emergency power to the brakes they have to be inspected for
serviceability .
Both the axle and drum motor brakes are spring pressure applied and hydraulic released.
The brake solenoid valve is located on the drive pump and is deactivated by a push button
on the instrument control panel. This solenoid valve has a dual function of releasing the
brake and supplying hydraulic power to the propulsion pump servo control system. Pushing
the brake button will activate the brake, but will also deactivate the pump servo system.
The brake system is equipped with a pressure change and horn arrangement which
provides a warning if the parking brake and powertrain are engaged at the same time. More
detail on the parking brake systems can be found in the hydraulic and electrical sections of
this manual.
6-2 July 1998

July 1998 6 - 11
BRAKE AND TOW RELEASE

When the machine is closed the brakes will fail to apply, therefore it is necessary to release
the hydraulic activated brakes before towing the machine. The machine is designed with a
brake release valve, located under the operator's seat box, and can be used in conjunction
with the steering hand pump to release the machine brakes. The tow valve is turned to the
lock position and the brakes are released by turning the steering wheel (hand pump) to the
right to generate parking brake release pressure. NOTE: Prior to tugboat it is also
necessary to back off the multifunction valves located on the propulsion pump port
block.
multifunction valves
NOTE: Do not tow the machine faster than 1.9 miles per hour (3 km/h).
NOTE: Do not tow the machine farther than 0.6 mile (1 km). If a disabled machine has to
be moved beyond this distance, use another means of transportation.
NOTE: Running the engine with the throttle valve in the throttle position may cause
brake system damage.
6-4 July 1998

DRUM MOTOR BRAKE

The Poclain ride motor uses a P3 type5 brake system.
Brake disc wear can be determined before disassembly by measuring piston stroke.
1) Remove the cover plug (142).

2) Brake supply oil pressure at 250 to 435 psi (17 to 30 bar).
3) I use a dial indicator to measure the piston stroke through the cover plug hole.
4) Piston stroke would have to measure between .031 and .055 inch (0.8 to 1.40mm).
July 1998 6-5

ENGINE BRAKE DISASSEMBLY
1. Take out the engine.
2. Place the engine on the support to hold it with the brakes up.
3. Remove the plug (142), discard the cover (141) and the o-ring (143).
4. Compress the washer spring (108) using a mandel and press..
5. Remove the snap ring (109) using an internal snap ring pliers.
6. Remove the washer spring (108), the brake piston (107), the shims (105), and the
brake discs (103) (104).
7. Take out and discard o-ring (106).
ENGINE BRAKE ASSEMBLY
1. Check the condition of the spline brake shaft and brake body. These parts have to be
clean and free of burrs.
2. Measure the total height of the stack disk (103 + 104).
3. Add shims (105) to the much needed disc stack to increase overall height to 2.362
inches (60mm) minimum.
4. Lubricate the discs and install alternately a friction disc (104) then a smooth disc
(103). In all cases the last disc must be smooth (103).
5. Clean all brake assembly separates including the snap ring and seal grooves.
6. Install the shim stack determined in step #3 above.
6-6 July 1998

7. Proceed with the brake adjustment. Installs brake piston (107) without o-ring (106)
and snapping ring (109).
8. Compress the brake discs. (Force F = 22,500 lbs or 100,000 Newtons)
Measurement dimension The amount of shims needed should equal X-X1 .
9. Remove the snap ring and piston and install the additional shims (105). Install the
shims with the thickest shim facing the piston.
10. Grease and install the o-ring (106) on the piston (107). The seal has to fit closely on
the piston.
11. Use anti-oxidizing grease to coat the snap ring and cover grooves, under side of
the brake piston, snap ring, spring washer, and the sealing surface on the brake
body.
12. Install the brake piston. Be careful when passing the seal over the snap ring
groove .
13. Install the washer spring and compress the washer using a mandrel and press.
14. Install the snap ring (109) using the internal snap ring pliers.
15. Brake supply oil pressure at 250 to 435 psi (17 to 30 bar).
16. I use a dial gauge to measure piston stroke.
17. Piston stroke would have to measure between .031 and .055 inch (0.8 to 1.40mm).
18. Install a new cover o-ring (143) and cover (141). Place the cover in the housing and
click into place using a mandrel. Make sure the outer edge of the cover is properly
seated in the groove.
19. Install the engine.
July 1998 6-7

STANDARD AXLE BRAKE

The standard axle brake is a band type located in the intermediate input shaft gearbox and
controlled by a hydraulic cylinder with a spring return .
6-8 July 1998

BRAKE BAND ADJUSTMENT

The band brake is adjusted by fixing screw (24) above brake lever (21). Turn the set screw
until the dimension between the cylinder and end of rod is 1.0 inch (25mm).
NOTE: The brake cylinder is assembled under a spring load!
July 1998 6-9

BRAKE CYLINDER BAND
WARNING! The steering cylinder is assembled under a spring load. Care

has to be taken during disassembly to avoid damage.
6 - 10 July 1998
HEAVY DUTY AXLE BRAKE
Brake
Assembly
gearbox
The heavy duty Speth brake shaft is located on the input shaft of the intermediate gearbox.
It is a disc type spring pressure applied and hydraulic released.
WARNING: The brake assembled under a spring load.
July 1998 6-
11
6 - 12 July 1998
SECTION SEVEN
VIBRATION SYSTEM
July 1998 7-1

SECTION SEVEN VIBRATION SYSTEM
VIBRATION SYSTEM
The vibration circuit consists of a Sunstrand Sauer Series 90 pump that provides oil to a
Sunstrand Sauer SF4 vibration motor. The pump is a variable displacement, axial piston
design with bidirectional flow, while the motor is a fixed displacement, bidirectional piston,
axial style.
Machines with smooth drums have two frequency ranges while the padfoot drum operates
with just the lowest frequency. When high frequency is desired, the solenoid controlled
pump is stroked to provide oil at a 42 cc per revolution rate to the vibration motor. This
results in a vibration frequency of 2160 vibrations per minute, rotating the vibration shaft
clockwise with a centrifugal force of 24053 lbs. When the low frequency is desired, the
solenoid controlled pump is stroked in the opposite direction, to provide oil at a 32 cc per
revolution rate to the vibration motor. This results in a vibration frequency of 1680 vibrations
per minute, rotating the shaft in a counter clockwise direction with a centrifugal force of
47211 lbs.
7-2 July 1998

Push button shifts on the operators control panel provide frequency options as well as
automatic vibration off into neutral. A thumb shift on the top of the front reverse control
handle enables the operator to start and stop vibration.
vibration circuit from excessive pressure, in the same way as in the propulsion circuit. The
upper valve controls the pressure when operating at the 2160 VPM frequency, low
amplitude. The 1680 VPM low frequency, high amplitude pressure is controlled through the
bottom valve. Home up pressure can be as high as 350 bar (5075 PSI) but will drop
between 100 bar (1450 PSI) and 150 bar (2200 PSI) once the operating vibration speed is
obtained.
VIBRATION FREQUENCY
This drawing illustrates a typical exciter shaft and the two overturning weights used to
change the amplitude on a vibrating roller.
Stem rotation may be faster in one direction and slower in the other direction. These two
speeds create the two frequencies available on some models. The amplitude is changed by
the use of overturning weights. In one direction the overturning weights are opposite the
shaft counterweight and create a low amplitude vibration. When the shaft is rotated in the
opposite direction the overturning weights are transferred to the same side as the shaft
counterweight causing an increase in amplitude. This design allows for a LOW amplitude
when the frequency is HIGH and a HIGH amplitude when the frequency is LOW.
July 1998 7 - 11
Models that offer only one frequency do not reverse the direction of shaft rotation nor do
they use the overturning weight design. For additional information on this contact your
Vibromax dealer.
Model freq#1 freq#2 ampl#1 ampl#2
1103D 28Hz 36Hz 1.6mm 0.6mm

1103PD 28Hz N/A 1.6mm N/A
1103HD 28Hz 36Hz 1.6mm 0.6mm
1103HPD 28Hz N/A 1.6mm N/A
LOW FREQUENCY
HIGH FREQUENCY
7-4 July 1998

VIBRATION AMPLITUDE
HIGH AMPLITUDE LOW FREQUENCY
AMPLITUDE
h1
TIME in seconds
h2
LOW AMPLITUDE HIGH FREQUENCY
h1 and h2 above = Jumping Height

1/2 of h1 or h2 = Width
One half the vertical distance that

the drum travels is called the
amplitude. The amplitude for any
given machine will vary depending
on ground conditions. The breadth
and height the machine lifts it of the
JUMPING HIGH ground gradually increase as the
AMPLITUDE
ground becomes denser or more
compacted.
July 1998 7-5

VIBRATORY SYSTEM DIAGNOSES

The 1103PD (padfoot) models have a vibration frequency of 1680 vibrations per minute (28
Hz). Padfoot models also use a single offset shaft without overturning weights. The
vibration motor only rotate in one direction due to machine control settings.
The 1103D (smooth drum) models are equipped with two overturning weights. The vibration
shaft is bi-directionally rotated to obtain a vibration frequency of 1680 vibrations per minute
(28 Hz) in one rotational direction and 2160 vibrations per minute (36 Hz) with the opposite
direction of rotation.
Vibration frequency is related to the speed at which the vibration shaft is rotated and can be
measured with a frequency meter. Low frequency problems will typically appear as
machine rough riding (often referred to as tan bucking). Operation at higher than
recommended frequency will manifest as shortened vibratory sustaining life.
Vibromax No. part

VT9013
To increase or decrease the shaft speed requires more or less flow from the vibration
pump. Before making adjustments to the pump displacement controls, always check that
the engine operating speed is set to maximum (2500 rpm) and pressure test the system to
ensure that the system is operating correctly. Hydraulic pressures can be tested at taps #3
and #4 of the hydraulic test station. Start up pressure can be as high as 350 bar (5075 PSI)
but would have to drop between 100 and 150 bar (1400 and 2200 PSI) once operating
speed has been obtained.
vibration system from excessive pressure. The upper valve controls the pressure when
operating at high frequency and low amplitude. The low frequency high amplitude circuit is
controlled through the lower valve.
7-6 July 1998

LIFTING DEVICE
July 1998 7-7

DRUM REMOVAL
1. Disconnect, tag, and cap the hydraulic lines for the drum drive motor on the left side
of the machine. Plug the engine ports.
2. Disconnect, tag, and cap the hydraulic lines to the vibration motor on the correct side of
the machine. Plug the engine ports.
3. Block and support the front frame of the machine.
4. Remove the motor adapter from the drive to frame screws on the left side of the machine.
5. Take out the front and rear buffer brackets on the correct side of the machine.
6. Remove the scraper bar from the front of the machine.
7. I run or lift the drum out of the front frame. Smooth drum weight = 9,372 lbs (4,250
kg) Padfoot drum weight = 10,197 lbs (4,625 kg)
DRUM INSTALLATION
1. I run or lift the drum into position on the front frame of the machine. The drum has to
be posi- tioned for alignment of the ride motor bracket to the left side frame screw
holes.
2. Install the screws on the front and rear buffer brackets on the correct side of the
machine. This will allow the machine frame to be lowered or raised as needed to
complete alignment of the ride motor bracket on the left side of the machine.
3. Install the front scraper bar and torque the screws to 313 ft. lbs (425 Nm).
4. Tighten and torque the motor bracket and buffer bracket screws to 313 ft. lbs (425 Nm).
5. Install the hydraulic hoses on both the vibration and ride motors. NOTE: Fill all
engine ports with clean hydraulic oil prior to hose installation.
6. Start the machine engine and let the hydraulic systems develop charge pressure. Let
the engine run at low idle for several minutes without loading to fill and flush the
system.
7. On machines that have a brake on the drum drive motor it may be necessary to bleed
the brake system at the brake port of the motor.
7-8 July 1998

EXCITER HOLDING EXTRACTION

1. Remove the drum from the machine and drain the exciter oil from the shaft.
2. Remove the drum drive motor and drive plate from the left side of the drum.
3. Position the drum at its end with the vibration motor facing upwards.
Note: Smooth drum = 9372 lbs (4250 kg) Drum padfoot = 10,197 lbs (4625 kg)
4. Remove the vibration motor (21) and motor coupling (33).
5. Remove plate (9) from holding rim (8).
6. Remove capscrews (44) from the holding housing (7) and use two jacking screws to
remove the housing from the drum. NOTE: care should be taken not to damage the
exciter shaft. The exciter holding the cone will come out with the housing.
7. Remove snap ring (31) and stretch the exciter holding cone (5) with an internal puller.
8. Remove snap ring (29) from the shaft holding flange (8) and press the holding shaft out of
the housing.
9. Use an external bearing puller to remove the inner drum bearing bearing (25) and spacer.
(28) of the accommodation.
10. Remove the old face seal (26) then remove the retaining snap ring (27) for the
holding outer drum ride (24).
11. Use an external holding puller to remove the holding drum drive (24).
12. Use the exciter shaft lifting device to secure and remove the exciter shaft from the drum.
13. Place the drum back on its side and remove the exciter holding housing from the left side
of the drum.
14. Use the appropriate holding pullers to remove the exciter holding parts of the exciter
shaft and housing.
July 1998 7-9

7 - 10 July 1998
July 1998 7 - 11
7 - 12 July 1998
July 1998 7 - 13
EXCITER HOLDING ASSEMBLY

1. Clean the exciter shaft housing on the drum.
2. Heat the interior withstanding races and press to exciter shaft.
3. Install a new bearing race to the left side housing and install the housing using a new o-
ring seal.
4. Install the M24x80 capscrews using Loctite 271 and torque to 471 ft lbs. (640 Nm).
5. Position the drum on top end with the vibration motor side on top.
6. Install the exciter shaft using the appropriate lifting device to avoid shaft or bearing
damage.
7. Add 12.7 quarts (12 liter) oil to the exciter housing. CLP ALBOROTO 51517/3 (Mobil
Marcha 629)
8. Press drive bearing (24) to bearing housing (7) and install snap ring (27).
9. Install seal halves (26) to bearing housing (7) and bearing flange (8).
10. Press the holding lip (8) into the holding housing (7).
11. Flip the housing over and install the spacer (28).
12. Walk bearing press drum (25) to flange shaft (8) and install snap ring (29).
13. Press the exciter shaft holding cone into the holding housing (7) and install snap ring
(31).
14. Replaces o-ring seal (64) in bearing housing.
15. Install the drive that holds the housing to the drum and install capscrews (44) using
Loctite 271 and torque to 471 ft lbs (640 Nm).
16. Install plate (9) using capscrews (58), washers (59), and Loctite 271. Torque
capscrews at 155 ft lbs (210 Nm).
17. Installs vibration motor ride coupling (33).
18. Install a new vibration motor o-ring (23) and assemble the vibration motor using
capscrew
(56) and washer (57).
7 - 14 July 1998
SMOOTH DRUM SHAFT
July 1998 7 - 15
PADFOOT DRUM SHAFT
7 - 16 July 1998
SECTION EIGHT
STEERING SYSTEM
July 1998 8-1

SECTION EIGHT STEERING SYSTEM
SPECIAL TOOLS
8-2 July 1998

ARTICULATION JOINTS
July 1998 8 - 11
8-4 July 1998

DISASSEMBLY BOARD
1. Support the rear end of the machine's rear frame with the appropriate jack positions.
2. Support the front part of the rear frame of the machine with the appropriate jack
positions.
3. Support the roller frame from the front of the machine with the appropriate jack positions.
4. Take out the roller drum. It reminds all hydraulic lines of labels and caps.
5. Remove the hose clamps and hoses from the front drum frame.
6. Remove the breaker pins (#10) and washers (#9) from the two steering cylinder pivot pins.
7. Remove the cylinder pivot pins (#7).
8. Sling the front roller frame in preparation for removal. The roller frame weight
is 4697 lbs (2130 Kg).
9. Remove the 16mm capscrews (#21) from the retaining cover (#22).
10. Remove the retaining cover (#22), washer spring (#23), and pushed neck (#24).
11. Install a 12mm lifting eyebolt into the tapped hole provided on the link plate (#28) and
support the plate for removal.
12. Remove the ten 20mm capscrews (#25) which secure the chainring (#28) to the
steering link (#31) and remove the chainring (#28).
13. Remove holding cup (#26) from the link plate (#28) with an internal holding puller.
14. Remove the roller frame from the front of the steering link machine (#31).
15. Remove the seal rings (#14) and stretch the holding cones (#27) from the frame roller
lugs by using an external holding puller.
16. Remove capscrew (#30) from the steering link and install a 16mm lifting eyebolt and
support the link for removal. The steering link weight is 420 lbs (190 Kg).
17. Remove the lower holding cover (#19), spring washer (#18), and pushed neck (#17) by
removing capscrews (#20).
18. Remove the shift plate (#2) and hold the cover (#3) to remove the capscrews (#1).
19. Install the bushing service (see special tools) to the upper steering link holding bores.
20. Install the bearing cover (#3) over the special bushing using two M16x120 capscrews.
21. Tighten the capscrews alternately until the holding cover is drawn down to the
steering link. This will force the link up and expose the lower holding cone (#15).
July 1998 8-5

8-6 July 1998

22. Remove the seal ring from the lower bearing and use an external bearing puller to
remove the bearing cone (#15) from the lower rear frame lug.
23. Support the steering link (#31) from the bottom with a floor jack.
24. Remove the upper holding cover (#3) and the special service bushing.
25. Allow the steering link (#31) to drop down by lowering the jack under the link. Drop
the link down until the top holding cone (#5) is fully exposed.
26. Remove the seal ring (#6) and bearing cone (#5) from the rear frame upper lug.
27. With the steering the link fully lowered and the cones to hold pull pulled out the link
clears the lower rear frame lug.
28. Lift the steering link up and rear frame upper lug.
29. Remove the holding cup (#29) from the steering link (#31).
July 1998 8-7

8-8 July 1998

BOARD ASSEMBLY
NOTE: The bearings in the steering knuckle joints are designed to be assembled
without grease or other lubricants. Lubricating these bearings will actually shorten
bearing life.
1. Install holding cup (#28) to steering link (#31) until fully seated.
2. With the eyebolt inserted in place of capscrew (#30) lift the steering link up and over
the rear frame upper lug.
3. Lower the link and guide it over the lower rear frame lug.
4. Lift the link up and evenly space the link between the upper and lower lugs.
5. Install a new sealing ring (#6) to the upper link holding bores. Safe mark is pressed to
place..
6. Install the new holding cone (#5) to the rear frame upper lug.
7. Install the new holding cup (#4) to the holding bore and make sure it is fully seated.
8. Install the upper one holding cover (#3) and shift plate (#2) using Loctite 271 and
cap screws (#1). Torque The capscrews at 182 ft lbs (247 Nm).
9. Install a new sealing ring to the lowest holding bores and press into place.
10. Install a new holding cone (#15) to the lower rear frame lug.
11. Install the new holding cup (#16) to the holding bore and make sure it is fully seated.
12. Install the washer spring (#18) and thrust collar (#17) to the lowest holding deck
(#19). The washer spring the outside diameter would have to contact the pushed
neck.
13. Install the lowest holding cover using Loctite 271 on capscrews (#20) and torque
the capscrews to 182 ft lbs (247 Nm).
14. Remove the eyebolt lifter from the steering link and install capscrew (#30).
15. Install new front and rear sealing rings (#14) to frame roller lugs.
16. Install new front and rear holding cones (#27) to frame roller lugs.
17. Move the roller frame into position on the steering link. Roller frame weight = 4697 lbs
(2130 Kg). Be careful not to damage the parts to hold on.
18. Install link plate (#28) with the ten capscrews (#25) using Loctite 271 and torque
the capscrews to 297 ft lbs (402 Nm).
19. Install the holding cup (#26) to the link plate (#28) bore and make sure it is fully
seated.
July 1998 8-9

8 - 10 July 1998
20. Install the washer spring (#23) and the thrust collar (#24) to the bearing cover (#22).
The washer spring the outer diameter has to contact the pushed neck.
21. Secure the hold-down cover (#22) using Loctite 271 and capscrews (#21). Torque cap
screws to 182 ft lbs (247 Nm).
22. Install the steering cylinder pivot pins (#7) and secure with washer (#9) and split
pin (#10).
23. Position and clamp the hydraulic hoses to the appropriate locations on the frame.
24. Install the drum from the front.
25. Take out all jack positions.
July 1998 8-
11
STEERING CYLINDER
8 - 12 July 1998
SECTION NINE
CHASSIS
July 1998 9-1

SECTION NINE CHASSIS
DRUM FRAME
9-2 July 1998

REAR FRAME
July 1998 9-3

SIDE FRAME
9-4 July 1998

ENGINE COMPARTMENT DASHBOARDS
July 1998 9-5

OPERATOR PLATFORM
9-6 July 1998

ROLLOVER PROTECTIVE STRUCTURE
Torque At 303 ft lbs.

(410 Nm.)
Torque At 738 ft lbs.

(1000 Nm.)
NOTE: The fasteners used to mount the ROPS are special for this application. I use only
recommended replacement parts.
NOTE: Never modify or repair ROPS parts. Always replace damaged parts with the
appropriate new parts!
July 1998 9-7

9-8 July 1998

SECTION TEN
ANNEXES
July 1998 10 - 1
SECTION TEN ANNEXES
LEVELING BLADE
10 - 2 July 1998
SECTION TEN ANNEXES
BLADE CONTROL
July 1998 10 - 3
SECTION TEN ANNEXES
HYDRAULIC LINES SHEET
10 - 4 July 1998
Index
A AND
Accessory plug......................................3 - 35 Change of emergency stoppage........3 - 27

Alternator voltage check......................3 - 19 Engine.......................................................1 - 3
The alternators explained....................3 - 17 Engine oil specification........................1 - 19
Axis information.......................................5 - 2 Engine specifications .................. 1 - 16, 2 - 3
shaft installation......................................5 - 7 Engine warranty......................................2 - 3
Axle removal............................................5 - 6
axle tube disassembly............................5 - 8
Axles.........................................................1 - 3
F
Fluid specifications...............................1 - 17
b
Fuse location...........................................3 - 3
The batteries explained........................3 - 15

Battery diagnostics...............................3 - 16
h
Screw Torque Chart.............................1 - 13
Brake adjustment....................................6 - 9 Heater.....................................................3 - 35
Brake cylinder........................................6 - 10 Hydraulic charging system..................4 - 11
Brake change........................................3 - 27 Hydraulic cooling system.......................4 - 4
Brake, heavy duty.................................6 - 11 Hydraulic drain lines...............................4 - 6
Brakes.......................................................1 - 4 Schematic hydraulic.............................4 - 38
Hydraulic Suction Lines.........................4 - 2
Hydraulic test fittings..............................4 - 9
c
Hydraulic testing station.........................4 - 8
hydrostatic pump.....................................1 - 3
California Proposition 65 ................... 2, 1 -
1
Cargo System Diagnostics..................3 - 18
I
Cleaning parts.......................................1 - 12
Instrument panel ......................... 3 - 4, 3 - 25
d Intermediate gearbox...........................5 - 18
Diesel fuel specification.......................1 - 18

l
Differential disassembly.......................5 - 22
Differential lock removal......................5 - 12 Leveling blade.......................................10 - 2
Differential locking system...................4 - 35 Turning on circuit..................................3 - 33
ride motor.................................................1 - 3
ride motor repair....................................5 - 36 M
ride motor writes....................................4 - 13
Ride System Specifications.................1 - 16
machine components.............................1 - 6
drum ride................................................5 - 30
Machine specifications.........................1 - 15
drum motor brake....................................6 - 5
multifunction valves..............................4 - 17
Drum removal........................................5 - 29
1
Index
EITHER Towing your machine...........................4 - 31
Operational data....................................1 - 16 OR
Q Comprehensive electrical schematics .. 3 - 7
Parking brake system...........................4 - 30 V

parking brakes.........................................6 - 2
planetary assembly...............................5 - 14
Vibration amplitude explained ... 4 - 25, 7 - 5
Disassembly planetarium.....................5 - 10
Vibration circuit ............................ 3 - 29, 7 - 2
Propulsion system diagnostics...........4 - 18
Vibration diagnostics..............................7 - 6
Servo control pump...............................4 - 19
Vibration frequency...............................4 - 23
vibration pump.........................................1 - 3
R Vibration shaft bearings.........................7 - 9
Vibration shaft, drum padfoot..............7 - 16
relay location............................................3 - 3 Vibration shaft, smooth drum..............7 - 15
Relays, understanding...........................3 - 9 vibration system....................................4 - 21
Relays, Vibromax writes......................3 - 11
ROPS........................................................9 - 7 W
Yes wipers......................................................3 - 35
Work turns on........................................3 - 35
Safety, electrical rules............................1 - 9
Security, general.....................................1 - 7
Safety, machine operation.....................1 - 8
Security, maintenance............................1 - 9
Personal security.....................................1 - 7
The serial number...................................1 - 5
spark arrester...........................................1 - 7
starter Diagnostics................................3 - 21
starter Engine test.................................3 - 23
starter/Charging circuit.........................3 - 13
starters Explained.................................3 - 20
steering ...................................Cylinder 8 - 12
steering .........................................Board 8 - 3
steering .........................................Bomb 1 - 4
steering .....................................System 4 - 27
tire ballast...............................................1 - 20
torque Data............................................1 - 13
tow valve.................................................4 - 31
2
VIBROMAX Inc. of VIBROMAX GmbH
AMERICA
Erkrather Str. 343
2823 Carlisle Avenue
40231 Dusseldorf, GERMANY
Racine, WI 53404 US
Telephone: (49) 211-9866-402
Phone: 1-262-637-8111
Fax: (49) 211-9866-555
Fax: 1-262-637-8211
VIBROMAX COMPACTION EQUIPMENT GmbH

VIBROMAX COMPACTION EQUIPMENT
72, Pasir Ris
GmbH
SINGAPORE Heights
Schaeferberg 1
519279
06466 Gatersleben, GERMANY
Telephone: (65) 5838297
Telephone: (49) 39482-9331
Fax: (65) 5838301
Fax: (49) 39482-9102

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1103 ROLLER SINGLE DRUM

SERVICE MANUAL SM90001

DIFFERENTIAL LOCK SYSTEM..............................................................4 - 35

The 1103 Vibratory Roller

The 1103 uses the

The 1103 has brakes on both the front drum

Pressure testing of the 1103 has been

The electrical system of the 1103 consists

1-4 July 1998

July 1998 1-5

IDENTIFYING MACHINE COMPONENTS

1-6 July 1998

The information in this manual does

Your safety and the safety of other people

• Don't try to do too much too quickly.

July 1998 1-7

This machine uses

SAFETY, MACHINE OPERATION Operating

your machine in, over, or approaching

Operate the Sparks from the

Electrical Safety Rules

Minimum Minimum Cable

50,000 volts at 10 feet (3m) plus 1/2 10 feet (3 meters)

345,000 volts at 10 feet (3m) plus 1/2 16 feet (5 meters)

Keep your work

STANDARD TORQUE SPECIFICATIONS +/- 10%

GRADE 8.8 GRADE 10.9 GRADE 12.9

EXTENT ft-lbs Nm ft-lbs Nm ft-lbs Nm

6mm 6.6 9 9.2 12.5 11 15

8mm 16.5 22.5 23 31.5 26.5 36

12mm 57 77.5 81 110 95 130

14mm 88 120 125 170 155 210

16mm 140 190 195 265 236 320

18mm 192 260 269 365 320 435

20mm 273 370 383 520 457 620

22mm 369 500 516 700 619 840

24mm 471 640 665 900 796 1080

27mm 702 950 996 1350 1195 1620

30mm 955 1300 1328 1800 1593 2160

NUTS FOR TUBES AND HOSES

RIDE SYSTEM DATA

MINIMUM REQUIREMENTS FOR No.2 DIESEL FUEL:

Maximum cloud point -10 ° F (-23 ° C)

Cetane Number, min 40 (45 to 55 in winter or at high altitude)

DistillUnt ien temperunt ure @ 90% point 540 to 6 25 O F (282-329 O

Viscosity at 100 O F (38 O C)

Water Calcium chloride Total Mix Weight

July 1998 2-1

2-2 July 1998

CUMMINS ENGINE WARRANTY

All Cummins engines manufactured by Cummins Diesel and installed on Vibromax

* A claim is submitted to Cummins.

July 1998 2-3

2. Remove the engine compartment hood and side panels.

2-4 July 1998

5. Remove the air intake system.

9. Remove the muffler motor.

10. Disconnect the following electrical wires:

July 1998 2-5

2-6 July 1998

July 1998 3-1

FUSE FUNCTION RELAY FUNCTION

F1 Backup & Dashboard Alarm D1 Vibration delay (before JKC8300700)