1. Manuals
  2. Brands
  3. Sakai Manuals
  4. Finishers
  5. R2H-2
  6. Shop manual

Sakai R2H-2 Shop Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

R2H
-2
SHOP MANUAL
3498-66344-0

Advertisement

Table of Contents
loading

Summary of Contents for Sakai R2H-2

  • Page 1 SHOP MANUAL 3498-66344-0...
  • Page 2 Introduction This manual provides important information to familiarize you with safe operating and maintenance procedures for your SAKAI roller. Even though you may be familiar with similar equipment you must read and understand this manual before operating or servicing this unit.

  • Page 3: Table Of Contents

    ○ CONTENTS 1. SAFETY 1. GENERAL SAFETY 1-1. Understanding the Safety Symbols and Words  1-001 1-2. General  1-001 1-3. Qualifications of Operators and Maintenance Personnel  1-002 1-4. Safety Practices and Policies 1-002 1-5. Pre Start Inspection   1-003 1-6.
  • Page 4 ○ 3. PUMP MOUNT 3-1. Pump Mount   3-005 3-1-1. Installation of pump   3-006 4. HYDRAULIC SYSTEMS 1. SYSTEM CIRCUIT DIAGRAM 1-1. Graphic Symbols for Hydraulic Circuits  4-001 1-2. Hydraulic Circuit Diagram 4-003 2. PROPULSION HYDRAULIC SYSTEM 2-1.
  • Page 5 ○ 7. BRAKE 1. BRAKE PEDAL  7-001 2. BRAKE SYSTEM   7-002 8. WATER SPRAY SYSTEM 1. WATER SPRAY PIPING  8-001 9. INSPECTION AND ADJUSTMENT 1. INSPECTION AND ADJUSTMENT 1-1. Safety Precautions for Inspection and Adjustment   9-001 1-2.
  • Page 6 ○ 11. ADJUSTMENT OF F-R LEVER LINKAGE 11-1. Adjustment  9-015 10. TROUBLESHOOTING 1. TROUBLESHOOTING 1-1. Safety Precautions for Troubleshooting  1 0-001 1-2. Important Information for Troubleshooting  1 0-001 1-3. Before Starting  1 0-002 1-4. Wire Color Code and Number   1 0-002 2.
  • Page 7 ○ 2-5-3. High-beam of head lamp does not light  1 0-038 2-5-4. Turn signal light does not blink  1 0-040 2-5-5. Hazard lamp does not light (Turn signal blinks)  1 0-042 2-5-6. Backup lamp does not light   1 0-044 2-5-7.

  • Page 8: Safety

    SAFETY...

  • Page 9: General Safety

    SAFETY 1. GENERAL SAFETY 1-1. Understanding the Safety Symbols and Words The words DANGER, WARNING, and CAUTION are used with the safety-alert symbol. DANGER identifies the most serious hazard. When the symbols DANGER, WARNING and CAUTION are displayed, become alert. Your safety or those around you may be involved. NOTICE is used to provide important information that is not hazard related.

  • Page 10: Qualifications Of Operators And Maintenance Personnel

    SAFETY • The machine is designed specifically for the compaction of asphalt or soil road construction materials. Use of the machine for other purposes such as towing other equipment is considered contrary to the designated use. The manufacturer cannot be responsible or held liable for any damage resulting from such use.

  • Page 11: Pre Start Inspection

    SAFETY • Observe all safety instructions and warnings attached to the machine. • Make sure all safety instructions and warnings on the machine are complete and perfectly legible. • Stop the machine immediately in the event of any malfunction. Report any malfunction immediately to the supervisor or other person of authority.

  • Page 12: Starting

    SAFETY 1-7. Starting • Start the machine only from the driver’s seat and always wear the seat belt. • Watch that the warning lights and indicators during start-up and shutdown are working in accordance with operating instructions. • Watch that no one is in danger before starting and when moving the machine. •...

  • Page 13: Maintenance

    SAFETY • Park behind a safe barrier, use proper flags, and warning devices, especially when parking in areas of heavy traffic. 1-10. Maintenance • In any performing any work concerning the operation, adjustment or modification of the machine or it’s safety devices or any work related to maintenance, inspection or repair, always follow the start-up and shut-down procedures in the Operator’s Manual and the Maintenance Manual.
  • Page 14 Always clean up any spilled fuel. • Ensure safe operation, optimum performance of the machine and its warranty by using only genuine SAKAI replacement parts. • Use only the specified fluids and lubricants. Substitute only products known to be equivalent from reputable manufacturers.

  • Page 15: Transporting The Machine

    SAFETY • Observe all product safety regulations when handling fuel, oils, grease, engine coolant and other chemical substances. Be careful especially when these items are hot as there is a risk of burning or scalding. • Operate internal combustion engines and fuel operated heating systems only in adequately ventilated premises.

  • Page 16: Specifications

    SPECIFICATIONS...

  • Page 17: Specification Data

    SPECIFICATIONS 1. SPECIFICATION DATA 1100 3400 1000 5020 0634-99023-0-11132-0 Model Operating weight 14,345 kg 31,625 lbs. ) Weight Front axle 7,050 kg 15,540 lbs. ) Rear axle 7,295 kg 16,085 lbs. ) Overall length 5,020 mm 198 in. Overall width 2,100 mm 83 in.
  • Page 18 SPECIFICATIONS KUBOTA V3307-DI-T-KDN Diesel Engine with turbo charger Name (EPA Interim Tier4) Water-cooled, 4-cycle, 4-cylinder in-line, vertical mounted, Model overhead valve, direct-injection type Number of cylinders - Bore × Stroke 4-94 mm × 120 mm (4-3.701 in. × 4.724 in.) Displacement 3.331 L 203 cu.in...

  • Page 19: Table Of Standard Values

    SPECIFICATIONS 2. TABLE OF STANDARD VALUES 2-1. Engine Item Standard value Remarks KUBOTA V3307-DI-T-KDN Diesel Engine Engine model with turbo charger (EPA Interim Tier4) 55.4/2,200 kW/min (74/2,200 HP/rpm) Rated output (SAE J1995 JUN95 2,400 2,400 Max. rpm under no load ±...

  • Page 20: Steering

    Clearance between brake pedal and 90 mm (3.5 in.) floorboard (when pressed down) Note 2 : See dimensions R2H-2-02001 Note 3 18.5 to 19.1 mm (0.73 to 0.75 in.) Note 3 : See dimensions Propulsion motor inner brake wear limit Allowable when thickness is within this range.

  • Page 21: Fuel And Lubricants Specification

    SPECIFICATIONS 3. FUEL AND LUBRICANTS SPECIFICATION 3-1. Rating Ambient temp. and applicable viscosity rating Service Applicable -15 to 30°C 0 to 40°C 15 to 55°C Lubricant classification Standards (5 to 86°F) (32 to 104°F) (59 to 131°F) Cold Moderate Tropical Engine oil API grade CF SAE10W-30...

  • Page 22: Tightening Torque Chart

    SPECIFICATIONS 4. TIGHTENING TORQUE CHART N·m (lbf·ft) Strength Classification Nominal Pitch Dia. 10.9 12.9 (3.6) (4.4) (5.8) (5.8) (5.8) (7.2) (9.6) (9.6) 1.25 (13) (17) (23) (23) (29) (36) (44) (44) 1.75 (51) (58) (80) (80) (72) (94) (123) (123) (116) (145) (195)

  • Page 23: Engine And Controls

    ENGINE AND CONTROLS...

  • Page 24: Engine

    ENGINE AND CONTROLS 1. ENGINE 1-1. Engine Mount 9,10 DETAIL B VIEW A 0634-01806-0-11087-0 (1) Engine (6) Bracket (11) Bracket (2) Bracket (7) Bolt : M12×40 P=1.25 (12) Bolt : M14×35 P=1.5 (3) Bolt : M16×130 (8) Stopper (13) Nut : M12 P=1.25 (4) Plate (9) Bolt...

  • Page 25: Engine Exterior

    ENGINE AND CONTROLS 1-2. Engine Exterior The actual equipment may differ from that shown above. SW652-1-03001 (1) Injection pump (8) Engine oil filter (15) Oil filler cap (2) Engine stop solenoid (9) Oil pressure switch (16) Speed control lever (3) EGR valve (10) Oil drain plug (17) Fuel filter (4) Cooling fan...

  • Page 26: Control System

    ENGINE AND CONTROLS 2. CONTROL SYSTEM 2-1. Throttle Control IDLE FULL FULL IDLE SECTION A-A VIEW B-B 0634-12808-0-11079-A (1) Control cable (8) Nut : M16 (2) Lock nut : M8 (9) Washer (Apply lithium-based grease) (3) Stopper bolt (FULL) : M8×35 (10) Shaft (4) Stopper bolt (IDLE) : M8×35...

  • Page 27: Forward-Reverse Control

    ENGINE AND CONTROLS 2-2. Forward-reverse Control VIEW C-C SECTION A-A SECTION B-B 0634-12809-0-11084-A (1) F-R lever (right) (8) F-R lever switch (15) Set screw : M12×30 (2) Shaft (9) Stopper bolt (reverse) : M8×25 (16) Set screw : M12×30 (3) Rod end (10) Lock nut : M8 (17) Lock nut...

  • Page 28: Pump Mount

    ENGINE AND CONTROLS 3. PUMP MOUNT 3-1. Pump Mount SECTION B-B VIEW A 0634-36811-0-11098-0 (1) Bolt : M10×30 P=1.25 (5) Bolt : M14×40 (2) Flange (6) Pump (3) Hub (7) Bolt : M10×20 P=1.25 (4) Housing (8) Bolt : M12×35 N•m (1) Bolt M10×30 P=1.25...

  • Page 29: Installation Of Pump

    (1) Bolt M10×30 P=1.25 : 49 N·m (36 lbf·ft) N•m SECTION B-B ⑥ Ensure engagement of flange (2) with hub (3) and install R2H-2-03001 pump subassembly to engine. ⑦ Tighten with twelve bolts (7). (7) Bolt M10×20 P=1.25 : 69 N·m (51 lbf·ft).

  • Page 30: Hydraulic Systems

    HYDRAULIC SYSTEMS...

  • Page 31: System Circuit Diagram

    HYDRAULIC SYSTEMS 1. SYSTEM CIRCUIT DIAGRAM 1-1. Graphic Symbols for Hydraulic Circuits Basic Symbols Pump, Motors and Cylinders DESCRIPTION SYMBOL DESCRIPTION SYMBOL Lines: Hydraulic pumps: Fixed displacement Main working Unidirectional Pilot control Bidirectional Drain or bleed Variable displacement Lines, joining Unidirectional Not connected Bidirectional...
  • Page 32 HYDRAULIC SYSTEMS Valves Methods of Operation DESCRIPTION SYMBOL DESCRIPTION SYMBOL Spring Check valve Manual shut off (On-Off) Manual Pressure compensated Pressure relief Reversing motor Flow control, adjustable Pilot pressure: Internal supply Valve symbols: The basic valve symbol Remote supply one or more squares with lines representing Solenoid: flow paths and flow con-...

  • Page 33: Hydraulic Circuit Diagram

    HYDRAULIC SYSTEMS 1-2. Hydraulic Circuit Diagram (1/2") Propulsion motor Propulsion motor (Front, Left) (Front, Right) Drum (1/2") Drum (Front, Left) (Front, Right) 55.1/28.5 i=32.11 cc/rev 55.1/28.5 i=32.11 1.7MPa cc/rev 1.7MPa (1/4") (1/4") (1/2") Propulsion pump Steering charge pump SG5 SG4 (3/4") (3/4") (3/8") 10 m...

  • Page 34: Propulsion Hydraulic System

    HYDRAULIC SYSTEMS 2. PROPULSION HYDRAULIC SYSTEM Propulsion motor (Front, Right) Hose (PA2 2-1. Propulsion Hydraulic Piping 2-1-1. Propulsion hydraulic piping (Front 1) Hose (ML2 MRB) Hose (MR2 MLB) Hose (PB3 BV2) To propulsion hydraulic piping (Rear) Hose (PA3 BV1) SECTION C-C SECTION D-D Propulsion motor (Front, Left) Bypass valve...

  • Page 35: Propulsion Hydraulic Piping (Front 2)

    HYDRAULIC SYSTEMS 2-1-2. Propulsion hydraulic piping (Front 2) Hose Hose (MRS (PD1 Hose Hose (PC2 MRP) (PC1 MLS) To propulsion hydraulic piping (Rear) Hose Hose (MLS MRS) (MRP MLP) SECTION A-A Hose Hose (MLP Hydraulic oil tank Hose Hose (SB4 SG4) (SG5 SB3)

  • Page 36: Propulsion Hydraulic Piping (Rear)

    HYDRAULIC SYSTEMS 2-1-3. Propulsion hydraulic piping (Rear) Propulsion motor (Rear) Pipe Pipe Pipe Pipe Pipe To propulsion hydraulic piping (Front) Hose Hose Hose RMB) RMP) Hose (RMD Hose VIEW A RMS) The letters and figures (such as RMB and RB) show each port and the arrow ( ) symbols show the hose connection and the direction of the flow of the oil.

  • Page 37: Hydraulic Component Specifications

    2-2-1. Hydraulic pump assembly (propulsion + steering・charge) 1-1 1-2 1-11 1-12 1-13 1-14 1-15 1-10 1-16 1-17 1-20 1-21 1-22 1-23 VIEW A 1-19 1-18 1-11 1-15 1-20 1-21 1-19 1-17 1-18 1-16 1-10 1-6 1-8 2-2 Pump circuit diagram R2H-2-04001 4-007...
  • Page 38 HYDRAULIC SYSTEMS (1) Propulsion pump (1-1) Charge pressure gauge port (After oil filter) : 9/16-18UNF (1-2) Charge pressure gauge port (Before oil filter) : 9/16-18UNF (1-3) Servo pressure gauge port [SG4] : 9/16-18UNF (1-4) Drain port [PD1] : 1 1/16-12UN (1-5) Servo pressure gauge port [SG5] : 9/16-18UNF (1-6) Port B (Reverse)

  • Page 39: Propulsion Hydraulic Motor (Front)

    HYDRAULIC SYSTEMS 2-2-2. Propulsion hydraulic motor (front) Motor circuit diagram R2H-2-04002 (1) Port B1 : G3/4 Parking brake pilot port [MLP] : G1/4 (2) Port A1 [ML1] [MR1] : G3/4 Speed change port [MLS] [MRS] : 9/16-18UNF (3) Parking brake pilot port [MRP]...
  • Page 40 12-8 12-9 12-10 11-12 11-11 11-9 11-8 11-7 11-6 11-5 12-13 12-12 12-11 11-10 11-4 R2H-2-04003 (11) Motor (12) Reduction gear (11-1) Cylinder block kit (12-1) Floating seal kit (11-2) Roller bearing (12-2) Angular bearing (11-3) Oil seal (12-3) Shaft B...

  • Page 41: Propulsion Hydraulic Motor (Rear)

    HYDRAULIC SYSTEMS 2-2-3. Propulsion hydraulic motor (rear) 11 4 Motor circuit diagram R2H-2-04004 (1) Port B (Reverse) [RMB] : G3/4 (7) Speed change port [RMS] : G1/4 (2) Port A (Forward) [RMA] : G3/4 (8) Motor (3) Drain port [RMD] : G1/2 (9)
  • Page 42 1) Internal structure of propulsion hydraulic motor (rear) 10-1 10-2 10-3 10-4 10-5 10-6 10-7 9-12 10-9 10-8 9-11 9-10 R2H-2-04005 (9) Motor (10) Reduction gear (9-1) Cylinder block kit (10-1) Floating seal kit (9-2) Control piston (10-2) Angular bearing (9-3)

  • Page 43: Steering System

    HYDRAULIC SYSTEMS 3. STEERING SYSTEM Hose (Hydraulic oil tank 3-1. Steering Hydraulic Piping Steering Charge pump Hose Hose (AD4 (AD3 Hose Hose (AD2 CSP) AD1) Orbitrol Hose SECTION A-A SECTION B-B AD1) Hose (AD2 CSP) Hose Hose AD2) AD3) Hose Hose (AD1 AD4)

  • Page 44: Steering Wheel

    HYDRAULIC SYSTEMS 3-2. Steering Wheel 0634-32802-0-20337-A (1) Column shaft (5) Nut : M12 P=1.25 (2) Steering wheel (6) Column shaft (3) Nut : M12 P=1.25 (7) Roller chain (4) Steering wheel N•m (3) Nut M12 P=1.25 : 64 N·m ( 47 lbf·ft ) (5) Nut M12 P=1.25 : 64 N·m ( 47 lbf·ft ) •...

  • Page 45: Hydraulic Component Specifications

    HYDRAULIC SYSTEMS 3-3. Hydraulic Component Specifications 3-3-1. Orbitrol Hydraulic circuit diagram R2H-2-04006 (1) Port L : 3/4-16UNF (2) Port R : 3/4-16UNF (3) Port T : 3/4-16UNF (4) Port P : 3/4-16UNF Specifications • Displacement : 277 cm /rev ( 16.9 cu.in./rev )

  • Page 46: Frame (Center Pin)

    HYDRAULIC SYSTEMS 3-4. Frame (Center Pin) 0634-61801-0-10007-D (1) Bolt : M16×60 (5) Yoke (9) Bracket (upper) (2) Bolt : M16×80 (6) Bolt : M16×45 (10) Bracket (lower) (3) Bolt : M20×70 (7) Cover (11) O-ring (4) Swing bearing (8) Roller bearing N•m (1) Bolt M16×60 : 265 N·m ( 196 lbf·ft )

  • Page 47: Electrical System

    ELECTRICAL SYSTEM...

  • Page 48: Electrical Circuit

    ELECTRICAL SYSTEM 1. ELECTRICAL CIRCUIT 1-1. Electrical Circuit Diagram COMBNATION LAMP (R. R) TURN SIGNAL LAMP (R) (21W) FLOOD LAMP (F. R) 1.25RG 33 GY (55W) STOP LAMP (21W) TAIL LAMP (5W) COMBNATION LAMP (F. R) BACKUP LAMP (21W) TURN SIGNAL 2BrW LAMP (R) (21W) 1.25RW...

  • Page 49: Electrical Components

    ELECTRICAL SYSTEM 2. ELECTRICAL COMPONENTS Combination lamp (F. R) Flood lamp (F. R) 2-1. Electrical Component Layout (1) Licence lamp Combination lamp (R. R) Flood lamp (R. R) Thermo unit Battery Alternator Head lamp (R) Head lamp (L) Tacho meter sensor Starter motor Servo bypass solenoid Oil pressure switch...

  • Page 50: Electrical Component Layout (2)

    ELECTRICAL SYSTEM 2-2. Electrical Component Layout (2) Hazard switch Parking brake switch Flood lamp switch Speed change switch Water spray timer Lighting Lo-Hi switch Lighting switch (SEC) SPRAY PAUSE TIMER Combination meter Horn switch Water spray switch Starter switch Horn switch VIEW A Parking interlock relay Interlock relay...

  • Page 51: Electrical Component Specifications

    Lighting relay Fuse box (WL) Battery relay (BW) Starter switch (WR) Battery relay R2H-2-05001 Harness color codes BW : Black/White stripe WL : White/Blue stripe WR : White/Red stripe WY : White/Yellow stripe BY : Black/Yellow stripe WG : White/Green stripe...

  • Page 52: Combination Meter

    Glow plug indicator Hydraulic filter of connecting surfaces on the Lamp check connector side. Coolant temperature 1 Coolant temperature 2 Wire number System configuration diagram Wire color Note: The circuit in the dashed box is not mounted. R2H-2-05002 5-005...

  • Page 53: Drum

    DRUM...

  • Page 54: Precautions For Disassembly And Reassembly

    DRUM 1. PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY • When removing, installing, disassembling or reassembling the unit, observe the general precautions described below. 1) Precautions for removal work • Coolant that contains antifreeze should be treated as a chemical, and must not be drained carelessly on the ground. • To prevent dust from getting into disconnected hoses and tubes, cover them with a plug or similar means. • When draining oil, use a receptacle with sufficient capacity to receive it.
  • Page 55 DRUM 3) Precautions when work is completed • If coolant has been drained, securely retighten the drain cock and fill with coolant (mixing in long- life coolant) to the specified level. Start the engine and allow the coolant to circulate through the piping. Then add coolant again to the specified level. • If hydraulic equipment has been removed and reinstalled, fill with hydraulic oil to the specified level. Start the engine and allow the oil to circulate through the piping. Then add oil again to the specified level. 6-002...

  • Page 56: Front Drum

    DRUM 2. FRONT DRUM 0634-24831-0-10190-A (1) Drum (F. R) (5) Plate (9) Propulsion motor (F. R) (2) Drum (F. L) (6) Propulsion motor (F. L) (10) Plate (3) Bolt : M16×50 (7) Plug (11) Bolt : M8×12 (4) Bolt : M8×12 (8) Plug (12) Bolt : M16×50 N•m (3) Bolt M16×50 : 265 N·m (195 lbf·ft) (12) Bolt M16×50 : 265 N·m (195 lbf·ft) 6-003...

  • Page 57: Rear Drum

    DRUM 3. REAR DRUM 0634-27831-0-10191-B (1) Drum (R) (6) End plate (11) Propulsion motor (R) (2) Plug (7) Retaining ring (12) Bolt : M20×60 (3) Ball bearing (8) Case (13) Bolt : M20×70 (4) Bolt : M16×50 (9) Plate (Apply liquid sealant to the (5) Bolt : M12×40 (10) Bolt : M20×60 threaded area) N•m (4) Bolt M16×50 : 265 N·m (195 lbf·ft) (10) Bolt M20×60 : 539 N·m (398 lbf·ft) (12) Bolt M20×60 : 539 N·m (398 lbf·ft) (13) Bolt M20×70 : 539 N·m (398 lbf·ft) 6-004...

  • Page 58: Brake

    BRAKE...

  • Page 59: Brake Pedal

    BRAKE 1. BRAKE PEDAL Return spring Bolt: M10x40 Nut: M10 Foot brake switch Damper Bolt: M10x40 P=1.25 Rod end Nut: M10 Bolt: M10x50 SECTION A-A SECTION B-B Shaft Brake pedal 0634-51802-0-11190-0 7-001...

  • Page 60: Brake System

    (F. L) condition) Fuse Parking brake solenoid when brake is ON. (without solenoid excited) Parking brake solenoid when brake is OFF. (with solenoid excited) Charge pump The arrow ( ) symbol shows the direction of the hydraulic oil flow. R2H-2-07001 7-002...

  • Page 61: Water Spray System

    WATER SPRAY SYSTEM...

  • Page 62: Water Spray Piping

    WATER SPRAY SYSTEM 1. WATER SPRAY PIPING To water spray pipe (F) Water spray tank Filler Water spray pipe (F) Water spray pipe (F) From filter OUT Water spray pipe (R) Drain valve Nozzle Level gauge SECTION A-A VIEW C-C Hose (Water spray tank Pump)

  • Page 63: Inspection And Adjustment

    INSPECTION AND ADJUSTMENT...

  • Page 64: Safety Precautions For Inspection And Adjustment

    INSPECTION AND ADJUSTMENT 1. INSPECTION AND ADJUSTMENT 1-1. Safety Precautions for Inspection and Adjustment WARNING Unexpected machine movement may cause a serious accident. When inspecting the machine while the engine is running, always follow the instructions below. • Park the machine on level, flat ground. • Apply the parking brake. • Set chocks in front and behind each drum or tire.

  • Page 65: Measurement And Adjustment Of Propulsion Circuit Pressure

    ③ S tart the engine and set throttle lever to “Full” position. ④ E stablish a condition in which machine propulsion load becomes maximal. (Pressure does not build up unless propulsion load is applied.) R2H-2-09001 ⑤ W ith propulsion load at maximum, slowly move F-R lever to the side to be measured. • Then, read pressure indicated by pressure gauge. ⑥ A fter measuring, promptly return F-R lever to “Neutral”...

  • Page 66: Adjustment

    (3). Adjustment screw turned clockwise : Pressure rise Adjustment screw turned counterclockwise 1-23 : Pressure drop R2H-2-09002 Pressure change rate : 9 MPa/turn (1,305 psi/turn) ③  I f there is no evidence of nut having loosened, remove multifunction valve. ④  C heck removed multifunction valve for trapped dirt and scratches on its seat. ⑤  I f trapped dirt is present, disassemble and clean multifunction valve.

  • Page 67: Measurement And Adjustment Of Propulsion Charge Circuit Pressure

    • Pressure gauge : 0 to 5 MPa (0 to 725 psi) ②  A pply parking brake by pressing parking brake switch button. ③  S tart the engine and set throttle lever to “Full” position. • Then, read pressure indicated by pressure gauge. ★ Standard charge relief valve setting : 2.4 MPa (348 psi) ± 0.2 ± 29 R2H-2-09003 PG001014 • The number “1-2” appearing in above illustrations is consistent with lead line numbers shown in illustration of propulsion pump in “2-2. Hydraulic Component Specifications” (page 4-007). 9-004...

  • Page 68: Adjustment

    : Pressure rise Adjustment screw turned counterclockwise : Pressure drop Pressure change rate : 0 .39 MPa/turn (57 psi/turn) ③  I f there is no evidence of nut having loosened, remove R2H-2-09004 charge relief valve. ④  C heck removed charge relief valve for trapped dirt and scratches on its seat. ⑤  I f trapped dirt is present, disassemble and clean charge relief valve.

  • Page 69: Measurement Of Propulsion Servo Circuit Pressure

    ④ O perate F-R lever and then read pressure indicated by pressure gauge. • With parking brake “ON”, measured pressures of (1) and (2) are same. • With parking brake “OFF”, measured pressures of (1) and (2) are different. R2H-2-09016 ★ Standard charge relief pressure setting : 2.4 MPa (348 psi) ± 0.2 ±...

  • Page 70: Measurement Of Machine High/Low Speed Change Circuit Pressure

    ②  A pply parking brake by pressing parking brake switch button. ③  S et propulsion speed change switch to “ ” position. ④  S tart the engine and set throttle lever to “Full” position. • Then, read pressure indicated by pressure gauge. ★ Standard charge relief valve setting : 2.4 MPa (348 psi) ± 0.2 ± 29 Rear propulsion motor R2H-2-09005 PG002002 9-007...

  • Page 71: Measurement Of Parking Brake Release Pressure

    ⑤  R elease parking brake by pressing parking brake switch button. • Then, read brake release pressure indicated by pressure gauge. Rear propulsion motor R2H-2-09006 ★ Brake release pressure Front motor : 1.3 to 1.7 MPa (189 to 247 psi) Rear motor : 1.3 to 1.6 MPa (189 to 232 psi) PG001002 9-008...

  • Page 72: Measurement And Inspection Of Steering Circuit Pressure

    • Pressure gauge : 0 to 25 MPa (0 to 3,625 psi) ②  C onfirm that F-R lever is in “Neutral” position properly. ③  S tart the engine and set throttle lever to “Full” position. • Turn steering wheel to operate relief valve. • Then, read pressure indicated by pressure gauge. ★ Standard maximum circuit pressure (orbitroll relief pressure + charge relief pressure) : 17.6 MPa (2,552 psi) ± 1.0 ± 145 R2H-2-09007 PG002006 9-009...

  • Page 73: Inspection

    INSPECTION AND ADJUSTMENT 7-2. Inspection • If measurement results indicate the pressure deviating from standard maximum circuit pressure range, make an adjustment in accordance with procedure described below. ① Remove relief valve (2) from orbitrol. ②  C heck removed relief valve for trapped dirt, scratches on its seat and other abnormalities. ③  I f trapped dirt is present, disassemble and clean relief valve.

  • Page 74: Measurement Of Hydraulic Pump Case Pressure

    ⑤ W ith propulsion load at maximum, measure pressure when speed change switch is in “ ” and “ ” positions and F-R lever is in “neutral”, “forward”, and “reverse” positions, respectively. R2H-2-09008 ★ Allowable pump case pressure : 0.3 MPa (44 psi) or less PG002006 9-011...

  • Page 75: Measurement Of Propulsion Motor Case Pressure

    ⑤ W ith propulsion load at maximum, measure pressure when speed change switch is in “ ” and “ ” R2H-2-09009 positions and F-R lever is in “neutral”, “forward”, and “reverse” positions, respectively. ★ Allowable motor case pressure : 0.3 MPa (43.5 psi) or less...

  • Page 76: Measurement Of Rear Propulsion Motor

    ⑤ W ith propulsion load at maximum, measure pressure when speed change switch is in “ ” and “ ” positions and F-R lever is in “neutral”, “forward”, and Rear propulsion motor “reverse” positions, respectively. R2H-2-09010 ★ Allowable motor case pressure : 0.3 MPa (43.5 psi) or less PG001004 9-013...

  • Page 77: Adjustment Of Throttle Lever Linkage

    ②  A ttach control cable (4) to fuel injection pump’s control IDLE lever (8). ③ Start the engine. ④ Loosen lock nut (2). ⑤  U sing stopper bolt (IDLE) (1), adjust so that standard minimum no-load rotational speed is achieved. R2H-2-09011 ★ Standard minimum no-load rotational speed : 1,000 ± 50 ⑥  S et throttle lever (3) in maximum no-load rotational speed position. ⑦ Loosen lock nut (6).

  • Page 78: Adjustment Of F-R Lever Linkage

    • If F-R lever linkage was replaced, make an adjustment in accordance with procedure described below. • Neutral position of F-R lever (1) and maximum stroke on forward-reverse side are positioned by notches. R2H-2-09018 ① Firmly secure F-R lever in neutral position. ② Firmly secure both ends of control cable (2). ★ Specified dimension of control cable ends a : 170 mm (6.69 in.)

  • Page 79: Troubleshooting

    TROUBLESHOOTING...

  • Page 80: Safety Precautions For Troubleshooting

    TROUBLESHOOTING 1. TROUBLESHOOTING 1-1. Safety Precautions for Troubleshooting WARNING Unexpected machine movement may cause a serious accident. When inspecting the machine while the engine is running, always follow the instructions below. • Park the machine on level, flat ground. • Apply the parking brake. •...

  • Page 81: Before Starting

    TROUBLESHOOTING 1-3. Before Starting The information in this section is provided to assist the troubleshooter in understanding the systems and quickly determine the causes when operating abnormalities occur. The following steps are recommended: 1. If not familiar with the machine, study the Operator’s Manual and this Shop Manual. 2.

  • Page 82: Electrical System Troubleshooting

    TROUBLESHOOTING 2. ELECTRICAL SYSTEM TROUBLESHOOTING 2-1. When Performing Electrical System Fault Diagnosis WARNING Be very careful because equipment can return to normal during an inspection and suddenly operate properly when a failure occurs due to a faulty contact or other such cause. 2-1-1.

  • Page 83: Inspection Procedures Using A Tester

    TROUBLESHOOTING 2-1-2. Inspection procedures using a tester Some of the various inspection procedures are presented here for reference, using a sample circuit below. Equipment A Main power source Ground of Power to Signal from of equipment B equipment A equipment A equipment A Battery Equipment B...
  • Page 84 TROUBLESHOOTING 1-2) Measuring resistance of harness (measuring resistance between terminal 1 of equipment A and terminal 2 of equipment B) Connector A Harness Connector B Equipment A Equipment A Equipment B Ohmmeter (tester) Main power source Ground of Signal from Power to of equipment B equipment A...
  • Page 85 TROUBLESHOOTING 2-1) Measuring voltage of equipment A (measuring voltage between terminals 1 and 3) Equipment A Equipment A Equipment B Voltmeter (tester) Main power source Ground of Signal from Power to of equipment B equipment A equipment A equipment A Equipment B GW750‑2‑10007 Inspection procedure...
  • Page 86 TROUBLESHOOTING Measurement using a test harness Test harness Equipment A Equipment B Measurement on a lead cable Measurement from the backside of connector Test probe Wire Connector Needle Lead cable GW750‑2‑10002 Measurement method For measurement of voltage, connect the tester probes in parallel to the portion to be measured. Because the voltage can be measured only when the connector is connected in position, contact the tester probes to the terminals without disconnecting the connector.
  • Page 87 TROUBLESHOOTING 2-2) Measuring current flowing from equipment B to equipment A (measuring current between terminal 2 of equipment B and terminal 1 of equipment A) Test harness Equipment A Equipment A Equipment B Harness Ammeter (connecting (tester) terminals) Main power source Ground of Signal from Power to...

  • Page 88: Inspection Of Electrical System

    TROUBLESHOOTING 2-1-3. Inspection of electrical system Operate the applicable switches and turn the relays ON and OFF. Ultimately, if the solenoid valve operates (makes a sound) and the pump runs, the electrical system is OK. If there is a failure (fault), narrow the range of the inspection to the six broad steps described below. 1) Ground inspection •...
  • Page 89 TROUBLESHOOTING 3) Connector inspection • Is a connector disconnected or loose? • Check that pins are not snapped or corroded. • If faulty contact is suspected Turn the starter switch OFF. Then disconnect and check the connectors (including relay and switch sockets).
  • Page 90 23 1.25BR 56 1.25LW STARTER 20 3WB 9 3Lg 5 2Y 21 1.25LgR MOTOR Acc B STARTER STARTER RELAY DIODE SWITCH BATTERY RELAY 1.25LgY FUSIBLE LINK 1.25G 1.25BY 1.25GW 1.25GW 12V 115D31R DIODE DIODE FUEL BATTERY PUMP SAFETY RELAY R2H-2-10001 10-011...

  • Page 91: Engine

    TROUBLESHOOTING 2-2. Engine Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. • Check any ground circuit which belongs to components to be checked. 2-2-1. Engine will not start (Starter motor does not run) 1/3 •...
  • Page 92 23 1.25BR 56 1.25LW STARTER 20 3WB 9 3Lg 5 2Y 21 1.25LgR MOTOR Acc B STARTER STARTER RELAY DIODE SWITCH BATTERY RELAY 1.25LgY FUSIBLE LINK 1.25G 1.25BY 1.25GW 1.25GW 12V 115D31R DIODE DIODE FUEL BATTERY PUMP SAFETY RELAY R2H-2-10001 10-013...

  • Page 93: Engine Will Not Start (Starter Motor Does Not Run) 2/3

    TROUBLESHOOTING 2-2-1. Engine will not start (Starter motor does not run) 2/3 • F-R lever must be in neutral. • Parking brake switch must be applied. Reference Fig.: 2-2-1 Check point Check/Cause Action 6. F-R Lever Switch (1) When starter switch is ON, measure voltage between Replace F-R lever F-R lever switch terminal COM inlet wire WL and switch.
  • Page 94 23 1.25BR 56 1.25LW STARTER 20 3WB 9 3Lg 5 2Y 21 1.25LgR MOTOR Acc B STARTER STARTER RELAY DIODE SWITCH BATTERY RELAY 1.25LgY FUSIBLE LINK 1.25G 1.25BY 1.25GW 1.25GW 12V 115D31R DIODE DIODE FUEL BATTERY PUMP SAFETY RELAY R2H-2-10001 10-015...

  • Page 95: Engine Will Not Start (Starter Motor Does Not Run) 3/3

    TROUBLESHOOTING 2-2-1. Engine will not start (Starter motor does not run) 3/3 • F-R lever must be in neutral. • Parking brake switch must be applied. Reference Fig.: 2-2-1 Check point Check/Cause Action 9. Starter Relay (1) When starter switch is ON, measure voltage between Replace starter relay.
  • Page 96 23 1.25BR 56 1.25LW STARTER 20 3WB 9 3Lg 5 2Y 21 1.25LgR MOTOR Acc B STARTER STARTER RELAY DIODE SWITCH BATTERY RELAY 1.25LgY FUSIBLE LINK 1.25G 1.25BY 1.25GW 1.25GW 12V 115D31R DIODE DIODE FUEL BATTERY PUMP SAFETY RELAY R2H-2-10001 10-017...

  • Page 97: Engine Will Not Start (But Starter Motor Runs)

    TROUBLESHOOTING 2-2-2. Engine will not start (But starter motor runs) • In case of engine will not start while starter motor runs, generally trouble is caused by that fuel is not supplied, supply amount of fuel is extremely low, or selection of fuel is not appropriate. •...
  • Page 98 23 1.25BR 56 1.25LW STARTER 20 3WB 9 3Lg 5 2Y 21 1.25LgR MOTOR Acc B STARTER STARTER RELAY DIODE SWITCH BATTERY RELAY 1.25LgY FUSIBLE LINK 1.25G 1.25BY 1.25GW 1.25GW 12V 115D31R DIODE DIODE FUEL BATTERY PUMP SAFETY RELAY R2H-2-10001 10-019...

  • Page 99: No Charging

    TROUBLESHOOTING 2-2-4. No charging Reference Fig.: 2-2-1 Check point Check/Cause Action 1. Alternator • After starting engine, measure voltage between alternator Replace alternator or terminal B wire BR and chassis ground. battery. Standard voltage: At least intermediate engine speed, 14 V or more •...
  • Page 100 PARKING BRAKE DIODE COMBINATION SWITCH FOOT BRAKE METER (WHEN RELEASE SWITCH BRAKE) 18 BrY 42 1.25BrB 1.25BrB (WHEN NOT DEPRESS) WB (COM) LgB (NO) 17 LgB PARKING BRAKE BRAKE RELAY SOLENOID DIODE 1.25BrB SERVO BYPASS SOLENOID FUSE BOX R2H-2-10002 10-021...

  • Page 101: Propulsion

    TROUBLESHOOTING 2-3. Propulsion Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. • Check any ground circuit which belongs to components to be checked. 2-3-1. Machine moves neither forward nor backward • Parking brake switch must be released. •...
  • Page 102 PARKING BRAKE DIODE COMBINATION SWITCH FOOT BRAKE METER (WHEN RELEASE SWITCH BRAKE) 18 BrY 42 1.25BrB 1.25BrB (WHEN NOT DEPRESS) WB (COM) LgB (NO) 17 LgB PARKING BRAKE BRAKE RELAY SOLENOID DIODE 1.25BrB SERVO BYPASS SOLENOID FUSE BOX R2H-2-10002 10-023...

  • Page 103: Machine Speed Cannot Be Changed

    TROUBLESHOOTING 2-3-2. Machine speed cannot be changed • Speed change switch must be “ ”. Reference Fig.: 2-3-1 Check point Check/Cause Action 1. Speed Change Sole- • Disconnect harness and measure resistance of coil. Replace speed change noid Standard voltage : 9 Ω...
  • Page 104 PARKING BRAKE DIODE COMBINATION SWITCH FOOT BRAKE METER (WHEN RELEASE SWITCH BRAKE) 18 BrY 42 1.25BrB 1.25BrB (WHEN NOT DEPRESS) WB (COM) LgB (NO) 17 LgB PARKING BRAKE BRAKE RELAY SOLENOID DIODE 1.25BrB SERVO BYPASS SOLENOID FUSE BOX R2H-2-10002 10-025...

  • Page 105: Brake Cannot Be Released

    TROUBLESHOOTING 2-3-3. Brake cannot be released • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). Reference Fig.: 2-3-1 Check point Check/Cause Action 1. Parking Brake Solenoid • Disconnect harness and measure resistance of coil. Replace parking brake Standard voltage : 9 Ω...
  • Page 106 PARKING BRAKE DIODE COMBINATION SWITCH FOOT BRAKE METER (WHEN RELEASE SWITCH BRAKE) 18 BrY 42 1.25BrB 1.25BrB (WHEN NOT DEPRESS) WB (COM) LgB (NO) 17 LgB PARKING BRAKE BRAKE RELAY SOLENOID DIODE 1.25BrB SERVO BYPASS SOLENOID FUSE BOX R2H-2-10002 10-027...

  • Page 107: Brake Does Not Work

    TROUBLESHOOTING 2-3-4. Brake does not work • Parking brake switch must be applied. • Foot brake switch must be OFF (Brake pedal is depressed). Reference Fig.: 2-3-1 Check point Check/Cause Action 1. Parking Brake Solenoid • Disconnect harness and measure resistance of coil. Replace parking brake Standard resistance : 9 Ω...
  • Page 108 Fig. : 2-4-1 WATER SPRAY TIMER 27 LR 41 LB WATER SPRAY SWITCH 34 LY 41 3LB 19 3LW 19 3LW 41 LB 34 LY 27 LR 41 LB WATER SPRAY WATER SPRAY PUMP RELAY COMBINATION METER BATTERY RELAY R2H-2-10004 10-029...

  • Page 109: Water Sprays

    TROUBLESHOOTING 2-4. Water Sprays Check following items before troubleshooting. • No blown fuses. • Check any ground circuit which belongs to components to be checked. 2-4-1. Continuous water spray does not operate • Water spray switch must be “ON” (continuous spraying). Reference Fig.
  • Page 110 Fig. : 2-4-1 WATER SPRAY TIMER 27 LR 41 LB WATER SPRAY SWITCH 34 LY 41 3LB 19 3LW 19 3LW 41 LB 34 LY 27 LR 41 LB WATER SPRAY WATER SPRAY PUMP RELAY COMBINATION METER BATTERY RELAY R2H-2-10004 10-031...

  • Page 111: Continuous Water Spray Works, But Intermittent Water Spray Does Not

    TROUBLESHOOTING 2-4-2. Continuous water spray works, but intermittent water spray does not operate • Water spray switch must be “INT” (intermittent water spraying). Reference Fig. : 2-4-1 Check point Check/Cause Action 1. Water Spray Timer (1) When starter switch is ON, measure voltage between Replace water spray water spray timer terminal 1 inlet wire LR, terminal 3 timer.
  • Page 112 (WHEN NOT DEPRESS) LEVER WB(COM) LgB(NO) B(COM) 31 RY W(NO) REVERSE BACKUP BUZZER SWITCH HORN STARTER 13 GY 13 GY 11 Gy SWITCH 12 P 11 Gy HORN RELAY 12 P FUSE 12 P HORN SWITCH BATTERY RELAY R2H-2-10005 10-033...

  • Page 113: Lighting

    TROUBLESHOOTING 2-5. Lighting Check following item before troubleshooting. • No blown fuses and power is applied up to fuses. • When measuring voltage and current without disconnecting connectors, refer to “measuring voltage and current following using tester” (P.10-006 to P.10-008). •...
  • Page 114 (WHEN NOT DEPRESS) LEVER WB(COM) LgB(NO) B(COM) 31 RY W(NO) REVERSE BACKUP BUZZER SWITCH HORN STARTER 13 GY 13 GY 11 Gy SWITCH 12 P 11 Gy HORN RELAY 12 P FUSE 12 P HORN SWITCH BATTERY RELAY R2H-2-10005 10-035...

  • Page 115: Head Lamp, Side Marker Lamp, Tail Lamp And License Lamp Do Not

    TROUBLESHOOTING 2-5-1. Head lamp, side marker lamp, tail lamp and license lamp do not light 2/2 Reference Fig.: 2-5-1 Check point Check/Cause Action 4. Lighting Lo-Hi Switch Replace lighting Lo-Hi (1) When starter switch is ON and lighting switch is “ ”, switch.
  • Page 116 (WHEN NOT DEPRESS) LEVER WB(COM) LgB(NO) B(COM) 31 RY W(NO) REVERSE BACKUP BUZZER SWITCH HORN STARTER 13 GY 13 GY 11 Gy SWITCH 12 P 11 Gy HORN RELAY 12 P FUSE 12 P HORN SWITCH BATTERY RELAY R2H-2-10005 10-037...

  • Page 117: High-Beam Of Head Lamp Does Not Light

    TROUBLESHOOTING 2-5-2. Flood lamp does not light 2/2 Reference Fig.: 2-5-1 Check point Check/Cause Action 4. Harness Connecting Measure resistance of harness connecting between Repair or replace Between Terminals terminals. harness. Standard resistance: 10 Ω or less • If resistance is abnormal, harness is faulty. 2-5-3.
  • Page 118 (WHEN NOT DEPRESS) LEVER WB(COM) LgB(NO) B(COM) 31 RY W(NO) REVERSE BACKUP BUZZER SWITCH HORN STARTER 13 GY 13 GY 11 Gy SWITCH 12 P 11 Gy HORN RELAY 12 P FUSE 12 P HORN SWITCH BATTERY RELAY R2H-2-10005 10-039...

  • Page 119: Turn Signal Light Does Not Blink

    TROUBLESHOOTING 2-5-4. Turn signal light does not blink Reference Fig.: 2-5-1 Check point Check/Cause Action 1. Each Bulb • Check that none of lamp bulbs is burned out or has a Replace each bulb. contact failure. • Bulb is faulty or poorly connected. 2.
  • Page 120 (WHEN NOT DEPRESS) LEVER WB(COM) LgB(NO) B(COM) 31 RY W(NO) REVERSE BACKUP BUZZER SWITCH HORN STARTER 13 GY 13 GY 11 Gy SWITCH 12 P 11 Gy HORN RELAY 12 P FUSE 12 P HORN SWITCH BATTERY RELAY R2H-2-10005 10-041...

  • Page 121: Hazard Lamp Does Not Light (Turn Signal Blinks)

    TROUBLESHOOTING 2-5-5. Hazard lamp does not light (Turn signal blinks) Reference Fig.: 2-5-1 Check point Check/Cause Action 1. Each Bulb • Check that none of lamp bulbs is burned out or has a Replace each bulb. contact failure. • Bulb is faulty or poorly connected. 2.
  • Page 122 (WHEN NOT DEPRESS) LEVER WB(COM) LgB(NO) B(COM) 31 RY W(NO) REVERSE BACKUP BUZZER SWITCH HORN STARTER 13 GY 13 GY 11 Gy SWITCH 12 P 11 Gy HORN RELAY 12 P FUSE 12 P HORN SWITCH BATTERY RELAY R2H-2-10005 10-043...

  • Page 123: Backup Lamp Does Not Light

    TROUBLESHOOTING 2-5-6. Backup lamp does not light Reference Fig.: 2-5-1 Check point Check/Cause Action 1. Each Bulb • Check that none of lamp bulbs is burned out or has a Replace each bulb. contact failure. • Bulb is faulty or poorly connected. 2.
  • Page 124 LIGHTING RELAY FUSE BOX 15 BW ALTERNATOR TACHO FUEL THERMO METER UNIT UNIT PRESSURE SENSOR SWITCH 57 L 48 W FUSE 21 1.25LgR STARTER SWICTH DIODE Acc B GLOW LAMP TIMER BATTERY RELAY 1.25LgY AV60 B TO BATTERY R2H-2-10006 10-045...

  • Page 125: Illumination Of Combination Meter Does Not Turn On

    TROUBLESHOOTING 2-5-8. Illumination of combination meter does not turn on Reference Fig. : 2-5-2 Check point Check/Cause Action 1. Harness • Measure resistance between lighting switch terminal 3 Repair or replace wire RL and combination meter connector terminal wire harness. No.
  • Page 126 LIGHTING RELAY FUSE BOX 15 BW ALTERNATOR TACHO FUEL THERMO METER UNIT UNIT PRESSURE SENSOR SWITCH 57 L 48 W FUSE 21 1.25LgR STARTER SWICTH DIODE Acc B GLOW LAMP TIMER BATTERY RELAY 1.25LgY AV60 B TO BATTERY R2H-2-10006 10-047...

  • Page 127: Tachometer Reading Is Abnormal

    TROUBLESHOOTING 2-5-10. Tachometer reading is abnormal Reference Fig. : 2-5-2 Check point Check/Cause Action 1. Combination Meter (1) When starter switch is ON, measure voltage between Replace tachometer (Tachometer) combination meter terminal wires and ground terminal sensor or combination wire. meter.
  • Page 128 LIGHTING RELAY FUSE BOX 15 BW ALTERNATOR TACHO FUEL THERMO METER UNIT UNIT PRESSURE SENSOR SWITCH 57 L 48 W FUSE 21 1.25LgR STARTER SWICTH DIODE Acc B GLOW LAMP TIMER BATTERY RELAY 1.25LgY AV60 B TO BATTERY R2H-2-10006 10-049...

  • Page 129: Temperature Meter Is Abnormal

    TROUBLESHOOTING 2-5-12. Temperature meter is abnormal Reference Fig. : 2-5-2 Check point Check/Cause Action 1. Thermo Unit • Disconnect harness and measure resistance of thermo Replace thermo unit. unit. Standard resistance : 164.6 Ω [(at unit temperature of 50°C (122°F)] 26.44 Ω...
  • Page 130 LIGHTING RELAY FUSE BOX 15 BW ALTERNATOR TACHO FUEL THERMO METER UNIT UNIT PRESSURE SENSOR SWITCH 57 L 48 W FUSE 21 1.25LgR STARTER SWICTH DIODE Acc B GLOW LAMP TIMER BATTERY RELAY 1.25LgY AV60 B TO BATTERY R2H-2-10006 10-051...

  • Page 131: Charge Warning Lamp Remains On

    TROUBLESHOOTING 2-5-14. Charge warning lamp remains ON • Check with engine running. Reference Fig. : 2-5-2 Check point Check/Cause Action 1. Harness • Disconnect connectors between alternator terminal L and Repair or replace combination meter. harness. • Measure resistance between terminals and chassis ground.
  • Page 132 SWITCH LIGHTING LIGHTING SWITCH TO TURN SIGNAL RELAY LAMP (L) TO TURN SIGNAL LAMP (R) 36 Lg 44 WG 57 L 48 W FUSE FUSIBLE LINK Acc B BATTERY FUSE BOX RELAY 1.25LgR DIODE STARTER SWICTH FUSIBLE LINK R2H-2-10008 10-053...

  • Page 133: Parking Brake Indicator Lamp Does Not Light

    TROUBLESHOOTING 2-5-16. Parking brake indicator lamp does not light Reference Fig. : 2-5-3 Check point Check/Cause Action 1. Harness • Measure resistance between parking brake switch Repair or replace terminal 4 wire YL and combination meter connector harness. terminal wire No. 39 wire YL. Standard resistance : 10 Ω...
  • Page 134 41 3LB 19 3LW 19 3LW 41 LB 34 LY 27 LR 41 LB WATER SPRAY WATER SPRAY PUMP RELAY FUSE 57 L 48 W FUSE STARTER SWICTH Acc B DIODE BATTERY RELAY 1.25LgY AV60 B TO BATTERY R2H-2-10007 10-055...

  • Page 135: Water Spray Indicator Lamp Does Not Light

    TROUBLESHOOTING 2-5-17. Water spray indicator lamp does not light • Check that water spray pump can be operated. Reference Fig.: 2-5-4 Check point Check/Cause Action 1. Harness • Measure resistance between water spray relay terminal B Repair or replace wire LW and combination meter connector terminal wire harness.
  • Page 136 SWITCH LIGHTING LIGHTING SWITCH TO TURN SIGNAL RELAY LAMP (L) TO TURN SIGNAL LAMP (R) 36 Lg 44 WG 57 L 48 W FUSE FUSIBLE LINK Acc B BATTERY FUSE BOX RELAY 1.25LgR DIODE STARTER SWICTH FUSIBLE LINK R2H-2-10008 10-057...

  • Page 137: Flood Lamp Indicator Lamp Does Not Light

    TROUBLESHOOTING 2-5-18. Flood lamp indicator lamp does not light • Check that flood lamp lights. Reference Fig. : 2-5-3 Check point Check/Cause Action 1. Harness • Measure resistance between flood lamp relay terminal 5 Repair or replace wire RG and combination meter connector terminal wire harness.
  • Page 138 SWITCH LIGHTING LIGHTING SWITCH TO TURN SIGNAL RELAY LAMP (L) TO TURN SIGNAL LAMP (R) 36 Lg 44 WG 57 L 48 W FUSE FUSIBLE LINK Acc B BATTERY FUSE BOX RELAY 1.25LgR DIODE STARTER SWICTH FUSIBLE LINK R2H-2-10008 10-059...

  • Page 139: Turn Signal Indicator Lamp Does Not Light

    TROUBLESHOOTING 2-5-20. Turn signal indicator lamp does not light Reference Fig.: 2-5-3 Check point Check/Cause Action 1. Harness (1) Measure resistance between turn signal switch terminal Repair or replace wire GR (left-hand side) and combination meter harness. connector terminal wire No.26 wire GR. Standard resistance: 10 Ω...
  • Page 140 RELAY 101 GR 1.25LgY 9 3Lg 20 3WB 1.25BY 23 1.25BR 56 1.25LW 67 1.25BY 1.25P STARTER DIODE DELAY RELAY RELAY DIODE FUEL PUMP AV60 B ENGINE STOP 1.25G 1.25G SOLENOID PARKING SAFETY TO BATTERY INTERLOCK RELAY RELAY R2H-2-10009 10-061...

  • Page 141: Glow (Preheating Plug) Indicator Lamp Does Not Light

    TROUBLESHOOTING 2-5-21. Glow (Preheating plug) indicator lamp does not light Reference Fig. : 2-5-5 Check point Check/Cause Action 1. Harness (1) Measure resistance between glow lamp timer terminal 6 Repair or replace wire GL and combination meter connector terminal wire harness.
  • Page 142 (WHEN NOT DEPRESS) LEVER WB(COM) LgB(NO) B(COM) 31 RY W(NO) REVERSE BACKUP BUZZER SWITCH HORN STARTER 13 GY 13 GY 11 Gy SWITCH 12 P 11 Gy HORN RELAY 12 P FUSE 12 P HORN SWITCH BATTERY RELAY R2H-2-10005 10-063...

  • Page 143: Horn Does Not Sound

    TROUBLESHOOTING 2-5-22. Horn does not sound Reference Fig. : 2-5-1 Check point Check/Cause Action 1. Horn • Disconnect horn and directly connect battery positive Replace horn. terminal to horn terminal wire Lg side and negative terminal to horn terminal chassis ground side. •...

  • Page 144: Hydraulic System Troubleshooting

    TROUBLESHOOTING 3. HYDRAULIC SYSTEM TROUBLESHOOTING 3-1. When Performing Hydraulic System Troubleshooting • The largest factor in the majority of failures of hydraulic devices operating under conditions of higher pressure and greater precision is the entry of dirt (foreign substances) into the hydraulic circuit. Particular caution is required when supplying hydraulic oil or when disassembling and assembling hydraulic devices.

  • Page 145: Propulsion System

    TROUBLESHOOTING 3-2. Propulsion System If a problem occurs in propulsion systems such as propulsion pump, propulsion motor and brakes, determine the cause and carry out action as required, according to following general troubleshooting items. (NOTICE) • When checking whether or not the pressure is correct, refer to the pressure standard value for each hydraulic circuit.

  • Page 146: Machine Moves Neither Forward Nor Backward 2/2

    TROUBLESHOOTING 3-2-1. Machine moves neither forward nor backward 2/2 Check point Cause Check/Action 9. Propulsion Pump Discharge flow rate is insufficient due to • Measure discharge flow rate of propulsion efficiency degradation of propulsion pump. pump with flow meter. • If discharge flow rate is not within specified range, repair propulsion pump or replace it if necessary.

  • Page 147: Slow Machine Speed Or Small Drive Force 2/2

    TROUBLESHOOTING 3-2-3. Slow machine speed or small drive force 2/2 Check point Cause Check/Action 5. Propulsion Motor Propulsion motor inlet pressure is low. • Measure propulsion motor inlet pressure. • If low, check and adjust multifunction valve or replace it if necessary. Propulsion circuit pressure is not held in If pressure in propulsion motor case is not propulsion motor case.

  • Page 148: Propulsion System Is Overheating

    TROUBLESHOOTING 3-2-6. Propulsion system is overheating Check point Cause Check/Action 1. Oil Level of Oil level in hydraulic oil tank is low. Fill tank until correct oil level is obtained. Hydraulic Oil Tank 2. Oil Cooler Cooling efficiency is reduced due to clogged Clean oil cooler fins.

  • Page 149: Steering System

    TROUBLESHOOTING 3-3. Steering System If a problem occurs in steering systems such as steering pump and orbitrol, determine cause and carry out action as required, according to following general troubleshooting items. (NOTICE) • When checking whether or not the pressure is correct, refer to the pressure standard value for each hydraulic circuit.

  • Page 150: Steering Wheel Backlash Or Play Is Large

    TROUBLESHOOTING 3-3-3. Steering wheel backlash or play is large Check point Cause Check/Action 1. Steering Column Spline of column shaft or orbitrol is worn. Replace column shaft or orbitrol. Column shaft bearings are worn. Replace column shaft bearings. 2. Steering Wheel Serration (spline) of wheel or column shaft Replace wheel or column shaft.
  • Page 151 SAKAI HEAVY INDUSTRIES, LTD. Head office: Seiwa Bldg., 4-8, Shibadaimon 1-chome, Minato-ku, Tokyo, Japan Telephone: +81-3-3434-3401 Global Service Division: 2500 Takayanagi, Kuki-shi, Saitama, Japan Telephone: +81-480-52-1111 Copyright © 2011 SAKAI HEAVY INDUSTRIES, LTD. All Rights Reserved. Printed in Japan 2012.01.50.M.B 0634-99234-0-31172-E...

Table of Contents