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Sakai SV410-2 Shop Manual

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SV410
-2
SHOP MANUAL
3498-6404A-0

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Summary of Contents for Sakai SV410-2

  • Page 1 SV410 SHOP MANUAL 3498-6404A-0...
  • Page 3 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 5: Table Of Contents

    SV410 ○ 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 6 SV410 ○ 3. ENGINE AND CONTROLS 1. ENGINE 1-1. Engine Mount  3-001 1-2. Engine Exterior  3-002 2. CONTROL SYSTEM 2-1. Throttle Control   3-003 2-2. Forward-reverse Control  3-004 3. PUMP MOUNT 3-1. Pump Mount   3-005 3-2.
  • Page 7 SV410 ○ 4-2. Steering Wheel  4-020 4-3. Hydraulic Component Specifications  4-021 4-3-1. Orbitrol    4-021 4-3-2. Valve (SV410TB , FB )  4-022 4-4. Frame (Center Pin)  4-023 5. BLADE SYSTEM (SV410TB , FB 5-1. Blade Hydraulic Piping   4-024 5-2.
  • Page 8 SV410 ○ 4-10. Parking Brake Switch Harness   5-027 4-11. Front Motor Solenoid Harness   5-028 4-12. Travel Mode Select Switch Harness  5-029 5. ELECTRICAL COMPONENT SPECIFICATIONS 5-1. Fuse Box  5-030 6. VIBRATORY DRUM • REAR AXLE 1.
  • Page 9 SV410 ○ 1-3. Precautions for Inspection and Adjustment   8-001 1-4. Warm-up   8-001 1-5. Inspection and Adjustment of Engine Related Items  8-001 2. MEASUREMENT AND ADJUSTMENT OF PROPULSION CIRCUIT PRESSURE 2-1. Measurement  8-002 2-2. Adjustment   8-003 3.
  • Page 10 SV410 ○ 14. MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE 14-1. Measurement  8-024 15. ADJUSTMENT OF THROTTLE LEVER LINKAGE 15-1. Adjustment  8-025 16. ADJUSTMENT OF F-R LEVER LINKAGE 16-1. Adjustment  8-026 17. BRAKE ADJUSTMENT 17-1. Manually Releasing the Brake 8-027 17-2.
  • Page 11 SV410 ○ 2-4. Vibration  9-032 2-4-1. No vibration occurs   9-032 2-4-2. Amplitude does not change (Remains either Low or High)   9-034 2-4-3. Vibration mode cannot be switched (F-R lever vibration switch does not work)  9-036 2-5.
  • Page 12 SV410 ○ 3-4-2. Steering response is slow   9-061 3-4-3. Steering wheel backlash or play is large   9-062 3-4-4. Steering system is overheating  9-062 3-4-5. Abnormal noise from steering system  9-062 3-5. Blade (SV410TB , FB )...

  • Page 13: Safety

    SAFETY...

  • Page 15: 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 16: 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 17: 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 18: 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 19: Maintenance

    • Never fill the fuel tank with the engine running, while near an open flame or while smoking. Always clean up any spilled fuel. • Ensure safe operation, optimum performance of the machine and its warranty by using only genuine SAKAI replacement parts. 1-005...
  • Page 20 SAFETY • Use only the specified fluids and lubricants. Substitute only products known to be equivalent from reputable manufacturers. • Disconnect the battery cables when working on the electrical system or when welding on the compactor. • Be sure the battery area is well ventilated (clear of fumes) should it be necessary to connect a jumper cable or battery charger.

  • Page 21: Transporting The Machine

    SAFETY 1-11. Transporting the Machine • Use only suitable and approved trailers and haul vehicles and lifting equipment of sufficient capacity. • Entrust to experienced personnel the fastening and lifting of loads and instructing of crane operators. • Only experienced persons familiar with the operation of the machine may load and unload the machine.

  • Page 23: Specifications

    SPECIFICATIONS...

  • Page 26: Specification Data

    SPECIFICATIONS 1. SPECIFICATION DATA 1-1. SV410D 1700 2650 1410 1300 1920 4980 0404-99028-0-11650-A Model SV410D Operating weight 7,430 kg 16,380 lbs. ) Weight Front axle 3,630 kg 8,000 lbs. ) Rear axle 3,800 kg 8,380 lbs. ) Overall length 4,980 mm 196 in.
  • Page 27 SPECIFICATIONS DEUTZ TCD2011L04w Diesel Engine Name with turbocharger (EPA Tier 3) Water-cooled, 4-cycle, 4-cylinder, in-line, vertical mounted, Model overhead valve, direct injection type Bore × Stroke 96 mm × 125 mm (3.780 in. × 4.921 in.) Displacement 3.619 L 221 cu.in Rated speed 2,300 min ( 2,300 rpm...

  • Page 28: Sv410T -2

    SPECIFICATIONS 1-2. SV410T 1700 2650 1415 1920 5000 1300 0404-99030-0-11665-A Model SV410T Operating weight 7,650 kg 16,865 lbs. ) Weight Front axle 3,880 kg 8,555 lbs. ) Rear axle 3,770 kg 8,310 lbs. ) Overall length 5,000 mm 197 in. Overall width 1,920 mm 76 in.
  • Page 29 SPECIFICATIONS DEUTZ TCD2011L04w Diesel Engine Name with turbocharger (EPA Interim Tier 3) Water-cooled, 4-cycle, 4-cylinder, in-line, vertical mounted, Model overhead valve, direct injection type Bore × Stroke 96 mm × 125 mm (3.780 in. × 4.921 in.) Displacement 3.619 L 221 cu.in Rated speed 2,300 min...

  • Page 30: Sv410Tf -2

    SPECIFICATIONS 1-3. SV410TF 1700 2650 1415 1920 5000 1300 0404-99031-0-11666-A Model SV410TF Operating weight 8,840 kg 19,490 lbs. ) Weight Front axle 5,110 kg 11,265 lbs. ) Rear axle 3,730 kg 8,225 lbs. ) Overall length 5,000 mm 197 in. Overall width 1,920 mm 76 in.
  • Page 31 SPECIFICATIONS DEUTZ TCD2011L04w Diesel Engine Name with turbocharger (EPA Tier 3) Water-cooled, 4-cycle, 4-cylinder, in-line, vertical mounted, Model overhead valve, direct injection type Bore × Stroke 96 mm × 125 mm (3.780 in. × 4.921 in.) Displacement 3.619 L 221 cu.in Rated speed 2,300 min ( 2,300 rpm...

  • Page 32: Sv410Tb -2

    SPECIFICATIONS 1-4. SV410TB 1700 1265 1415 2650 5330 1300 1920 2250 0404-99038-0-11831-0 Model SV410TB Operating weight 8,050 kg 17,745 lbs. ) Weight Front axle 4,380 kg 9,655 lbs. ) Rear axle 3,670 kg 8,090 lbs. ) Overall length 5,330 mm 210 in.
  • Page 33 SPECIFICATIONS DEUTZ TCD2011L04w Diesel Engine Name with turbocharger (EPA Tier 3) Water-cooled, 4-cycle, 4-cylinder, in-line, vertical mounted, Model overhead valve, direct injection type Bore × Stroke 96 mm × 125 mm (3.780 in. × 4.921 in.) Displacement 3.619 L 221 cu.in Rated speed 2,300 min ( 2,300 rpm...

  • Page 34: Sv410Fb -2

    SPECIFICATIONS 1-5. SV410FB 1265 2650 1415 1700 1300 1920 5330 2250 0404-99039-0-11832-A Model SV410FB Operating weight 9,250 kg 20,390 lbs. ) Weight Front axle 5,630 kg 12,410 lbs. ) Rear axle 3,620 kg 7,980 lbs. ) Overall length 5,330 mm 210 in.
  • Page 35 SPECIFICATIONS DEUTZ TCD2011L04w Diesel Engine Name with turbocharger (EPA Tier 3) Water-cooled, 4-cycle, 4-cylinder, in-line, vertical mounted, Model overhead valve, direct injection type Bore × Stroke 96 mm × 125 mm (3.780 in. × 4.921 in.) Displacement 3.619 L 221 cu.in Rated speed 2,300 min ( 2,300 rpm...

  • Page 36: Table Of Standard Values

    SPECIFICATIONS 2. TABLE OF STANDARD VALUES 2-1. Engine Item Standard value Remarks DEUTZ TCD2011L04w Diesel Engine Engine model with turbocharger Rated output 74.9/2,300 kw/rpm ( 100/2,300 HP/rpm ) 2,530 Max. rpm under no load Min. rpm under no load ± 25 Cylinder head tightening torque 80 N·m 59 lbf·ft...

  • Page 37: Steering Devices

    SPECIFICATIONS 2-4. Steering Devices Item Standard value Remarks Steering wheel 5 to 10 mm ( 0.2 to 0.4 in. ) circumference Play in steering wheel Steering column shaft 0.5 mm ( 0.02 in. ) or less direction 2-5. Brakes Item Standard value Remarks Clearance between brake pedal and...

  • Page 38: 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 CH-4 SAE15W-40...

  • Page 39: 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 41: Engine And Controls

    ENGINE AND CONTROLS...

  • Page 43: Engine

    ENGINE AND CONTROLS 1. ENGINE 1-1. Engine Mount VIEW A SV400-2-03001 (1) Damper (4) Damper (2) Nut : M12 (5) Damper (3) Damper (6) Bolt : M12×100 N•m (6) Bolt M12×100 : 108 N·m ( 80 lbf·ft ) • Engine dry weight : 268 kg ( 591 lbs.

  • Page 44: Engine Exterior

    ENGINE AND CONTROLS 1-2. Engine Exterior SV400-2-03002 * The actual equipment may differ from that shown above. (1) Crankcase breather (16) Shut off lever (2) Coolant outlet from engine to cooler (17) Lube oil cooler (3) Coolant pump (18) Coolant inlet from the thermostat housing to the (4) Generator lubricating oil cooler (5) V-belts...

  • Page 45: Control System

    ENGINE AND CONTROLS 2. CONTROL SYSTEM 2-1. Throttle Control IDEL FULL IDLE FULL VIEW C SECTION B-B SECTION A-A SV400-2-03004 (1) Throttle lever (6) Lock nut (2) Control cable (7) Shaft (3) Adjusting bolt (Full) (8) Nut (4) Lock nut (9) Rod end (5) Adjusting bolt (Idle) 3-003...

  • Page 46: Forward-Reverse Control

    ENGINE AND CONTROLS 2-2. Forward-reverse Control Apply grease* VIEW B-B SECTION A-A 0404-12805-0-11624-C (1) F-R lever (6) Nut : M16 (11) Washer (Apply grease*) (2) F-R lever switch (7) Spring (Fill grease) (12) Washer (3) Backup buzzer switch (8) Steel ball (13) Nut (4) Control cable (9) Washer (Apply grease*)

  • Page 47: Pump Mount

    ENGINE AND CONTROLS 3. PUMP MOUNT 3-1. Pump Mount SECTION A-A SECTION B-B SV400-2-03006 (1) Propulsion pump (7) Housing (2) Flange (8) Hexagon socket head bolt : M10×35 (3) Hub (9) Hexagon socket head bolt : M12×35 (4) Snap ring (10) Bolt : M10×25 (5) Vibrator pump...

  • Page 48: Installation Of Pump

    ENGINE AND CONTROLS 3-2. Installation of Pump • When the pump has been removed from the engine for repair or replacement, reinstall it in accordance with the following procedure. ① Apply adequate amount of grease to pump (1) and hub (3) splines.
  • Page 49 HYDRAULIC SYSTEMS...

  • Page 52: Hydraulic Systems

    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 53 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 55: Hydraulic Circuit Diagram

    35.0 cc/rev i=6.00 Tire Low : 93.1 kN/2300vpm (9.5 ton) High : 117.7 kN/1800vpm TIRE DIA. (12 ton) 1306 (1/2") T,TF Low : 103.0 kN/2300vpm TIRE SIZE:16.9-24 6PR-OR (10.5 ton) Suction filter High : 127.5 kN/1800vpm 150mesh (13 ton) SV410-2-04004 4-003...

  • Page 57: Hydraulic Circuit Diagram

    2 3.0 MPa Vibrator motor (1/2") (3/4") (1/4") (1/2") TOTAL:i=43.72 35.0 cc/rev i=6.00 Tire Low : 103.0 kN/2300vpm (10.5 ton) High : 127.5 kN/1800vpm TIRE DIA. (13 ton) 1336 (1/2") Suction filter TIRE SIZE:16.9-24 6PR-OR 150mesh SV410-2-04005 4-004...

  • Page 59: Propulsion Hydraulic System

    HYDRAULIC SYSTEMS 2. PROPULSION HYDRAULIC SYSTEM 2-1. Propulsion Hydraulic Piping Hydraulic oil tank Hose Propulsion motor (Rear) 2-1-1. Propulsion hydraulic piping (Front) (FMD Gear box Hose Hose (VBB FMA) (RBM FMB) Propulsion motor (Front) DETAIL A The letters and figures (such as RBM and FMB) show each port and the arrow ( ) symbols show the hose connection and the direction of the flow of the oil.

  • Page 61: Propulsion Hydraulic Piping (Rear)

    HYDRAULIC SYSTEMS 2-1-2. Propulsion hydraulic piping (Rear) Hose Hose (RMD PD1) (PDC Coupling : High pressure gauge port Hydraulic oil tank Servo bypass solenoid valve Hose Hose (PPA VBP) (PPB RBP) SECTION A-A SECTION B-B Hose Hose Coupling : (BVX BV1) (VBA RMA)

  • Page 64: Hydraulic Component Specifications

    2-2-1. Hydraulic pump assembly (propulsion + vibrator • steering) (SV410D , TF 2-3 1-4 2-10 1-10 1-12 1-13 2-12 2-13 2-11 1-11 1-14 VIEW A 1-2 1-3 B N A 1-11 1-13 2-10 2-13 2-11 1-12 1-9 1-5 Pump circuit diagram SV410-2-04006 4-007...
  • Page 65 HYDRAULIC SYSTEMS (1) Propulsion pump (1-1) Multifunction valve (For port A1) (1-2) Charge pressure gauge port 7/16-20UNF (1-3) Charge supply port [PPC] : 7/ 8-14UNF (1-4) Multifunction valve (For port B1) (1-5) Port B1 (Forward) [PPB] : SAE 1’’ (1-6) Drain port [PD1] : 1 1/16-12UN (1-7) Servo pressure gauge port [SGA] :...
  • Page 66 2-2-2. Hydraulic pump assembly (propulsion + vibrator • steering) (SV410TB , TF 2-3 1-4 2-10 1-10 1-12 1-13 2-12 2-13 2-11 1-11 1-14 VIEW A 1-2 1-3 B N A 1-11 1-13 2-10 2-13 2-11 1-12 1-9 1-5 Pump circuit diagram SV410-2-04007 4-009...
  • Page 67 HYDRAULIC SYSTEMS (1) Propulsion pump (1-1) Multifunction valve (For port A1) (1-2) Charge pressure gauge port 7/16-20UNF (1-3) Charge supply port [PPC] : 7/ 8-14UNF (1-4) Multifunction valve (For port B1) (1-5) Port B1 (Forward) [PPB] : SAE 1’’ (1-6) Drain port [PD1] : 1 1/16-12UN (1-7) Servo pressure gauge port [SGA] :...

  • Page 68: Propulsion Hydraulic Motor (Front)

    HYDRAULIC SYSTEMS 2-2-3. Propulsion hydraulic motor (Front) Motor circuit diagram VIEW A SV410-2-04001 (1) Port B (Forward) [FMB] : SAE 3/4” (7) Loop flushing shuttle valve (2) Servo pressure gauge port (max.) : 9/16-18UNF (8) Charge pressure relief valve (3) Control pressure gauge port...

  • Page 69: Gear Box

    HYDRAULIC SYSTEMS 2-2-4. Gear box SV410-2-04002 (1) Gear box Specifications • Reduction ratio : 1/47.00 • Weight 90 kg ( 198 lbs. ) 4-012...
  • Page 70 1-18 1-17 1-23 1-13 1-24 1-25 1-18 1-26 1-27 1-19 1-28 1-29 1-30 1-31 1-32 1-33 SV410-2-04003 (1) Gear box (1-1) Plug : 9/16-18UNF (1-18) Plug : 9/16-18UNF (1-2) (1-19) Cover (1-3) Spacer (1-20) Pad (1-4) Plate (1-21) Shim (1-5)

  • Page 71: Propulsion Hydraulic Motor (Rear)

    HYDRAULIC SYSTEMS 2-2-5. Propulsion hydraulic motor (Rear) Motor ciruit diagram SV505- -04003 (1) Charge pressure relief valve (6) Servo pressure gauge port 9/16-18UNF (2) Pilot supply port [RMP] : 9/16-18UNF (7) Port B (Reverse) [RMB] : SAE 1” (3) Drain port [RMD] : 1 1/16-12UN (8) Port A (Forward) [RMA] : SAE 1”...

  • Page 72: Servo Bypass Solenoid Valve

    HYDRAULIC SYSTEMS 2-2-6. Servo bypass solenoid valve Hydraulic circuit diagram (＋) (−) Connection diagram K-40146 (1) Solenoid (2) O-ring (1B P14) (3) Spool (K) (4) Body (5) Spring (6) Port T : 9/16-18UNF-2B (7) Port A [SBA] : 9/16-18UNF-2B (8) Port P [SBP] : 9/16-18UNF-2B Specifications •...

  • Page 73: Vibrator Hydraulic System

    HYDRAULIC SYSTEMS 3. VIBRATOR HYDRAULIC SYSTEM 3-1. Vibrator Hydraulic Piping Hose (VPA FVB) Vibrator motor Hose (FVD Hydraulic oil tank Hose Coupling (VD2 PDV) : High pressure Hose (VPB FVA) SECTION A-A Hose (VD1 LS2) Hose Hose Coupling (LO2 (VD1 LS2) : High pressure Hose...

  • Page 75: Vibrator Hydraulic Motor

    HYDRAULIC SYSTEMS 3-2. Hydraulic Component Specification 3-2-1. Vibrator hydraulic motor 3,4,5 Hydraulic circuit diagram Flow of oil 1 Clockwise rotation 2 Counterclockwise rotation SV400-2-04012 (1) Port B [FVB] : 1 1/16-12UN (2) Port A [FVA] : 1 1/16-12UN (3) Drain port [FVD] : 7/ 8-14UNF (4) Drain port 7/ 8-14UNF...

  • Page 77: Steering Hydraulic Piping

    HYDRAULIC SYSTEMS 4. STEERING SYSTEM Hydraulic oil tank 4-1. Steering Hydraulic Piping Hose SRR) Hose Hose 4-1-1. Steering hydraulic piping (SV410D , TF SLB) (SRL (SCD Hose (SCD Hose SRR) Steering cylinder (R) Hose SLL) Hose Hose LSO) SRB) (SLR VIEW B SECTION A-A Hose...
  • Page 79 HYDRAULIC SYSTEMS 4-1-2. Steering hydraulic piping (SV410TB , FB Hydraulic oil tank Hose Hose SRR) Hose (SRL SLB) (SCD FDP) Hose (FDA Hose SRR) Steering cylinder (R) Hose SLL) Hose LSO) Hose (SLR SRB) VIEW B SECTION A-A Hose Hose (SCD FDP) (Hydraulic oil tank...
  • Page 81 HYDRAULIC SYSTEMS 4-2. Steering Wheel VIEW A-A 0404-32804-021754-Ａ (1) Column shaft (6) Bolt : M10×30 (2) Nut : M12 P=1.25 (7) Bracket (3) Steering wheel (8) Bolt : M 8×12 (4) Nut : M10 (9) Orbitrol (5) Damper N•m (2) Nut M12 P=1.25 : 35 N·m ( 26 lbf·ft ) (4) Nut M10 : 49 N·m ( 36 lbf·ft ) (6) Bolt M10×30...
  • Page 82 HYDRAULIC SYSTEMS 4-3. Hydraulic Component Specifications 4-3-1. Orbitrol Hydraulic circuit diagram SV510- -04010 (1) Port L [L] : 3/4-16UNF (2) Port R [R] : 3/4-16UNF (3) Port T [T] : 3/4-16UNF (4) Port P [P] : 3/4-16UNF Specifications • Displacement : 400 cm /rev ( 24.4 cu.in./rev ) •...
  • Page 83 HYDRAULIC SYSTEMS 4-3-2. Valve (SV410TB , FB Hydraulic circuit diagram SV412-04003 (1) Port A [FDA] : G1/2” (2) Port B [FDB] : G1/2” (3) Body (4) Spool (5) Cover (6) Spring (7) O-ring (8) Port P [FDP] : G3/4” Specifications •...
  • Page 84 HYDRAULIC SYSTEMS 4-4. Frame (Center Pin) 0402-61802-0-10059-G (1) Bolt : M16×60 (5) Swing bearing (9) Roller bearing (2) Bolt : M16×80 (6) Yoke (10) Bracket (upper) (3) Nut : M20 (7) Bolt : M16×45 (11) Bracket (lower) (4) Bolt : M20×100 (8) Cover (12) O-ring N•m...
  • Page 85 HYDRAULIC SYSTEMS 5. BLADE SYSTEM (SV410TB , FB 5-1. Blade Hydraulic Piping Hose Hose (ARD BRD) (ARU BRU) Blade cylinder (R) Hose (SVA AS1) Hydraulic oil tank Hose (SVA AS1) Hose (SVB AS2) DETAIL A SECTION B-B Valve Hose (SVB AS2) Down Neutral...
  • Page 87 HYDRAULIC SYSTEMS 5-2. Hydraulic Component Specification 5-2-1. Valve Hydraulic circuit diagram SV201-1-04010 (1) Relief valve (4) Pressure gauge port : Rc 1/4 (2) Port T [SVT] : G3/4 (5) Port B [SVB] : G1/2 (3) Port P [SVP] : G3/4 (6) Port A [SVA] : G1/2...
  • Page 89 ELECTRICAL SYSTEM...
  • Page 91 ELECTRICAL SYSTEM 1. PRECAUTIONS FOR wORk 1-1. Wire Numbers, Wire Sizes, Wire Colors and Connectors Shown in Electrical Circuit Diagram, Wiring Harness Layout and Wiring Harnesses • Codes used in electrical circuit diagrams give the following information. • The wire size is AVS 0.85 unless otherwise specified. 26 Lg 24 1.25 BR Wire color...
  • Page 92 ELECTRICAL SYSTEM • Wire color code chart Black/ Black/ Black/ Black/ Black/ Yellow/ B Black Orange White stripe Yellow stripe Red stripe Green stripe Blue stripe Orange stripe white/ white/ white/ white/ white/ Blue/ W White Red stripe Black stripe Blue stripe Yellow stripe Green stripe...
  • Page 93 ELECTRICAL SYSTEM 2. SYSTEM CIRCUIT DIAGRAM TRAVEL MODE SELECT SWITCH 2-1. Electrical Circuit Diagram POSITION MODE CONNECTION 2 GB LEFT HAND 1-2,4-6 FOOT BRAKE CENTER 1-3,4-6 SWITCH STOP 37 BrW 66 LY 36 LgR RIGHT HAND 1-3,4-5 38 GR PARKING FORWARD REVERSE BRAKE...
  • Page 95 ELECTRICAL SYSTEM 3. ELECTRICAL COMPONENTS 3-1. Battery Layout To starter motor From battery (+) SECTION A-A 0404-09813-0-11629 (1) Cord (Pump housing – Ground) (5) Cord (Battery (-) – Ground) (2) Backup buzzer (6) Battery (3) Cord (Battery relay (NO) – Starter motor (terminal 30)) (7) Starter motor (4) Cord (Battery (+) –...
  • Page 97 ELECTRICAL SYSTEM 3-2. Wiring Harness Layout – Type 1-(1) Mark G Dashboard harness Main frame harness Mark T Mark R Mark P Servo bypass solenoid Backup buzzer (LY),(B) (P.5-017) (P.5-009) DETAIL J (F-R lever vibration switch) Front motor solenoid harness (P.5-028) F-R lever switch Front motor solenoid...
  • Page 99 ELECTRICAL SYSTEM 3-3. Wiring Harness Layout – Type 1-(2) Mark K Combination meter Vibration mode change switch 1(RY),2(Y),3(RG) ENGINE WARNING lamp (YW,L) 2 WY Travel mode select switch Vibration select switch 1(L),2(G),3(WR),4(L),5(LW),6(LR) 1(Y),2(YB),4(Y),5(YR) (W  2) Mark B Travel mode select switch harness (P.5-029) Battery relay Parking brake switch...
  • Page 101 ELECTRICAL SYSTEM 3-4. Wiring Harness Layout – Type 2-(1) Mark R Mark P Servo bypass solenoid Mark G Dashboard harness Main frame harness Mark T Backup buzzer (LY),(B) (P.5-019) (P.5-011) DETAIL J (F-R lever vibration switch) Front motor solenoid harness (P.5-028) F-R lever switch Front motor solenoid...
  • Page 103 ELECTRICAL SYSTEM 3-5. Wiring Harness Layout – Type 2-(2) Mark K Combination meter Vibration mode change switch 1(RY),2(Y),3(RG) ENGINE WARNING lamp (YW,L) 2×WY Travel mode select switch Vibration select switch 1(L),2(G),3(WR),4(L),5(LW),6(LR) 1(Y),2(YB),4(Y),5(YR) (W×2) Mark B Travel mode select switch harness (P.5-029) Battery relay Parking brake switch...
  • Page 104 Corrugate Corrugate 58X-2M 5BY,200 LCR RL-1B Marking 5R,100 LCR RL-1B 2B,350 Ground bolt LA208 CB104 SWP-2F Parking brake Hydraulic oil Fusible link solenoid filter harness (P.5-023) LA205 SWP-2F 58Y-2M Starter relay SWP-8F Engine harness (type 1 only) (P.5-013) SV410-2-05010 5-009...
  • Page 105 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS A , P , R , Backup buzzer, Battery relay, Fuel unit, A , Fusible link 45A B, 2B Parking brake solenoid, Servo bypass solenoid A , Battery relay-BR A , Backup buzzer A , P A , Fusible link 75A...
  • Page 106 Starter relay Marking 5R,100 2W,100 LCR RL-1B LA205 2B,100 LA205 2B,350 Ground bolt LA208 CB104 SWP-2F Hydraulic oil Parking brake filter harness solenoid (P.5-023) Fusible link SWP-2F 58Y-2M LCR RL-1A LCR RL-1B SWP-8F Engine harness (type 2 only) (P.5-015) SV410-2-05003 5-011...
  • Page 107 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS A , P , R , Backup buzzer, Battery relay, Fuel unit, A , Hydraulic oil filter harness B, 2B Parking brake solenoid, Servo bypass solenoid, Starter relay, A , Fusible link 45A Ground bolt A , Battery relay-BR...
  • Page 108 4-2-1. Engine harness (type 1 only) Vibrator solenoid harness (P.5-022) SWP-4F Marking 58Y-2F Marking YR,50 LA104 Thermo unit SWP-8M Corrugate Corrugate Corrugate Corrugate LgB BrR LgY YR 8W,150 SWP-2M LA308 (B+) Alternator 8W,150 LA308 (B+) LgY BrR Tachometer sensor Concentrate connector SV410-2-05011 5-013...
  • Page 109 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS H × 2, P , Concentrate connector P , Concentrate connector P , Concentrate connector P × 2, Alternator × 2 P , H P , Concentrate connector P , H P , Tachometer sensor P , Thermo unit...
  • Page 110 58Y-2F Marking YR,50 SWP-8M LA104 Thermo unit Corrugate Corrugate Corrugate Corrugate LgB BrR LgY YR 8W,150 SWP-2M LA308 (B+) Alternator 8W,150 LA308 (B+) 5R,100 (50) LA304 Starter motor Corrugate 5RB,100 (30) LA308 Concentrate connector LgY BrR Tachometer sensor SV410-2-05004 5-015...
  • Page 111 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS H × 2, P , Concentrate connector P , Concentrate connector P , Concentrate connector P , Concentrate connector P , H P × 2, Alternator × 2 P , H P , Concentrate connector P , Starter motor-(50)
  • Page 112 LA208 Ground bolt 2W,110 CA104 CB104 PB104 LA108 LCR RL-1B (NO) (COM) Horn Horn ground Foot brake switch 3RG,80 LCR RL-1B Diode unit Tape Marking COIL 2BW,110 LCT RL-1A Marking COIL RY,80 LCT RL-1A SV410-2-05012 1 : Pin position 5-017...
  • Page 113 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS C , Relay box- R1 , R2 , R4 , R5 , R6 , Combination meter, Control box, 1.25LgW, LgW E , Relay box- R4 , Fuse 10A B, 2B Ground bolt, Horn ground, Orbitrol mount A , Relay box- R4...
  • Page 114 LA208 Ground bolt 2W,110 LCR RL-1B CB104 CA104 PB104 LA108 (COM) (NO) Horn Horn ground Foot brake switch 3RG,80 LCR RL-1B Diode unit Tape Marking 2BW,110 COIL LCT RL-1A Marking COIL RY,80 LCT RL-1A SV410-2-05005 1 : Pin position 5-019...
  • Page 115 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS C , Relay box- R1 , R2 , R4 , R5 , R6 , Combination meter, Control box, 1.25LgW, LgW E , Relay box- R4 , Fuse 10A B, 2B Ground bolt, Horn ground, Orbitrol mount A , Relay box- R4...
  • Page 117 LCT RL-1A Marking Dashboard Starter harness switch Tape (P.5-017,019) 2Lg,70 LA205 (C) 1.25LgW,70 LA105 (ACC) 1.25LgW 58X-3M SV410-2-05013 CONTACT SIZE, COLOR CONNECTION POINTS E , Starter switch-B E , Starter switch-BR E , Starter switch-C 2LgW E , Starter switch-ACC 5-021...
  • Page 118 4-5. Vibrator Solenoid Harness Vibrator solenoid b LA103 LA103 LA103 Marking Main frame Vibrator harness solenoid a Corrugate 7 Corrugate 7 (P.5-009,011) LA103 SWP-4M SV410-2-05014 CONTACT SIZE, COLOR CONNECTION POINTS H × 2, Vibrator solenoid-a,b H , Vibrator solenoid-a H , Vibrator solenoid-b 5-022...
  • Page 119 ELECTRICAL SYSTEM 4-6. Hydraulic Oil Filter Harness LE105 Main frame Hydraulic oil filter harness switch Tape (P.5-009,011) CA104 LE105 SV410-2-05015 CONTACT SIZE, COLOR CONNECTION POINTS Main frame harness, Hydraulic oil filter switch × 2 5-023...
  • Page 120 LA304 (50) Starter motor Starter 5RB,100 5RB,100 2100   LA308 LA308 (30) relay Tape Tape 2B,200 2B,100 LA205 LA210 Ground bolt SV410-2-05016 CONTACT SIZE, COLOR CONNECTION POINTS Starter relay, Ground bolt Starter relay, Starter motor-(50) Starter relay, Starter motor-(30) 5-024...
  • Page 121 ELECTRICAL SYSTEM 4-8. Rear Motor Solenoid Harness LA103 Marking Main frame Rear motor harness solenoid Corrugate 7 (P.5-009,011) SWP-2M LA103 SV410-2-05008 CONTACT SIZE, COLOR CONNECTION POINTS R , Rear motor solenoid R , Rear motor solenoid 5-025...
  • Page 122 Tape (P.5-017,019) Y,150 SWP-6M RY,150 Vibration mode change switch RG,150 SV410-2-05009 CONTACT SIZE, COLOR CONNECTION POINTS B , Vibration select switch-5 B , Vibration select switch-2 B , Vibration select switch-1, 4, Vibration mode change switch-2 B , Vibration mode change switch-1...
  • Page 123 BrW,150 Parking brake harness Tape switch (P.5-017,019) GR,150 SWP-6M B,150 SV410-2-05017 CONTACT SIZE, COLOR CONNECTION POINTS C , Parking brake switch-5 C , Parking brake switch-2 C , Parking brake switch-1 C , Parking brake switch-3 C , Parking brake switch-4...
  • Page 124 ELECTRICAL SYSTEM 4-11. Front Motor Solenoid Harness LA103 SWP-2F Marking Travel mode Front motor 2700 select switch solenoid Corrugate 7 harness (P.5-029) LA103 SV410-2-05007 CONTACT SIZE, COLOR CONNECTION POINTS T , Front motor solenoid T , Front motor solenoid 5-028...
  • Page 125 SWP-2M LW,150 LR,150 COIL LA210 COIL Orbitrol mounting bolt 1 : Pin position SV410-2-05006 CONTACT SIZE, COLOR CONNECTION POINTS T , R7 , Orbitrol mounting bolt K , Travel mode select switch-1,4 K , R7 , Travel mode select switch-5...
  • Page 126 (BW) (RY) Combination meter 20A 15A 15A 15A 15A 15A Starter relay Battery relay (R) (RG) Battery relay SV410-2-05018 Harness color codes : white RY : Red/Yellow stripe : Red RG : Red/Green stripe : Blue YW : Yellow/white stripe...
  • Page 127 VIBRATORY DRUM • REAR AXLE...
  • Page 129 VIBRATORY DRUM • REAR AXLE 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.
  • Page 130 VIBRATORY DRUM • REAR AXLE 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.
  • Page 131 VIBRATORY DRUM • REAR AXLE 2. VIBRATORY DRUM 2-1. Removal and Installation of Vibratory Drum 2-1-1. Removal of vibratory drum 1) Using the steering lock bar (1), connect the front and rear frames. Firmly secure it so that the front and rear frames do not move. SV400-2-06001 SV400-2-06001 2) As shown in the figure on the right, lift the rear...
  • Page 132 VIBRATORY DRUM • REAR AXLE 3) Lift the front frame with a crane. With the drum Lift with crane Lift with crane slightly above the ground surface, place support stands at the right and left sides of the front frame. Firmly secure the vehicle body. Front axle weight SV410D : 3,630 kg ( 8,003 lbs.)
  • Page 133 VIBRATORY DRUM • REAR AXLE ➁ Vibrator motor piping Disconnect the hydraulic hoses (7, 8 and 9) that are connected to the vibrator motor. Either plug both sides of disconnected connections or take other steps to prevent dust from getting inside. SV400-2-06006 SV400-2-06006 6) Lift the drum (11) with a crane.
  • Page 134 VIBRATORY DRUM • REAR AXLE 8) Place chock blocks at the front and rear of the removed drum assembly (11) to prevent the drum assembly from moving. Chock block Chock block Chock block Chock block SV400-2-06009 SV400-2-06009 6-006...
  • Page 135 VIBRATORY DRUM • REAR AXLE 2-1-2. Installation of vibratory drum 1) Install the vibratory drum in the reverse order in which it was removed. • Tightening torque for bolts in locations requiring particular attention during reinstallation of the vibratory drum: (10) M20×90: 540 N·m (398 lbf·ft) (2) M20×100: 540 N·m (398 lbf·ft) 2) When installing the vibratory drum, pay...
  • Page 137 VIBRATORY DRUM • REAR AXLE 2-2. Vibratory Drum Assembly (1) Drum (3) Vibrator bearing (4) Eccentric shaft (5) Shaft (6) Bolt (M10×40) (7) Sleeve 11 12 13 14 15 (8) Spring pin (9) Bolt (M16×50) (10) Plug (11) Housing (12) Oil seal (13) Roller bearing (14) Disc (15) Bolt (M12×40)
  • Page 139 VIBRATORY DRUM • REAR AXLE 2-3. Disassembly and Reassembly of Vibratory Drum • Leader numbers appearing in the vibratory drum disassembly and reassembly procedure illustrations shown below correspond to the numbers indicating the parts of the vibratory drum assembly (page 6-030). 2-3-1.
  • Page 140 VIBRATORY DRUM • REAR AXLE 3) Remove the two bolts (24). • Remove the vibrator motor (46). • Remove the breather (21). Use aids such as work stepladders when working, and work with a natural, unstrained posture. SV400-2-06014 SV400-2-06014 4) Remove the sixteen bolts (16). Lift with crane Lift with crane •...
  • Page 141 VIBRATORY DRUM • REAR AXLE 6) Attach the lifting bolts (M16×2.0) as shown in Lift with crane Lift with crane the figure on the right. Wooden block Wooden hammer Wooden block Wooden hammer • Using a crane, slowly lift and remove the axle shaft (32).
  • Page 142 : 2,425 kg (5,346 lbs.) SV410FB : 3,765 kg (8,300 lbs.) Inverting the drum can be dangerous work. Therefore, be very careful, confirm that the SV410-2-06001 SV410-2-06001 surrounding area is safe and work in a natural, unstrained posture. Lift with crane Lift with crane 10) Remove the seventeen bolts (40).
  • Page 143 12) Remove the sixteen bolts (34). • Remove the housing (36). Axle shaft: 100 kg (220 lbs.) SV410-2-06004 SV410-2-06004 13) The figure on the right shows the condition in which all parts have been removed from the vibratory drum assembly.
  • Page 144 VIBRATORY DRUM • REAR AXLE 15) Remove the eight bolts (23). • Remove the cover (27). SV400-2-06026 SV400-2-06026 16) Place the plate at the end of the axle shaft. with Puller Puller the puller against the housing (11), separate the housing, including the roller bearing, from the axle shaft.
  • Page 145 VIBRATORY DRUM • REAR AXLE 2-3-2. Reassembly of vibratory drum Before reassembling, confirm that each part that was disassembled has been well cleaned and is free of any abnormality. 1) Lightly apply gear oil to the press-fitting surface of the roller bearing (13) outer race. •...
  • Page 146 VIBRATORY DRUM • REAR AXLE 4) Apply an ample amount of lithium-based grease to the rolling surfaces of the roller bearing (13). • Lightly apply the same grease to the lip surfaces of the oil seal (12). • Join the axle shaft (32) subassembly and housing (11).
  • Page 147 VIBRATORY DRUM • REAR AXLE 7) Roller bearing preload adjustment ➀ Remove the four bolts (23). • Remove the cover (27) and shim (31). SV400-2-06034 SV400-2-06034 ➁ Without inserting shims, install the cover (27). Then install washers to the four bolts (23) and There must be no gap There must be no gap tighten.
  • Page 148 Drive the vibrator bearing (3) into the axle shaft (36). Axle shaft : 100 kg (220 lbs.) Vibrator bearing : 10 kg (22 lbs.) SV410-2-06007 SV410-2-06007 10) Install the O-ring (35) to the housing (36). • Lightly apply grease to the entire circumference of the O-ring (35).
  • Page 149 Propulsion motor SUBASSY : 145 kg (320 lbs.) (48) M16×50: 270 N·m (199 lbf·ft) SV410-2-06003 SV410-2-06003 12) Using the seventeen bolts (40) and washers, firmly secure the subassembly of the holder (41), damper (42) and disc (38) to the propulsion motor.
  • Page 150 VIBRATORY DRUM • REAR AXLE 14) Attach a lifting bolt (M10×1.5) to the end of the Lower with crane Lower with crane vibrator shaft (4). Then lift with a crane, slowly lower and attach. When inserting the vibrator shaft into the vibrator bearing for attachment, be careful not to allow the inner race of the vibrator bearing to lean.
  • Page 151 VIBRATORY DRUM • REAR AXLE 17) Attach a lifting bolt (M10×1.5) to the vibrator Lift with crane Lift with crane shaft end. Then slowly lift with a crane. Confirm Shaft must move 1 to 3 mm Shaft must move 1 to 3 mm that 1 to 3 mm (0.04 to 0.12 in.) of play exists in the axial direction.
  • Page 152 VIBRATORY DRUM • REAR AXLE 20) Attach the breather (21). • Attach the O-ring (25) to the vibrator motor (46). Using the two bolts (24) and washers, firmly secure it to the cover. Attach by aligning the top side of the vibrator motor (46) and breather (21) with the top side of the propulsion motor.
  • Page 153 VIBRATORY DRUM • REAR AXLE 3. AXLE 3-1. Rear Axle (SV410D (1) Tire {Tire inflation pressure: 137.34 kPa (20 psi)} (2) Nut (M22 p=1.5) 785 N·m (579 lbf·ft) (3) Hub reduction gear (4) Brake (5) Differential (6) Center housing (7) Bolt (for brake release) (8) Plug (for brake component lubrication) (9) Plug (for brake and differential component lubrication and level gauge) (10) Bolt (for brake adjustment)
  • Page 155 VIBRATORY DRUM • REAR AXLE 3-2. Rear Axle (SV410T , TF , TB , FB (1) Tire {Tire inflation pressure: 137.34 kPa (20 psi)} (2) Nut (M22 p=1.5) 785 N·m (579 lbf·ft) (3) Hub reduction gear (4) Brake (5) Differential (6) Center housing (7) Bolt (for brake release) (8) Plug (for brake component lubrication)
  • Page 157 VIBRATORY DRUM • REAR AXLE 3-3. Rear Axle Lubrication Center housing (differential + brake) Drain Hub reduction gear Supply Drain SV201-1-06094 (1) Filler port (2) Level gauge (3) Drain port • Change oil : Gear oil API-grade GL4 SAE90 (See recommended lubrication.) •...
  • Page 158 VIBRATORY DRUM • REAR AXLE 3-4. Rear Axle Structure 3-4-1. Center housing SV201-1-06095 SV201-1-06095 (1) O-ring (5) Vent (9) Snap ring (2) Cover (6) Housing (10) Magnet plug (3) Bolt (7) Plug (4) Seal washer (8) Plug 6-026...
  • Page 159 VIBRATORY DRUM • REAR AXLE 3-4-2. Differential SV400-2-06053 SV400-2-06053 (1) Cylinder bolt (6) No spin differential (11) Spacer (2) Ring nut (7) Bolt (12) Shim (3) Taper roller bearing (8) Bevel gear set (13) Shim (4) Cylinder bolt (9) Ring nut (5) Differential carrier (10) Taper roller bearing 6-027...
  • Page 160 VIBRATORY DRUM • REAR AXLE 3-4-3. Hub reduction gear SV400-2-06054 SV400-2-06054 (1) Axle case (11) Bearing (21) Seal washer (2) Spring washer (12) Circlip (22) Countersunk bolt (3) Bolt (13) Ring gear (23) Planetary gear carrier (4) Plug (14) Ring gear support (24) Nut (5) Plug (15) Lock plate...
  • Page 161 VIBRATORY DRUM • REAR AXLE 3-4-4. Brake SV412-06001 SV412-06001 (1) Spring (8) Brake disc (15) O-ring (2) O-ring (9) Ring (16) Pinion (3) Piston (10) Lock washer (17) Intermediate brake disc (4) O-ring (11) Nut (18) Disc (5) Cover (12) Adjustment bolt (19) Bolt (6) O-ring (13) Hexagon bolt...
  • Page 163 BRAkE...
  • Page 165 BRAKE 1. BRAkE SYSTEM 1-1. Brake Pedal SECTION A-A 0404-51802-0-21623-0 (1) Brake pedal (5) Return spring (2) Foot brake switch (6) Stopper bolt : M10× 40 (3) Stopper bolt : M10× 40 (7) Nut : M10 (4) Nut : M10 7-001...
  • Page 167 BRAKE 2. BRAkE HYDRAULIC PIPING Hydraulic oil tank Brake Hose RMP) (BPM Hose (RBL RBR) Hose Axle assembly (LOB BPF) Brake Hose (BSA RBL) Hydraulic oil filter 1 Parking brake solenoid valve Hose Propulsion motor (Rear) (BST The letters and figures (such as BA and BL) show each port and the arrow ( ) symbols show the hose connection and the direction of the flow of the oil.
  • Page 169 BRAKE 3. BRAkE SYSTEM Fuse Foot brake switch (Condition in which brake pedal pressed) To Parking interlock relay To combination meter Parking brake switch (Brake OFF condition) Servo bypass relay (R5) Hydraulic pump neutral holding relay (R6) Brake (Brake ON condition) Parking brake solenoid valve when brake is ON.
  • Page 170 BRAKE 4. HYDRAULIC COMPONENT SPECIFICATION 4-1. Brake Solenoid Valve Hydraulic circuit diagram (＋) (−) Connection diagram J-40146 (1) Solenoid (2) O-ring (1B P14) (3) Spool (J) (4) Body (5) Spring (6) Port P [BSP] : 9/16-18UNF-2B (7) Port A [BSA] : 9/16-18UNF-2B (8) Port T [BST] : 9/16-18UNF-2B Specifications...
  • Page 171 INSPECTION AND ADJUSTMENT...
  • Page 173 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. •...
  • Page 174 ② Set propulsion travel mode select switch to “ ”. ③ Start the engine and set throttle lever to “FULL”. ④ Establish a condition in which machine propulsion load SV410-2-08014 SV410-2-08014 becomes maximum. (Pressure does not build up unless propulsion load is applied.)
  • Page 175 (3). Adjustment screw turned clockwise : Pressure rise Adjustment screw turned counterclockwise : Pressure drop SV410-2-08002 SV410-2-08002 Pressure change rate : 9 MPa/turn (1,305 psi/turn) ③  I f there is no evidence of nut having loosened, remove multifunction valve.
  • Page 176 ② Tighten adjustment screw (2) by 1/2 complete turns. Adjustment screw turned clockwise : Pressure rise Adjustment screw turned counterclockwise : Pressure drop SV410-2-08003 SV410-2-08003 Pressure change rate : 0.54 MPa/ 1/2 turn (78.3 psi/ 1/2 turn) SV520-08004 SV520-08004 •...
  • Page 177 INSPECTION AND ADJUSTMENT 3-1. Measurement • Oil temperature during measurement : 50 °C (122 °F) ± 5 ± 9 ① Remove plug from coupling (1) of hydraulic oil filter 1. Attach pressure gauge with hose ⓢ and connector ⓤ . •...
  • Page 178 : Pressure drop Pressure change rate : 0.39 MPa/turn (57 psi/turn) ③  I f there is no evidence of nut having loosened, remove SV410-2-08004 SV410-2-08004 charge relief valve. ④  C heck removed charge relief valve for trapped dirt and scratches on its seat.
  • Page 179 INSPECTION AND ADJUSTMENT 4. MEASUREMENT OF PROPULSION SERVO CIRCUIT PRESSURE 4-1. Measurement • Oil temperature during measurement : 50 °C (122 °F) ± 5 ± 9 ① Disconnect the hoses (1) and (2) from servo bypass solenoid valve. Attach pressure gauge through adapter ⓦ . •...
  • Page 180 ③  S et propulsion travel mode select switch to “ ” or “ ”. ④  S tart the engine and set throttle lever to “FULL”. • Then, read pressure indicated by pressure gauge. SV410-2-08012 SV410-2-08012 Standard charge relief valve setting ★ : 2.5 MPa (363 psi) ±...
  • Page 181 INSPECTION AND ADJUSTMENT 5-2. Measurement of Rear Propulsion Motor • Oil temperature during measurement : 50 °C (122 °F) ± 5 ± 9 ① Remove plugs from rear propulsion motor gauge ports (1) and (2). Attach pressure gauge with the adapter ⓗ . •...
  • Page 182 INSPECTION AND ADJUSTMENT 6. MEASUREMENT OF PARkING BRAkE RELEASE PRESSURE • Since oil in charge circuit is supplied from steering circuit, confirm that steering operation is normal before measurement. 6-1. Measurement • Oil temperature during measurement : 50 °C (122 °F) ±...
  • Page 183 INSPECTION AND ADJUSTMENT 7. MEASUREMENT AND INSPECTION OF VIBRATOR CIRCUIT PRESSURE 7-1. Measurement C AUTION Take care not to operate the vibratory drum for a longer period of time than necessary with the machine stationary. Otherwise, the vibrator bearing could be seized.
  • Page 184 ⑤  A fter inspection, measure pressure again and check that pressure reaches maximum circuit pressure range. Plug : 40 N·m (30 lbf·ft) SV410-2-08005 SV410-2-08005 N•m (NOTICE) •...
  • Page 185 ① Loosen nut (2) from charge relief valve (1-10) on propulsion pump side. ② Tighten adjustment screw (3) by one complete turns. Adjustment screw turned clockwise : Pressure rise SV410-2-08004 SV410-2-08004 Adjustment screw turned counterclockwise : Pressure drop Pressure change rate : 0.78 MPa/2 turns (113 psi/2 turns)
  • Page 186 INSPECTION AND ADJUSTMENT 8-1. Measurement • Oil temperature during measurement : 50 °C (122 °F) ± 5 ± 9 ① Remove plug from coupling (1) of hydraulic oil filter 1. Attach pressure gauge with hose ⓢ and connector ⓤ . •...
  • Page 187 • To adjust pressure, loosen nut and turn adjustment screw (2). Adjustment screw turned clockwise : Pressure rise SV410-2-08003 SV410-2-08003 Adjustment screw turned counterclockwise : Pressure drop Pressure change rate : 0.27 MPa/ 1/4 turn (39.2 psi/ 1/4 turn) ③...
  • Page 188 ④ Set vibration select switch and then read pressure indicated by pressure gauge. • With vibration select switch is “ ”, measured pressures of (2-3) and (2-10) are same. SV410-2-08007 SV410-2-08007 • With vibration select switch is “ ” or “ ”, measured pressures of (2-3) and (2-10) are different.
  • Page 189 INSPECTION AND ADJUSTMENT 10. MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE 10-1. Measurement w AR N ING Make sure that there is no person around the articulated portion of the machine before operating the steering wheel. • Oil temperature during measurement : 50 °C (122 °F) ±...
  • Page 190 INSPECTION AND ADJUSTMENT 10-2. Inspection • If measurement results indicate the pressure deviating from standard maximum circuit pressure range, make an inspection 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.
  • Page 191 INSPECTION AND ADJUSTMENT 11. MEASUREMENT AND INSPECTION OF BLADE CIRCUIT PRESSURE (SV410TB , FB 11-1. Measurement w AR N ING Make sure that there is no person around the blade portion of the machine before operating the blade control lever. •...
  • Page 192 INSPECTION AND ADJUSTMENT 11-2. Inspection • If measurement results indicate the pressure deviating from standard maximum circuit pressure range, make an inspection in accordance with procedure described below. ① Remove relief valve (3) from stack valve. ② Check removed relief valve for trapped dirt, scratches on its seat and other abnormalities.
  • Page 193 INSPECTION AND ADJUSTMENT 12. MEASUREMENT OF HYDRAULIC PUMP CASE PRESSURE 12-1. Measurement • Oil temperature during measurement : 50 °C (122 °F) ± 5 ± 9 ① Disconnect hose (1) from propulsion pump. Attach pressure gauge through adapter ⓚ . •...
  • Page 194 ⑤ With propulsion load at maximum, measure pressure when travel mode select switch is “ ”, “ ” and “ ” and F-R lever is “N”, “F”, and “R”, respectively. SV410-2-08001 SV410-2-08001 Allowable motor case pressure ★ : 0.3 MPa (43.5 psi) or less PG001027...
  • Page 195 INSPECTION AND ADJUSTMENT 13-2. Measurement of Rear Propulsion Motor • Oil temperature during measurement : 50 °C (122 °F) ± 5 ± 9 ① Remove plug from drain port (1). Attach pressure gauge and adapter ⓩ . • Adapter ⓩ : 1 1/16-12UN •...
  • Page 196 INSPECTION AND ADJUSTMENT 14. MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE 14-1. Measurement CAU T ION Take care not to operate the vibratory drum for a longer period of time than necessary with the machine stationary. Otherwise, the vibrator bearing could be seized.
  • Page 197 Standard minimu m no-load rotational speed ★ : 750 ± 25 ⑦ Using lock nut (3), firmly secure stopper bolt (4). SV410-2-08008 SV410-2-08008 ⑧ Set throttle lever (1) to “FULL”. ⑨ Loosen lock nut (5). ⑩ Using stopper bolt (6), adjust so that standard maximum...
  • Page 198 ① Set F-R lever in “N”. ② Attach both ends of control cable (2). Specified dimension a : 239 mm (9.41 in.) ★ SV410-2-08010 SV410-2-08010 ③ Confirm the strokes of propulsion pump control lever (3). Specified dimension b : 208 mm ( 8.19 in.) ★...
  • Page 199 INSPECTION AND ADJUSTMENT 17. BRAkE ADJUSTMENT 17-1. Manually Releasing the Brake 1)  L oosen nut (24) of bolt (25). • Loosen nut on the opposite side. 24 25 24 25 SV510- -08027 SV510- -08027 2) Tighten bolt (25), and press it into disc (16). •...
  • Page 200 INSPECTION AND ADJUSTMENT 17-2. Adjustment after Manual Release of Brake ① Remove bolt (25), nut (24), and seal washer (26). ②  R eplace seal washer (26) with a new one. ③ Apply grease to bolt (25) threads. ④  A s shown on the right, install bolt (25), nut (24), and seal washer (26).
  • Page 201 INSPECTION AND ADJUSTMENT 17-3. Brake Clearance Adjustment • Remove bolt (2) and lock plate (3). • Rotate adjustment pinion (4) counterclockwise to eliminate all existing clearance between braking discs. Rotate up to a torque of 8 to 10 N·m (5.9 to 7.4 lbf·ft) N•m SV510- -08026 SV510- -08026...
  • Page 203 TROUBLESHOOTING...
  • Page 205 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 206 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 207 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 208 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 Signal from Power to of equipment B equipment A equipment A equipment A Battery Equipment B...
  • Page 209 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 210 TROUBLESHOOTING 2) Measuring voltage and current flowing using tester 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...
  • Page 211 TROUBLESHOOTING Measurement using a test harness Test harness Equipment A Equipment B Measurement from the backside of connector Measurement on a lead cable 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 212 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 213 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 214 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 216 16 2W X 2B STARTER RELAY 95E41R BATTERY (N100) STARTER AV60 MOTOR 15 5RB AV60 NEGATIVE TORQUE CONTROL SOLENOID show the engine concentration connector, and the number in the shows the terminal number of the engine concentration connector. SV410-2-09001 9-011...
  • Page 217 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. • Engine warning lamp must not be lighting. If lamp lights, refer to “workshop manual” of engine manufacturer. 2-2-1.
  • Page 218 16 2W X 2B STARTER RELAY 95E41R BATTERY (N100) STARTER AV60 MOTOR 15 5RB AV60 NEGATIVE TORQUE CONTROL SOLENOID show the engine concentration connector, and the number in the shows the terminal number of the engine concentration connector. SV410-2-09001 9-013...
  • Page 219 TROUBLESHOOTING 2-2-1. Engine will not start (Starter motor does not run) 2/3 • F-R lever must be “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). Reference Fig.: 2-2-1 Check point Check/Cause Action...
  • Page 220 16 2W X 2B STARTER RELAY 95E41R BATTERY (N100) STARTER AV60 MOTOR 15 5RB AV60 NEGATIVE TORQUE CONTROL SOLENOID show the engine concentration connector, and the number in the shows the terminal number of the engine concentration connector. SV410-2-09001 9-015...
  • Page 221 TROUBLESHOOTING 2-2-1. Engine will not start (Starter motor does not run) 3/3 • F-R lever must be “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). Reference Fig.: 2-2-1 Check point Check/Cause Action...
  • Page 222 16 2W X 2B STARTER RELAY 95E41R BATTERY (N100) STARTER AV60 MOTOR 15 5RB AV60 NEGATIVE TORQUE CONTROL SOLENOID show the engine concentration connector, and the number in the shows the terminal number of the engine concentration connector. SV410-2-09001 9-017...
  • Page 223 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 224 16 2W X 2B STARTER RELAY 95E41R BATTERY (N100) STARTER AV60 MOTOR 15 5RB AV60 NEGATIVE TORQUE CONTROL SOLENOID show the engine concentration connector, and the number in the shows the terminal number of the engine concentration connector. SV410-2-09001 9-019...
  • Page 225 TROUBLESHOOTING 2-2-5. Starter motor runs even when F-R lever is not at “N” and parking brake is not applied Reference Fig.: 2-2-1 Check point Check/Cause Action 1. F-R Lever Switch • when starter switch is OFF and F-R lever is “F” or “R”, Replace F-R lever check continuity between F-R lever switch terminal COM switch.
  • Page 226 77 5BW 4 5BY 4 5BY F.L. 75A 24 BR 61 8W 74 8WY F.L. 75A ALTERNATOR 61 8W 74 8WY STARTER STARTER SWITCH SWITCH AV60 AV60 TO STARTER MOTOR 24 BR BATTERY RELAY 95E41R BATTERY (N100) AV60 SV410-2-09002 9-021...
  • Page 227 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 1/2 • Parking brake switch must be released.
  • Page 228 77 5BW 4 5BY 4 5BY F.L. 75A 24 BR 61 8W 74 8WY F.L. 75A ALTERNATOR 61 8W 74 8WY STARTER STARTER SWITCH SWITCH AV60 AV60 TO STARTER MOTOR 24 BR BATTERY RELAY 95E41R BATTERY (N100) AV60 SV410-2-09002 9-023...
  • Page 229 TROUBLESHOOTING 2-3-1. Machine moves neither forward nor backward 2/2 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • F-R lever must not be “N”. Reference Fig.: 2-3-1 Check point Check/Cause Action 5.
  • Page 230 77 5BW 4 5BY 4 5BY F.L. 75A 24 BR 61 8W 74 8WY F.L. 75A ALTERNATOR 61 8W 74 8WY STARTER STARTER SWITCH SWITCH AV60 AV60 TO STARTER MOTOR 24 BR BATTERY RELAY 95E41R BATTERY (N100) AV60 SV410-2-09002 9-025...
  • Page 231 TROUBLESHOOTING 2-3-2. Travel mode cannot be changed 1/2 • No blown fuses and power is applied up to fuses. • Check any ground circuit which belongs to components to be checked. Reference Fig.: 2-3-1 Check point Check/Cause Action 1. Front Motor Solenoid •...
  • Page 232 77 5BW 4 5BY 4 5BY F.L. 75A 24 BR 61 8W 74 8WY F.L. 75A ALTERNATOR 61 8W 74 8WY STARTER STARTER SWITCH SWITCH AV60 AV60 TO STARTER MOTOR 24 BR BATTERY RELAY 95E41R BATTERY (N100) AV60 SV410-2-09002 9-027...
  • Page 233 TROUBLESHOOTING 2-3-2. Travel mode cannot be changed 2/2 • No blown fuses and power is applied up to fuses. • Check any ground circuit which belongs to components to be checked. Reference Fig.: 2-3-1 Check point Check/Cause Action 4. Travel Mode Select (1) when starter switch is ON, measure voltage between Replace travel mode Switch...
  • Page 234 77 5BW 4 5BY 4 5BY F.L. 75A 24 BR 61 8W 74 8WY F.L. 75A ALTERNATOR 61 8W 74 8WY STARTER STARTER SWITCH SWITCH AV60 AV60 TO STARTER MOTOR 24 BR BATTERY RELAY 95E41R BATTERY (N100) AV60 SV410-2-09002 9-029...
  • Page 235 TROUBLESHOOTING 2-3-3. 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 : 12.3 Ω...
  • Page 236 F.L. 65A 77 5BW 4 5BY 4 5BY 24 BR STARTER STARTER SWITCH SWITCH 14 5R 15 5RB 16 2W X 2B STARTER RELAY STARTER MOTOR 15 5RB AV60 AV60 AV60 24 BR BATTERY RELAY 95E41R BATTERY (N100) AV60 SV410-2-09003 9-031...
  • Page 237 TROUBLESHOOTING 2-4. Vibration 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. 2-4-1. No vibration occurs • Vibration mode change switch must be “CONT” (continuous mode). •...
  • Page 238 F.L. 65A 77 5BW 4 5BY 4 5BY 24 BR STARTER STARTER SWITCH SWITCH 14 5R 15 5RB 16 2W X 2B STARTER RELAY STARTER MOTOR 15 5RB AV60 AV60 AV60 24 BR BATTERY RELAY 95E41R BATTERY (N100) AV60 SV410-2-09003 9-033...
  • Page 239 TROUBLESHOOTING 2-4-2. Amplitude does not change (Remains either Low or High) • Vibration mode change switch must be “CONT” (continuous mode). Reference Fig.: 2-4-1 Check point Check/Cause Action 1. Vibrator Solenoid • Disconnect harness and measure resistance of coil. Replace vibrator Standard resistance : 5.1 Ω...
  • Page 240 F.L. 65A 77 5BW 4 5BY 4 5BY 24 BR STARTER STARTER SWITCH SWITCH 14 5R 15 5RB 16 2W X 2B STARTER RELAY STARTER MOTOR 15 5RB AV60 AV60 AV60 24 BR BATTERY RELAY 95E41R BATTERY (N100) AV60 SV410-2-09003 9-035...
  • Page 241 TROUBLESHOOTING 2-4-3. Vibration mode cannot be switched (F-R lever vibration switch does not work) • Vibration mode change switch to “ ” (manual mode). • Vibration select switch must not be “ ”. Reference Fig.: 2-4-1 Check point Check/Cause Action 1.
  • Page 242 AV60 TO STARTER MOTOR 24 BR CONTROL BATTERY RELAY ENGINE OIL PRESSURE SWITCH TACHOMETER SENSOR 95E41R BATTERY (N100) AV60 show the engine concentration connector, and the number in the shows the terminal number of the engine concentration connector. SV410-2-09004 9-037...
  • Page 243 TROUBLESHOOTING 2-5. Lighting Check following items before troubleshooting. • No blown fuse 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. 9-006 to P. 9-008). •...
  • Page 244 AV60 TO STARTER MOTOR 24 BR CONTROL BATTERY RELAY ENGINE OIL PRESSURE SWITCH TACHOMETER SENSOR 95E41R BATTERY (N100) AV60 show the engine concentration connector, and the number in the shows the terminal number of the engine concentration connector. SV410-2-09004 9-039...
  • Page 245 TROUBLESHOOTING 2-5-2. Combination meter warning lamp or indicator lamp is abnormal 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 (charge warning lamp, engine oil pressure warning lamp, hydraulic oil filter warning lamp and parking brake indicator lamp).
  • Page 246 AV60 TO STARTER MOTOR 24 BR CONTROL BATTERY RELAY ENGINE OIL PRESSURE SWITCH TACHOMETER SENSOR 95E41R BATTERY (N100) AV60 show the engine concentration connector, and the number in the shows the terminal number of the engine concentration connector. SV410-2-09004 9-041...
  • Page 247 TROUBLESHOOTING 2-5-3. Tachometer reading is abnormal Reference Fig.: 2-5-1 Check point Check/Cause Action 1. Tachometer Sensor • Start engine and fix engine speed at 1,000 rpm. Measure Replace tachometer pulse between tachometer sensor terminal wire No. 63 sensor. outlet wire BrR and ground terminal wire LgY. Standard pulse : 110,011/min.
  • Page 248 AV60 TO STARTER MOTOR 24 BR CONTROL BATTERY RELAY ENGINE OIL PRESSURE SWITCH TACHOMETER SENSOR 95E41R BATTERY (N100) AV60 show the engine concentration connector, and the number in the shows the terminal number of the engine concentration connector. SV410-2-09004 9-043...
  • Page 249 TROUBLESHOOTING 2-5-5. Temperature meter is abnormal Reference Fig.: 2-5-1 Check point Check/Cause Action 1. Thermo Unit • Disconnect harness and measure resistance of thermo Replace thermo unit. unit. Standard resistance : 153.9 Ω [(at unit temperature of 50°C (122°F)] 24.9 Ω [(at unit temperature of 103°C (217°F)] •...
  • Page 250 AV60 TO STARTER MOTOR 24 BR CONTROL BATTERY RELAY ENGINE OIL PRESSURE SWITCH TACHOMETER SENSOR 95E41R BATTERY (N100) AV60 show the engine concentration connector, and the number in the shows the terminal number of the engine concentration connector. SV410-2-09004 9-045...
  • Page 251 TROUBLESHOOTING 2-5-7. Hydraulic oil filter warning lamp remains ON Reference Fig.: 2-5-1 Check point Check/Cause Action 1. Hydraulic Oil Filter • when starter switch is OFF, check continuity between Replace hydraulic oil Switch 1 or 2 hydraulic oil filter switch 1 or 2 inlet terminal and chassis filter switch 1 or 2.
  • Page 252 TO STARTER MOTOR 10 YB 24 BR 81 RG 30 RY BATTERY 11 Y RELAY VIBRATION MODE F-R LEVER CHANGE SWITCH VIBRATION SWITCH HIGH 9 YR 11 Y 95E41R BATTERY 10 YB (N100) VIBRATION SELECT AV60 SWITCH VIBRATOR SOLENOID SV410-2-09005 9-047...
  • Page 253 TROUBLESHOOTING 2-5-9. Vibration indicator lamp does not light • Check that vibrator can be operated. Reference Fig.: 2-5-2 Check point Check/Cause Action 1. Bulb • Check if bulb has burned out or is poorly contacted. Replace bulb. • Bulb is faulty or poorly connected. 2.
  • Page 254 TO STARTER MOTOR 10 YB 24 BR 81 RG 30 RY BATTERY 11 Y RELAY VIBRATION MODE F-R LEVER CHANGE SWITCH VIBRATION SWITCH HIGH 9 YR 11 Y 95E41R BATTERY 10 YB (N100) VIBRATION SELECT AV60 SWITCH VIBRATOR SOLENOID SV410-2-09005 9-049...
  • Page 255 TROUBLESHOOTING 2-5-10. Parking brake indicator lamp does not light Reference Fig.: 2-5-2 Check point Check/Cause Action 1. Bulb • Check if bulb has burned out or is poorly contacted. Replace bulb. • Bulb is faulty or poorly connected. 2. Parking Brake Switch •...
  • Page 256 34 LgW 30 1.25RY 33 Lg 30 RY HORN RELAY (R3) 33 Lg HORN SWITCH FUSE BOX 4 5BY 24 BR STARTER STARTER SWITCH SWITCH ALTERNATOR AV60 AV60 TO STARTER MOTOR 24 BR BATTERY RELAY 95E41R BATTERY (N100) AV60 SV410-2-09006 9-051...
  • Page 257 TROUBLESHOOTING 2-5-11. Horn does not sound Reference Fig.: 2-5-3 Check point Check/Cause Action 1. Horn • Disconnect horn and directly connect battery positive Replace horn. terminal to horn terminal wire LgW side and negative terminal to horn terminal wire B side. •...
  • Page 258 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 259 TROUBLESHOOTING 3-2. Propulsion System If a problem occurs in the propulsion systems such as the propulsion pump, propulsion motor and brakes, determine the cause and carry out action as required, according to the 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 260 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 261 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 262 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 263 TROUBLESHOOTING 3-3. Vibrator System If a problem occurs in the vibrator systems such as the vibrator pump, vibrator motor and vibrator solenoid valve, determine the cause and carry out action as required, according to the following general troubleshooting items. (NOTICE) •...
  • Page 264 TROUBLESHOOTING 3-3-2. Vibrator frequency is too low 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. Charge Circuit Stroke of vibrator pump swash plate is small •...
  • Page 265 TROUBLESHOOTING 3-3-4. Vibrator does not stop Check point Cause Check/Action 1. Vibrator Solenoid Vibrator solenoid valve spool does not Repair vibrator solenoid valve or replace it if Valve return to neutral position. necessary. 2. Vibrator Pump Vibrator pump swash place does not return Repair vibrator pump or replace it if to neutral position.
  • Page 266 TROUBLESHOOTING 3-4. Steering System If a problem occurs in the steering systems such as the steering pump and orbitrol, determine the cause and carry out action as required, according to the 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 267 TROUBLESHOOTING 3-4-3. 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 268 TROUBLESHOOTING 3-5. Blade (SV410TB , FB If a problem occurs in the blade control system, determine the cause and carry out action as required, according to the 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 269 TROUBLESHOOTING 3-5-3. Blade floating operation not possible Check point Cause Check/Action Stack Valve Blade floating operation is not possible If stack valve lever does not move, check because stack valve spool does not change. and clean spool, or replace stack valve. 3-5-4.
  • Page 270 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 © 2013 SAKAI HEAVY INDUSTRIES, LTD. All Rights Reserved. Printed in Japan 2013.07.50 ○ 0404-99027-0-31649-F...

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