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Sakai SV540 Shop Manual

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SV540
SHOP MANUAL
3498-6418A-0

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  • Page 1 SV540 SHOP MANUAL 3498-6418A-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

    SV540 ○ 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 SV540 ○ 3. ENGINE AND CONTROLS 1. ENGINE 1-1. Engine Mount  3-001 1-2. Engine Exterior  3-002 2. FUEL SYSTEM  3-003 3. CONTROL SYSTEM 3-1. Forward-reverse Control  3-004 4. PUMP MOUNT 4-1. Pump Mount   3-005 4-1-1.
  • Page 7 SV540 ○ 5. 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  5-001 1-2. Electrical Equipment Installation  5-002 2. SYSTEM CIRCUIT DIAGRAM 2-1.
  • Page 8 SV540 ○ 3. REAR AXLE 3-1. Rear Axle (SV540/640D)   6-037 3-2. Rear Axle (SV540/640T, TF, DF)  6-038 3-3. Rear Axle Lubrication  6-039 3-4. Rear Axle Structure   6-040 3-4-1. Center housing  6-040 3-4-2. Differential   6-041 3-4-3.
  • Page 9 SV540 ○ 5. MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE 5-1. Measurement  8-009 6. MEASUREMENT AND INSPECTION OF VIBRATOR CIRCUIT PRESSURE 6-1. Measurement  8-010 6-2. Inspection  8-011 7. MEASUREMENT AND ADJUSTMENT OF VIBRATOR CHARGE CIRCUIT PRESSURE  8-012 7-1.
  • Page 10 SV540 ○ 2-2. Fault Codes 9-011 2-2-1. Fault detection  9-011 2-2-2. Fault lamps  9-011 2-2-3. Flash out of fault codes  9-012 2-2-4. Fault code list  9-013 2-3. Error Codes 9-022 2-4. Engine   9-025 2-4-1. Engine will not start (Starter motor does not run) 1/4   9-025 2-4-1.
  • Page 11 SV540 ○ 2-7-2. Tachometer reading is abnormal  9-073 2-7-3. Hour meter is abnormal   9-073 2-7-4. Temperature meter is abnormal  9-075 2-7-5. Fuel meter is abnormal  9-075 2-7-6. Hydraulic oil filter warning lamp remains ON  9-077 2-7-7.

  • 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. SV540D 2130 1095 2970 1775 1560 2295 5840 0418-99024-0-10980-0 Model SV540D Operating weight 10,710 kg 23,610 lbs. ) Weight Front axle 5,470 kg 12,060 lbs. ) Rear axle 5,240 kg 11,550 lbs. ) Overall length 5,840 mm 230 in.
  • Page 27 SPECIFICATIONS CUMMINS QSB4.5 Diesel Engine Name with turbocharger (EPA Interim Tier 4) Water-cooled, 4-cycle, 4-cylinder, in-line, vertical mounted, Model overhead valve, direct injection type Bore × Stroke 107 mm × 124 mm (4.213 in. × 4.882 in.) Displacement 4.460 L ( 272.2 cu.in Rated speed 2,200 min...

  • Page 28: Sv540T

    SPECIFICATIONS 1-2. SV540T 2130 1095 2970 1770 1560 2295 5835 0418-99026-0-10982-0 Model SV540T Operating weight 11,090 kg 24,450 lbs. ) Weight Front axle 5,855 kg 12,910 lbs. ) Rear axle 5,235 kg 11,540 lbs. ) Overall length 5,835 mm 230 in. Overall width 2,295 mm 90 in.
  • Page 29 SPECIFICATIONS CUMMINS QSB4.5 Diesel Engine Name with turbocharger (EPA Interim Tier 4) Water-cooled, 4-cycle, 4-cylinder, in-line, vertical mounted, Model overhead valve, direct injection type Bore × Stroke 107 mm × 124 mm (4.213 in. × 4.882 in.) Displacement 4.460 L ( 272.2 cu.in Rated speed 2,200 min...

  • Page 30: Sv540Tf

    SPECIFICATIONS 1-3. SV540TF 2130 1095 2970 1770 1560 2295 5840 0418-99027-0-10983-0 Model SV540TF Operating weight 13,350 kg 29,430 lbs. ) Weight Front axle 8,120 kg 17,900 lbs. ) Rear axle 5,230 kg 11,530 lbs. ) Overall length 5,840 mm 230 in. Overall width 2,295 mm 90 in.
  • Page 31 SPECIFICATIONS CUMMINS QSB4.5 Diesel Engine Name with turbocharger (EPA Interim Tier 4) Water-cooled, 4-cycle, 4-cylinder, in-line, vertical mounted, Model overhead valve, direct injection type Bore × Stroke 107 mm × 124 mm (4.213 in. × 4.882 in.) Displacement 4.460 L ( 272.2 cu.in Rated speed 2,200 min...

  • Page 32: Sv540Df

    SPECIFICATIONS 1-4. SV540DF 2130 1095 2970 1770 1560 5840 2295 0418-99025-0-10981-0 Model SV540DF Operating weight 12,385 kg 27,305 lbs. ) Weight Front axle 7,215 kg 15,905 lbs. ) Rear axle 5,170 kg 11,400 lbs. ) Overall length 5,840 mm 230 in. Overall width 2,295 mm 90 in.
  • Page 33 SPECIFICATIONS CUMMINS QSB4.5 Diesel Engine Name with turbocharger (EPA Interim Tier 4) Water-cooled, 4-cycle, 4-cylinder, in-line, vertical mounted, Model overhead valve, direct injection type Bore × Stroke 107 mm × 124 mm (4.213 in. × 4.882 in.) Displacement 4.460 L ( 272.2 cu.in Rated speed 2,200 min...

  • Page 34: Sv640D

    SPECIFICATIONS 1-5. SV640D 2130 1095 2970 1775 1560 2295 5840 0418-99028-0-10984-0 Model SV640D Operating weight 13,150 kg 28,990 lbs. ) Weight Front axle 7,150 kg 15,760 lbs. ) Rear axle 6,000 kg 13,230 lbs. ) Overall length 5,840 mm 230 in. Overall width 2,295 mm 90 in.
  • Page 35 SPECIFICATIONS CUMMINS QSB4.5 Diesel Engine Name with turbocharger (EPA Interim Tier 4) Water-cooled, 4-cycle, 4-cylinder, in-line, vertical mounted, Model overhead valve, direct injection type Bore × Stroke 107 mm × 124 mm (4.213 in. × 4.882 in.) Displacement 4.460 L ( 272.2 cu.in Rated speed 2,200 min...

  • Page 36: Sv640T

    SPECIFICATIONS 1-6. SV640T 2130 1095 2970 1770 1560 2295 5835 0418-99029-0-10985-0 Model SV640T Operating weight 13,525 kg 29,820 lbs. ) Weight Front axle 7,485 kg 16,500 lbs. ) Rear axle 6,040 kg 13,320 lbs. ) Overall length 5,835 mm 230 in. Overall width 2,295 mm 90 in.
  • Page 37 SPECIFICATIONS CUMMINS QSB4.5 Diesel Engine Name with turbocharger (EPA Interim Tier 4) Water-cooled, 4-cycle, 4-cylinder, in-line, vertical mounted, Model overhead valve, direct injection type Bore × Stroke 107 mm × 124 mm (4.213 in. × 4.882 in.) Displacement 4.460 L ( 272.2 cu.in Rated speed 2,200 min...

  • Page 38: Table Of Standard Values

    SPECIFICATIONS 2. TABLE OF STANDARD VALUES 2-1. Engine Item Standard value Remarks CUMMINS QSB4.5 T4i Diesel Engine Engine model with turbocharger Rated output 119.0/2,200 kw/ min ( 160/2,200 HP/rpm ) 2,200 rpm Max. rpm under no load Min. rpm under no load 700 rpm 90 N·m 66 lbf·ft...

  • Page 39: Steering

    SPECIFICATIONS 2-4. Steering 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 140 mm (5.5 in.)

  • Page 40: 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 CJ-4 SAE15W-40...

  • Page 41: 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 43: Engine And Controls

    ENGINE AND CONTROLS...

  • Page 45: Engine

    ENGINE AND CONTROLS 1. ENGINE 1-1. Engine Mount DETAIL C DETAIL B VIEW A 0418-01804-0-10898-A (1) Base (7) Bracket (13) Bolt : M12×80 (2) Base (8) Bracket (14) Bolt : M16×40 (3) Bolt : M16×40 (9) Nut : M12 (15) Bolt : M12×40 (4) Bolt : M12×30...

  • Page 47: Engine Exterior

    VIEW A Starter motor Air intake Fuel filter Crankcase breather Alternator Oil pressure Oil level gauge Flywheel housing Flywheel Oil heater Fuel pump Tachometer sensor Oil drain Water inlet * The actual equipment may differ from that shown above. SV540-03001 3-002...

  • Page 49: Fuel System

    ENGINE AND CONTROLS 2. FUEL SYSTEM DETAIL A 0418-02805-0-10899-B (1) Fuel unit (10) Hose (Fuel tank → Fuel pre-filter) (2) Hose (Fuel cooler OUT → Tank) (11) Cap (3) Fuel cooler (12) Breather (4) Hose (Fuel gear pump → Fuel cooler IN) (13) Hose (Breather →...

  • Page 50: Control System

    ENGINE AND CONTROLS 3. CONTROL SYSTEM 3-1. Forward-reverse Control Apply grease* VIEW B SECTION A-A 0418-12804-0-11150-0 (1) F-R lever switch (6) Nut : M12 (11) Spring (Fill grease*) (2) Backup buzzer switch (7) washer (Apply grease*) (12) Steel ball (3) F-R lever (8) Rod end (Apply grease*) (13) Rod end (Apply grease*) (4) Control cable...

  • Page 51: Pump Mount

    ENGINE AND CONTROLS 4. PUMP MOUNT 4-1. Pump Mount 2-M8 1.25 3-M8 1.25 SECTION A-A SECTION B-B 0418-36814-0-20909-0 (1) Bolt M10×30 (6) Housing (2) Bolt : 3/8-16UNC×22 (7) Bolt : M14×45 (3) Retaining ring (8) Pump (4) Hub (9) Bolt : M12×35 (5) Flange N•m...

  • Page 52: Installation Of Pump

    (7) Bolt M14×45 : 167 N·m (123 lbf·ft) N•m 3-M8 1.25 3-M8 1.25 (NOTICE) • Bolt (2) is treated with thread-locking fluid. Use new SECTION A-A SECTION A-A thread-locking fluid treated bolt for installation. SECTION B-B SECTION B-B SV540-03002 SV540-03002 3-006...

  • Page 53: Hydraulic Systems

    HYDRAULIC SYSTEMS...

  • Page 56: 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 57 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 59: Hydraulic Circuit Diagram

    HYDRAULIC SYSTEMS 1-2. Hydraulic Circuit Diagram Steering cylinder (Right) 70X 35-380 (1/2") (3/8") cc/rev Motor speed change solenoid valve (front) (3/8") (1/4") (1/2") 14 MPa (1/4") at 20L/min Orbitrol (1/4") 70X 35-380 Steering cylinder (Left) Parking brake Propulsion motor (Front) solenoid valve (3/8") (1/4") (1/4")

  • Page 61: Propulsion Hydraulic System

    HYDRAULIC SYSTEMS 2. PROPULSION HYDRAULIC SYSTEM 2-1. Propulsion Hydraulic Piping Hydraulic oil tank Hose 2-1-1. Propulsion hydraulic piping (front) (1) (RMB FMB) Hose Propulsion motor (Rear) (FMD Hose Hose (AD1 FMC) (AD2 FGB) Hose Hose (RMB FMB) (FMD Hose (RMA FMA) SECTION A-A Hose...

  • Page 63: Propulsion Hydraulic Piping (Front) (2)

    HYDRAULIC SYSTEMS 2-1-2. Propulsion hydraulic piping (front) (2) Hose Hose (SCA AD1) (SCA AD1) SECTION A-A SECTION B-B Hose (BPS SCP) Hose (SCA AD1) SECTION D-D SECTION E-E Motor speed change solenoid valve (front) Hose Hose (SCA AD1) (SCT BTS) SECTION C-C SECTION F-F The letters and figures (such as SCA and AD1) show each port and the arrow (...

  • Page 65: Propulsion Hydraulic Piping (Rear)

    HYDRAULIC SYSTEMS 2-1-3. Propulsion hydraulic piping (rear) Hydraulic oil tank Hose (AD6 Hose Hose Hose Hose (PPB RBP) (RMD PD1) (PPB RBP) (RMD PD1) Hose (RBB BV1) Hose (PDC AD5) Hose Hose Hose (PPA RAP) (PDC AD5) (PPA RAP) SECTION A-A SECTION B-B Oil cooler Hose...

  • Page 68: Hydraulic Component Specifications

    HYDRAULIC SYSTEMS 2-2. Hydraulic Component Specifications 2-2-1. Hydraulic pump assembly (propulsion + vibrator) 2-7 2-6 2-5 1-4 1-10 2-10 2-11 2-17 2-16 2-15 2-14 2-13 2-12 1-12 1-11 VIEW A B N A 1-12 2-12 2-14 2-13 2-10 1-2 1-9 1-4 1-5 2-11 2-5 Pump circuit diagram SV520-04001...
  • Page 69 HYDRAULIC SYSTEMS (1) Propulsion pump (1-1) Servo pressure gauge port 9/16-18UNF (1-2) Drain port [PD1] : 1 1/16-12UN (1-3) Servo pressure gauge port 9/16-18UNF (1-4) Port B1 (Reverse) [PPB] : SAE 1” (1-5) High pressure gauge port (For Port B1) 9/16-18UNF (1-6) Charge relief valve (1-7) High pressure gauge port (For Port A1)

  • Page 70: Propulsion Hydraulic Motor (Front)

    HYDRAULIC SYSTEMS 2-2-2. Propulsion hydraulic motor (front) Motor circuit diagram VIEW A SV540-04001 (1) Port A (Forward) [FMA] : 3/4” (DN19) (6) Drain port [FMD] : 7/8-14UNF [FMB] : 3/4” (DN19) (2) Servo pressure gauge port (min.) : 9/16-18UNF (7) Port B (Reverse)

  • Page 71: Gear Box

    HYDRAULIC SYSTEMS 2-2-3. Gear box SV540-04002 (1) Gear box (4) Drain port : M16 P=1.5 (2) Oil filler port/Oil level check port : M16 P=1.5 (5) Brake port [FGB] : M16 P=1.5 (3) Oil filler port/Oil level check port : M16 P=1.5 Specifications •...

  • Page 72: Propulsion Hydraulic Motor (Rear)

    HYDRAULIC SYSTEMS 2-2-4. Propulsion hydraulic motor (rear) min. disp. Motor circuit diagram VIEW A SV540-04003 (1) Drain port : 7/ 8-14UNF (7) Loop flushing shuttle valve (2) Servo pressure gauge port (min.) : 9/16-18UNF (8) Servo pressure gauge port (max.) :...

  • Page 73: Motor Speed Change Solenoid Valve (Front)

    HYDRAULIC SYSTEMS 2-2-5. Motor speed change solenoid valve (front) Hydraulic circuit diagram (＋) (−) Connection diagram J-40146 (1) Solenoid (2) O-ring (1B P14) (3) Spool (J) (4) Body (5) Spring (6) Port P [SCP] : 9/16-18UNF-2B (7) Port A [SCA] : 9/16-18UNF-2B (8) Port T [SCT] : 9/16-18UNF-2B Specifications...

  • Page 75: Vibrator Hydraulic System

    HYDRAULIC SYSTEMS 3. VIBRATOR HYDRAULIC SYSTEM 3-1. Vibrator Hydraulic Piping Hose Hose Hose Hose (VPA AD3) (VPB AD4) (VPA AD3) (VPB AD4) Hose Hose (LO2 (LO2 SECTION A-A SECTION B-B Hydraulic oil tank Hose Hose Hose (AD3 FVA) (AD4 FVB) (LO2 Hose LS2)

  • Page 77: Hydraulic Component Specifications

    HYDRAULIC SYSTEMS 3-2. Hydraulic Component Specifications 3-2-1. Vibrator hydraulic motor Hydraulic circuit diagram Flow of oil   1 2 Clockwise rotation   2 1 Counterclockwise rotation SV510- -04008 (1) Port A [FVA] : SAE 3/4” [FVB] : SAE 3/4” (2) Port B (3) Drain port (L) [FVD] : 7/8-14UNF (4) Drain port (L1) : 7/8-14UNF...

  • Page 79: Steering System

    HYDRAULIC SYSTEMS 4. STEERING SYSTEM 4-1. Steering Hydraulic Piping Hose Hose SCS) (SCD Hose (SLR SRB) Hose Hose Hose Coupling : PCF) SRR) SCS) (LOP Charge pressure gauge port Hose Steering cylinder (R) Hose (PCV VPC) Hose LS1) LS1) SECTION B-B SECTION A-A Hose Hose...

  • Page 81: Steering Wheel

    HYDRAULIC SYSTEMS 4-2. Steering Wheel 0418-62801-0-10174-C (1) Steering wheel (4) Nut : M12 P=1.25 (2) Bolt : M10×30 (5) Orbitrol (3) Column shaft N•m (2) Bolt M10×30 : 49 N·m ( 36 lbf·ft ) (4) Nut M12 P=1.25 : 35 N·m ( 26 lbf·ft ) 4-016...

  • Page 82: Hydraulic Component Specifications

    HYDRAULIC SYSTEMS 4-3. Hydraulic Component Specifications 4-3-1. Orbitrol Hydraulic circuit diagram SV510- -04010 (1) Port L [L] : 3/4-16UNF (4) Port T [T] : 3/4-16UNF (2) Port R [R] : 3/4-16UNF (5) Relief valve (3) Port P [P] : 3/4-16UNF Specifications •...

  • Page 83: Steering • Charge Pump

    HYDRAULIC SYSTEMS 4-3-2. Steering • charge pump Hydraulic circuit diagram VIEW A SV540-04004 (1) Pump (2) Outlet port [SCD] : 7/ 8-14UNF (3) Inlet port [SCS] : 1 5/16-12UN Specifications • Displacement : 24.9 cm /rev ( 1.5 cu.in./rev ) •...

  • Page 85: Electrical System

    ELECTRICAL SYSTEM...

  • Page 87: Precautions For Work

    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 88: Electrical Equipment Installation

    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 89: System Circuit Diagram

    ELECTRICAL SYSTEM 2. SYSTEM CIRCUIT DIAGRAM 2-1. Electrical Circuit Diagram OPTION OPTION OPTION ROTATORY ROTATORY LAMP LAMP C1-P11 SWITCH (LOW) VIBRATOR PROPORTIONAL 1.25R 1.25R 1.25R SOLENOID 1 OPTION TURN SIGNAL OPTION C1-P12 LAMP(R) (25W) INDICATOR OPTION FLOOD LAMP FLOOD LAMP (HI) CONTROLLER VIBRATOR PROPORTIONAL...

  • Page 91: Electrical Components

    ELECTRICAL SYSTEM 3. ELECTRICAL COMPONENTS 3-1. Battery Layout SECTION A-A DETAIL C SECTION B-B 0418-09819-0-10904-A (1) Cord (Fuse – Alternator) (7) Cord (Battery (-) – Ground) (2) Alternator (8) Cord (Battery (+) – Battery (-)) (3) Starter motor (9) Cord (Battery (+) – Battery relay (COM)) (4) Cord (Starter motor (terminal G) –...

  • Page 93: Wiring Harness Layout (1)

    ELECTRICAL SYSTEM 3-2. Wiring Harness Layout (1) Foot brake switch Not in use COM(R),NO(LgR) Motor proportional solenoid (rear) INC/DEC switch (BW),Ground(B) Flood lamp (option) (not in use) (L),(BW),(G) MAF connector Motor speed change solenoid (front) S Mark R-LAMP (R), (B) Panel harness (1) (p.5-006) (BL),(B)

  • Page 95: Wiring Harness Layout (2)

    ELECTRICAL SYSTEM 3-3. Wiring Harness Layout (2) Mark 7A3 Fuse relay harness (1) Mark 8F2 (P.5-007), (P.5-009) (P.5-013) (P.5-007), (P.5-013) Control switch harness Combination meter Panel harness (2) Rotatory lamp switch (option) Mark 6A2 Fuse  relay harness (2) Marking tape (color:green) (P.5-021) (P.5-011) (RG),(RL)
  • Page 96 #4T6 SWP-2PM 1.25RW 58Y-2PM Fuse relay harness (2) #7T2 55 54 53 52 51 (black) (P.5-015) 90 15WR Twist cable Engine ECM. 66 66 67 67 #6T3 58X-2PM (3 cables) *1 : Connection status *2 : Connection status SV540-05001 5-007...
  • Page 97 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS Datalink interface connector-D, Engine ECM-18, 1 , 2 , 7A3 , 8F2 , 9A1 × 2, #7T2 , BOTTOM , P , S , TOP , B, 1.25B, 2B, Backup buzzer, Cylinder block, Fuel unit harness, Terminating resistor (120Ω) -B ×...
  • Page 98 SWP-4PF SWP-8PM Flood lamp (R) Motor rotation sensor Control switch harness (option) 2B 2B harness (front) (P.5-021) (P.5-022) SWP-16PM SWP-12PM 1.25RL Cabin (Rotatory lamp, turn signal, 040DL-20PM flood lamp, head lamp, cabin, radio) (option) Panel harness (2) (P.5-011) SV540-05002 5-009...
  • Page 99 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS 9A1 × 2, Combination meter (16PF) × 2, ECO lamp, Horn, 1.25RG 5F4 , B1 B, 1.25B, 2B Orbitrol mounting bolt, #3E (option), #5D × 2 (option), B1 , B1 , Combination meter (12PF), #5D ×...
  • Page 100 060-1PFS 060-1PFS Vibration select switch Tape Tape Tape Tape Tape Not in use 060-1PFS Vibration mode change switch Tape 060-1PFS 060-1PFS Speed change switch Rotatory lamp swtich (not in use) (option) Wire number Switch terminal number Wire color SV540-05003 5-011...
  • Page 101 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS B1 , Parking brake switch-5 B1 , Speed change switch-1 (not in use) 1.25R B1 , Lighting switch-5 (option) 1.25RG B1 , Lighting switch-1 (option), Lighting switch-4 (not in use) B1 , Vibration select switch-2 B1 , Lighting switch-3 (option) 1.25RW...
  • Page 102 Cabin and A/C harness 1_11 (option) 1.25YR 1.25WB 1.25RB 1.25RB SWP-2PF Spare power source CN-4PF DTM-06-12SA Glow plug timer 2(coil) Control harness SWP-6PF Ground (not in use) ECO controller (P.5-020) 1(coil) Supply Pin position (relay) 1(coil) 2(coil) Supply Ground SV540-05004 5-013...
  • Page 103 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS 3AC1 , 8F2 , Relay box A-1, 2, 3, 4, 5, 6, Flasher unit (option), 5F4 , Fuse box 1-8 B, 1.25B, 2B, 3B Glow plug timer (not in use) 5F4 , Relay box A-3 2C , 12F1 5F4 , Fuse box 1-6...
  • Page 104 #7T2 (AVSSCS 0.75f×2) (black) Engine harness (P.5-007) #6T3 58X-2PF DTM06-2S-E007 Terminating resistor (120 ) Marking tape (color:gray) 1.25RB Marking tape Panel harness (1) SWP-16PF (color:yellow) (P.5-009) 2(coil) 1.25RL Ground 1(coil) Supply Pin position (relay) 1(coil) 2(coil) Supply Ground SV540-05005 5-015...
  • Page 105 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS B, 3B #7T2 , Relay box B-1, 2, 4, 5 × 2, #9P (option) 4T4 , #10T1 , T/C controller C1-8 4T4 , Relay box B-4 4T4 , #10T1 , T/C controller C1-9 #10T1 , T/C controller C1-7, #9P (option) RL, 1.25RL 4T4 , Relay box B-2, 3...

  • Page 106: Battery Relay Harness

    1.25RB,50 LA104 (BR) (COM) (COM) (COM) Battery relay 15W,50 LA408 Fuse 125A 15L,50 LA408 F.L. 65A F.L. 65A F.L. 65A F.L. 75A (black) (black) (black) (gray) 15WR LA105 LA105 LA408 LA408 *1 : Connection status Grid heater relay SV540-05006 5-017...
  • Page 107 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS 1.25B, 3B 1 , 2 , Battery relay-Ground, Starter relay 6 , Starter relay 5 , F.L. 75A Battery relay-NO, F.L. 65A 4 , F.L. 65A Battery relay-NO, F.L. 75A 1.25RB 1 , Battery relay-BR Battery relay-COM, F.L.

  • Page 109: Starter Switch Harness

    Tape (BR) (P.5-009) 1.25Lg,70 LA105 1.25Lg 1.25BR LgW,70 LA105 (ACC) SWP-3PF SV540-05007 CONTACT SIZE, COLOR CONNECTION POINTS Panel harness (1), Starter switch-B Panel harness (1), Starter switch-R2 1.25BR Panel harness (1), Starter switch-BR 1.25Lg Panel harness (1), Starter switch-C Panel harness (1), Starter switch-ACC...

  • Page 110: Control Harness

    CA104 F-R lever vibration switch CA104 CB104 (NC) (COM) ECO lamp switch (not in use) SV540-05008 CONTACT SIZE, COLOR CONNECTION POINTS 2C , Backup buzzer switch-NO 2C , F-R lever vibration switch-2 2C , Backup buzzer switch-COM, F-R lever switch-COM,...

  • Page 111: Control Switch Harness

    Tape 060-1PES SWP-8PF 060-1PES Throttle switch Wire number Switch terminal number Wire color SV540-05009 CONTACT SIZE, COLOR CONNECTION POINTS B2 , Speed change switch-1, Speed change switch-4 B2 , Throttle switch-4 B2 , Speed change switch-5 B2 , Speed change switch-2...

  • Page 112: Motor Rotation Sensor Harness (Front)

    Woven braid (color : black) Motor rotation Panel harness (1) sensor (front) (P.5-009) SWP-4PＭ DTM 06-6S SV540-05010 CONTACT SIZE, COLOR CONNECTION POINTS TC , Motor rotation sensor (front) TC , Motor rotation sensor (front) TC , Motor rotation sensor (front)

  • Page 113: Fuel Unit Harness

    ELECTRICAL SYSTEM 4-11. Fuel Unit Harness YB,50 YB,50 CA104 CB104 Engine harness Fuel unit (P.5-007) Corrugate B,50 B,50 CB104 CA104 SV540-05011 CONTACT SIZE, COLOR CONNECTION POINTS Engine harness, Fuel unit Engine harness, Fuel unit 5-023...

  • Page 114: Diagnostic Switch Harness

    94 96 Tape Br,100 LA104 (3) SWP-4M Diagnostic switch BW,100 LA104 (2) SV540-05012 CONTACT SIZE, COLOR CONNECTION POINTS J , INC/DEC switch-1 (not in use) J , Diagnostic switch-2, INC/DEC switch-2 (not in use) J , INC/DEC switch-3 (not in use)

  • Page 115: Electrical Component Specifications

    Battery relay (BY) (RG) Battery relay Starter switch Radio (option) Stater lockout relay (RW) (R) Battery relay SV540-05013 Harness color codes : Red RW : Red/white stripe : Blue RY : Red/Yellow stripe BW : Black/white stripe RG : Red/Green stripe...

  • Page 116: Fuse Box (2)

    Engine ECM (BY) Engine ECM Brake relay (BG) (WR) Battery relay (W) Battery relay (R) Battery relay SV540-05014 Harness color codes : white BG : Black/Green stripe : Red WR : white/Red stripe : Green RB : Red/Black stripe BY : Black/Yellow stripe...

  • Page 117: Combination Meter

    Charge warning indicator Hydraulic oil filter Engine oil pressure warning indicator warning Preheating indicator Hydraulic oil filter warning SWP-12PF Lamp check Coolant temp. SEL.1 Coolant temp. SEL.2 System configuration diagram Note: The circuit in the dashed box is not mounted. SV540-05015 5-027...

  • Page 119: Vibratory Drum • Rear Axle

    VIBRATORY DRUM • REAR AXLE...

  • Page 121: Precautions For Disassembly And Reassembly

    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 122 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 123: Vibratory Drum

    SV540D : 5,240 kg (11,550 lbs.) SV540T : 5,235 kg (11,540 lbs.) Support stand Support stand SV540TF : 5,230 kg (11,530 lbs.) SV540-06101 SV540-06101 SV540DF : 5,170 kg (11,400 lbs.) SV640D : 6,000 kg (13,230 lbs.) SV640T : 6,040 kg (13,320 lbs.) Lift with crane.
  • Page 124 SV640D : 1,345 kg ( 2,965 lbs.) SV640T : 1,440 kg ( 3,175 lbs.) Support stand Support stand SV540-06103 SV540-06103 w AR NING The hydraulic oil in the machine is hot and compressed immediately after the machine is stopped. Disconnecting the hydraulic hoses in this condition can cause burns.
  • Page 125 SV540DF : 6,145 kg ( 13,547 lbs.) SV640D : 4,505 kg ( 9,932 lbs.) SV640T : 4,835 kg ( 10,659 lbs.) Support stand Support stand SV540-06106 SV540-06106 7) Put chocks or the like under removed drum (13) to prevent it from moving. Chock...

  • Page 126: Installation Of Vibratory Drum

    VIBRATORY DRUM • REAR AXLE 2-1-2. Installation of vibratory drum 1) Install vibratory drum in the reverse order in which it was removed. • Tightening torque for bolts where particular care is required when installing vibratory drum. Vibratory drum N•m (2) Bolts (propulsion motor side) M20×120 : 539 N·m (398 lbf·ft) Bolts (vibrator motor side)

  • Page 127: Vibratory Drum Assembly

    VIBRATORY DRUM • REAR AXLE 2-2. Vibratory Drum Assembly (1) Drum (2) Disc (3) Bolt : M20×70 (4) Vibrator bearing (5) Eccentric shaft (6) Shaft (7) Bolt : M12×40 (8) Sleeve (9) Spring pin (10) Bolt : M20×60 (11) Plug (12) Housing (13) Oil seal (14) Roller bearing...

  • Page 129: Disassembly And Reassembly Of Vibratory Drum

    VIBRATORY DRUM • REAR AXLE 2-3. Disassembly and Reassembly of Vibratory Drum • Lead line numbers shown in the illustrations for the following vibratory drum disassembly and reassembly procedures 11-1 11-1 are constant with part numbers of vibratory drum assembly shown on page 6-007.
  • Page 130 VIBRATORY DRUM • REAR AXLE w AR NING Lifting bolt Lifting bolt When installing lifting bolts, secure them with nuts. 4) Install lifting bolts and nuts (M20) to holders (20) and (34). SV510- -06013 SV510- -06013 5) Remove sixteen bolts (17). SV510- -06014 SV510- -06014 6) Lift holders (20), (34), dampers (19) and disc (15) together with a crane and remove them.
  • Page 131 VIBRATORY DRUM • REAR AXLE 7) Pull out sleeve (8). • Remove sixteen bolts (10). SV510- -06015 SV510- -06015 8) Lift axle shaft (35) using two pulling bolts (M20×60). Pulling bolt Pulling bolt SV510- -06021 SV510- -06021 w AR N ING When attaching lifting bolts, screw in the threads fully Lifting bolt Lifting bolt before using.
  • Page 132 VIBRATORY DRUM • REAR AXLE 10) Slowly lift axle shaft subassembly (35) with a crane and remove it. Wooden hammer Wooden hammer Wooden bar Wooden bar (NOTICE) • In order not to lift eccentric shaft (5) together with axle shaft subassembly (35), tap on the eccentric shaft end with a wooden hammer via a wooden bar during lifting.
  • Page 133 Total weight of parts to be lifted SV540D : 3,720 kg ( 8,201 lbs.) SV540T : 4,045 kg ( 8,918 lbs.) SV540TF : 6,450 kg (14,220 lbs.) SV540DF : 5,400 kg (11,905 lbs.) SV540-06508 SV540-06508 SV640D : 3,720 kg ( 8,201 lbs.) SV640T : 4,045 kg ( 8,918 lbs.)
  • Page 134 VIBRATORY DRUM • REAR AXLE 16) Remove propulsion motor (49). SV540-06019 SV540-06019 17) Install lifting bolts (M20) to holders (46) and (54). Lifting bolt Lifting bolt SV540-06501 SV540-06501 18) Remove twenty bolts (48). SV540-06502 SV540-06502 6-013...
  • Page 135 19) Lift holders (46), (54), dampers (45) and disc (2) together with a crane and remove them. Total weight of parts to be lifted : 220 kg (485 lbs.) SV540-06016 SV540-06016 20) Install lifting bolts (M20) to gear box (42).
  • Page 136 22) Install lifting bolts (M20) on axle shaft (41). • Remove sixteen bolts (39). Lifting bolt Lifting bolt SV540-06504 SV540-06504 23) Lift axle shaft (41) with a crane and remove it. (41) Axle shaft : 230 kg (507 lbs.) SV540-06006 SV540-06006 24) Put removed axle shaft (41) on wooden blocks.
  • Page 137 VIBRATORY DRUM • REAR AXLE 25) The right illustration shows axle shaft subassembly (35) removed from vibratory drum. SV510- -06032 SV510- -06032 26) Remove six bolts (32). • Remove cover (24). (24) Cover : 10 kg (22 lbs.) SV510- -06033 SV510- -06033 27) Remove eight bolts (25). •...
  • Page 138 VIBRATORY DRUM • REAR AXLE 28) Put a piece of wooden board on the end of axle shaft (35) and set a puller on housing (12). Puller Puller • Separate housing (12) together with roller bearing from Wooden board Wooden board axle shaft (35).
  • Page 139 VIBRATORY DRUM • REAR AXLE 31) The right illustration shown axle shaft (41) removed from vibratory drum. SV540-06509 SV540-06509 32) Remove bolt (38). SV540-06506 SV540-06506 33) Remove vibrator bearing (4) from axle shaft (41) using long bolts (M10). Long bolt...

  • Page 140: Reassembly Of Vibratory Drum

    • Drive in vibrator bearing (4). (NOTICE) • Take care not to damage the bearing when installing SV540-06001 SV540-06001 3) A pply grease to entire periphery of O-ring (40). • Install O-ring (40) on axle shaft subassembly (41) SV540-06002...
  • Page 141 VIBRATORY DRUM • REAR AXLE 4) Install bolts (38) and seal washers to axle shaft (41). SV540-06003 SV540-06003 w AR N ING When attaching lifting bolts, screw in the threads fully Lifting bolt Lifting bolt before using. 5) Lift axle shaft (41) with a crane and reverse it.
  • Page 142 VIBRATORY DRUM • REAR AXLE 7) Secure axle shaft (41) to vibratory drum (1) with sixteen bolts (39) and washers. (39) Bolts M20×60 : 539 N·m (398 lbf·ft) N•m SV540-06007 SV540-06007 8) Install ring (44) to mounting surface of gear box (42). (NOTICE) •...
  • Page 143 VIBRATORY DRUM • REAR AXLE 10) Install lifting bolts (M20) to gear box subassembly (42). Lifting bolt Lifting bolt SV540-06010 SV540-06010 11) Lift gear box subassembly (42) with a crane and lower it on the mounting surface of axle shaft (41).
  • Page 144 (46), (54), dampers (45) and disc (2) as shown on Lifting bolt Lifting bolt the right. SV540-06014 SV540-06014 14) Lift disc subassembly (2) with a crane and lower it on mounting surface of gear box (42). (2) Disc subassembly : 220 kg (485 lbs.)
  • Page 145 VIBRATORY DRUM • REAR AXLE 16) Secure disc subassembly (2) with twenty bolts (48) and washers. (44) Bolts M20×50 P=1.5 : 588 N·m (434 lbf·ft) N•m SV540-06018 SV540-06018 17) Install propulsion motor (49) to gear box (42). SV540-06021 SV540-06021 18) Secure propulsion motor (49) with two bolts (50) and washers.
  • Page 146 VIBRATORY DRUM • REAR AXLE w AR NING Be careful because reversing the vibratory drum involves risk. Confirm that the surrounding area is safe, and work in a natural, unstrained posture. 19) Lift vibratory drum subassembly (1) with a crane and reverse it.
  • Page 147 VIBRATORY DRUM • REAR AXLE 22) Apply a coat of gear oil to eccentric shaft subassembly (5) at where bearing will be installed. Movable weight Movable weight • Lift eccentric shaft subassembly (5) with a crane and install it on vibratory drum slowly. (5) Eccentric shaft subassembly : 280 kg (617 lbs.) (NOTICE) •...
  • Page 148 VIBRATORY DRUM • REAR AXLE 24-2) Apply a thin coat of gear oil to axle shaft (35) on its surface where vibrator bearing (37) will be press-fitted. • Drive in vibrator bearing (37). (NOTICE) • Take care not to damage the bearing when installing Wooden block Wooden block SV510- -06058...
  • Page 149 VIBRATORY DRUM • REAR AXLE 24-5) Apply a thin coat of gear oil to roller bearing (14) outer race on its surface to be press-fitted. • Drive outer race of roller bearing (14) into housing (12). • Install oil seal (13). •...
  • Page 150 VIBRATORY DRUM • REAR AXLE 24-8) Apply sufficient amount of lithium-based grease to rollers of roller bearing (14) inner race. • Drive in roller bearing (14) inner race until rollers come in contact with outer race. SV510- -06064 SV510- -06064 24-9) Preload adjustment of roller bearing ①...
  • Page 151 VIBRATORY DRUM • REAR AXLE ② Remove four bolts (25). • Remove cover (29). • Remove shim (33). SV510- -06067 SV510- -06067 ③ w ithout inserting shim, install cover (29). • Install washers to four bolts (25) and tighten. • Using a thickness gauge, measure the gap at dimension There must be no gap There must be no gap “A”.
  • Page 152 VIBRATORY DRUM • REAR AXLE ⑤ Install oil seal (31) on cover (24). • Apply a thin coat of grease to lip of oil seal (31). • Apply liquid packing to mounting surface. SV510- -06070 SV510- -06070 ⑥ S ecure cover (24) to housing subassembly (12) with six bolts (32) and spring washers.
  • Page 153 VIBRATORY DRUM • REAR AXLE 25) Install lifting bolts (M20) to axle shaft subassembly (35). Lifting bolt Lifting bolt SV510- -06077 SV510- -06077 26) Apply grease to entire periphery of O-ring (36). • Install O-ring (36) on axle shaft subassembly (35). SV510- -06078 SV510- -06078 27) Lift axle shaft subassembly (35) with a crane and lower it Pipe...
  • Page 154 VIBRATORY DRUM • REAR AXLE 28) Secure axle shaft subassembly (35) to drum with sixteen bolts (10). (10) Bolts M20×60 : 539 N·m (398 lbf·ft) N•m SV510- -06080 SV510- -06080 29) Install a lifting bolt (M8) on shaft end of eccentric shaft (5). Lifting bolt Lifting bolt SV510- -06081...
  • Page 155 VIBRATORY DRUM • REAR AXLE 31) Install lifting bolts and nuts (M20) on a subassembly of Lifting bolt Lifting bolt holders (20), (34), dampers (19) and disc (15) as shown on the right. SV510- -06083 SV510- -06083 32) Lift disc subassembly (15) with a crane and lower it on mounting surface of housing (12).
  • Page 156 VIBRATORY DRUM • REAR AXLE 34) Drive two spring pins (9) into sleeve (8). SV510- -06086 SV510- -06086 35) Apply molybdenum-based grease to splined portion of sleeve (8). • Fit sleeve (8) to splined shaft on eccentric shaft end. SV510- -06087 SV510- -06087 36) Apply grease to O-ring (27). •...
  • Page 157 VIBRATORY DRUM • REAR AXLE 37) Secure vibrator motor (26) to cover (24) with two new thread sealant bolts (28) and washers. (26) Vibrator motor : 20 kg (44 lbs.) (28) Bolts M14×40 : 108 N·m (80 lbf·ft) N•m • Wind seal tape around the threaded portion of breather (23).

  • Page 159: Rear Axle

    VIBRATORY DRUM • REAR AXLE 3. REAR AXLE 3-1. Rear Axle (SV540/640D) (1) Tire (2) Nut : M22 P=1.5 (3) Hub reduction gear (4) Bolt (brake release) (5) Plug (brake drain) (6) Plug (brake filler and level gauge) (7) Plug (gear box filler and level gauge)

  • Page 161: Rear Axle (Sv540/640T, Tf, Df)

    VIBRATORY DRUM • REAR AXLE 3-2. Rear Axle (SV540/640T, TF, DF) (1) Tire (2) Nut : M22 P=1.5 (3) Hub reduction gear (4) Bolt (brake release) (5) Plug (brake drain) (6) Plug (brake filler and level gauge) (7) Plug (gear box filler and level gauge)

  • Page 163: Rear Axle Lubrication

    VIBRATORY DRUM • REAR AXLE 3-3. Rear Axle Lubrication Center housing Gear box (differential + brake) 1, 3 1, 3 1, 3 Drain Drain Hub reduction gear 1, 3 Drain Supply SV510- -06100 (1) Filler port (2) Drain port (3) Level gauge •...

  • Page 164: Rear Axle Structure

    VIBRATORY DRUM • REAR AXLE 3-4. Rear Axle Structure 3-4-1. Center housing SV510- -06093 (1) O-ring (5) Bolt (9) Snap ring (2) Cover (6) Seal washer (10) Magnet plug (3) Vent (7) Plug (4) Housing (8) Cover 6-040...

  • Page 165: Differential

    VIBRATORY DRUM • REAR AXLE 3-4-2. Differential SV510- -06101 (1) Bolt (6) Bevel gear set (11) Taper roller bearing (2) Ring nut (7) Nospin differential (12) Shim (3) Taper roller bearing (8) Spacer (13) Seal (4) Bolt (9) Bolt (14) Spacer (5) Differential carrier (10) Ring nut (15) Shim...

  • Page 166: Hub Reduction Gear

    VIBRATORY DRUM • REAR AXLE 3-4-3. Hub reduction gear SV510- -06095 (1) Half shaft (10) O-ring (19) Snap ring (2) Seal (11) Stud (20) Planet gear (3) Spring washer (12) Plug (21) Bearing (4) Bolt (13) Nut (22) Planet gear carrier (5) Seal (14) Magnet plug (23) Stud...

  • Page 167: Brake

    VIBRATORY DRUM • REAR AXLE 3-4-4. Brake SV700-06094 (1) Spring (7) Brake disc (2) O-ring (8) Plug (3) Piston (9) Bolt (4) O-ring (10) Nut (5) Ring (11) Lock washer (6) Dowel (12) Plug 6-043...

  • Page 168: Gear Box

    VIBRATORY DRUM • REAR AXLE 3-4-5. Gear box SV510- -06097 (1) Vent (7) Cover (13) Gear (2) Housing (8) Cylinder bolt (14) Plug (3) Ball bearing (9) O-ring (15) Spring washer (4) Circlip (10) Intermediate cover (16) Bolt (5) Spacer (11) Cylinder bolt (17) Magnet plug (6) Gear...

  • Page 169: Brake

    BRAkE...

  • Page 171: Brake Pedal

    BRAKE 1. BRAkE PEDAL DETAIL A 0418-62801-0-10174-C (1) Brake pedal (4) Stopper bolt : M10×50 (2) Return spring (5) Foot brake switch (3) Nut : M10 7-001...

  • Page 173: Brake Hydraulic Piping

    BRAKE 2. BRAkE HYDRAULIC PIPING Hose (TBR RBR) Axle ASSY Hose Hose Brake Hose Hose Hose Hose (VB1 TVB) (VBT (VB1 TVB) (VBT TVB) (VB1 (VBT Hose Hose (VB2 AD2) (VB2 AD2) SECTION A-A SECTION B-B Hose (LOB BPF) Parking brake solenoid valve Hydraulic oil filter 1 Hose Hose...

  • Page 175: Brake System

    ON. (without solenoid excited) Parking brake solenoid valve when brake is OFF. (with solenoid excited) Steering ・ charge pump Hand pump Rotary valve The arrow ( ) symbol shows the direction of the hydraulic oil flow. SV540-07001 7-003...

  • Page 176: Hydraulic Component Specifications

    BRAKE 4. HYDRAULIC COMPONENT SPECIFICATIONS 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 177: Valve Block

    BRAKE 4-2. Valve Block Hydraulic circuit diagram GW750-2-04011 (1) System block (2) Port B2 [VB2] : 9/16-18UNF N•m N•m (3) Port B1 [VB1] : 9/16-18UNF (6) Rotary valve : 70 N·m (51.6 lbf·ft) [VBA] : 9/16-18UNF (4) Port A (7) Hand pump : 70 N·m (51.6 lbf·ft) (5) Port P [VBP] : 9/16-18UNF Specifications...

  • Page 179: Inspection And Adjustment

    INSPECTION AND ADJUSTMENT...

  • Page 181: 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. •...

  • Page 182: Measurement And Adjustment Of Propulsion Circuit Pressure

    INSPECTION AND ADJUSTMENT 2. MEASUREMENT AND ADJUSTMENT OF PROPULSION CIRCUIT PRESSURE 2-1. Measurement w AR NING Confirm that the parking brake works properly before measurement. • Oil temperature during measurement : 50 °C (122 °F) ± 5 ± 9 ① Remove plugs from couplings (1) and (2) of propulsion pump.

  • Page 183: Adjustment

    INSPECTION AND ADJUSTMENT 2-2. Adjustment • If measurement results indicate the pressure deviating from maximum circuit pressure range, make an adjustment in accordance with procedure described below. ① C heck nut (2) of multifunction valve (1-10) or (1-11) for evidence of having loosened.

  • Page 184: Measurement And Adjustment Of Propulsion Charge Circuit

    INSPECTION AND ADJUSTMENT 3. MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT PRESSURE • Since oil in charge circuit is supplied from steering circuit, confirm that steering operation is normal before measurement. • Propulsion charge circuits and vibration charge circuits consist of parallel circuits. Thus, in order to measure whether vibrator charge circuit pressure is within standard value, use following operation to ensure that oil does not escape to the charge relief valve on vibrator pump side.

  • Page 185: Pressure

    ③ S tart the engine and set throttle switch to “FULL”. • Then, read pressure indicated by pressure gauge. Standard charge relief valve setting ★ : 2.4 MPa (348 psi) ± 0.2 ± 29 SV540-08001 SV540-08001 PG003163 PG003163 8-005...

  • Page 186: Adjustment

    INSPECTION AND ADJUSTMENT 3-2. Adjustment • If measurement results indicate the pressure deviating from standard charge relief pressure setting range, make an adjustment in accordance with procedure described below. ① C heck nut (2) of charge relief valve (1-6) for evidence of having loosened.

  • Page 187: Measurement Of Machine High/Low Speed Change Circuit Pressure

    ” or “ ”. ④ S tart the engine and set throttle switch to “FULL”. • Then, read pressure indicated by pressure gauge. Standard charge relief valve setting ★ SV540-08002 SV540-08002 : 2.4 MPa (348 psi) ± 0.2 ± 29...

  • Page 188: Measurement Of Propulsion Motor (Rear)

    ” or “ ”. ④ S tart the engine and set throttle switch to “FULL”. • Then, read pressure indicated by pressure gauge. Standard charge relief valve setting ★ SV540-08004 SV540-08004 : 2.0 MPa (290 psi) ± 0.2 ± 29...

  • Page 189: Measurement Of Parking Brake Release Pressure

    ④ S tart the engine and set throttle switch to “FULL”. ⑤ R elease parking brake by pressing parking brake switch button. • Then, read brake release pressure indicated by pressure SV540-08006 SV540-08006 gauge. Brake release pressure ★...

  • Page 190: Measurement And Inspection Of Vibrator Circuit Pressure

    INSPECTION AND ADJUSTMENT 6. MEASUREMENT AND INSPECTION OF VIBRATOR CIRCUIT PRESSURE 6-1. 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 191: Inspection

    High pressure High pressure check relief valve check relief valve SV540-08012 SV540-08012 • The numbers “2-9” and “2-17” appearing in above illustrations are consistent with lead line numbers shown in illustration of vibrator pump in “2-2. Hydraulic Component Specifications” (page 4-007).

  • Page 192: Measurement And Adjustment Of Vibrator Charge Circuit

    INSPECTION AND ADJUSTMENT 7. MEASUREMENT AND ADJUSTMENT OF VIBRATOR CHARGE CIRCUIT PRESSURE • Since oil in charge circuit is supplied from steering circuit, confirm that steering operation is normal before measurement. • Propulsion charge circuits and vibration charge circuits consist of parallel circuits. Thus, in order to measure whether vibrator charge circuit pressure is within standard value, use following operation to ensure that oil does not escape to the charge relief valve on propulsion pump side.

  • Page 193: Pressure

    ③ S tart the engine and set throttle switch to “FULL”. • Then, read pressure indicated by pressure gauge. Standard charge relief valve setting ★ : 2.4 MPa (348 psi) ± 0.2 ± 29 SV540-08001 SV540-08001 PG003163 PG003163 8-013...

  • Page 194: Adjustment

    INSPECTION AND ADJUSTMENT 7-2. Adjustment • If measurement results indicate the pressure deviating from standard charge relief pressure setting range, make an adjustment in accordance with procedure described below. ① Check nut (1) of charge relief valve (2-8) for evidence of having loosened.

  • Page 195: Measurement Of Vibrator High/Low Change Circuit Pressure

    INSPECTION AND ADJUSTMENT 8. MEASUREMENT OF VIBRATOR HIGH/LOw CHANGE CIRCUIT PRESSURE 8-1. Measurement • Oil temperature during measurement : 50 °C (122 °F) ± 5 ± 9 ① Remove plugs from servo pressure gauge ports (2-4) and (2-12). Attach pressure gauge with the adapter ⓗ . •...

  • Page 196: Measurement And Inspection Of Steering Circuit Pressure

    ④ Turn steering wheel to operate relief valve. • Then, read pressure indicated by pressure gauge. Standard maximum circuit pressure ★ (orbitroll relief pressure + charge relief pressure) : 16.4 MPa (2,378 psi) ± 1.0 ± 145 SV540-08007 SV540-08007 PG002090 PG002090 8-016...

  • Page 197: Inspection

    INSPECTION AND ADJUSTMENT 9-2. 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 198: Measurement Of Hydraulic Pump Case Pressure

    ⑤ With propulsion load at maximum, measure pressure when speed change switch is in “ ” and “ ” and SV540-08008 SV540-08008 F-R lever is in “N”, “F”, and “R”, respectively. Allowable pump case pressure ★ : 0.3 MPa (43.5 psi) or less...

  • Page 199: Measurement Of Vibrator Pump Case Pressure

    ⑥ Measure pressure when vibration select switch is in ” and “ ”, respectively. “ ⑦ Press F-R lever vibration switch OFF as soon as SV540-08009 SV540-08009 measurement is finished. Allowable pump case pressure ★ : 0.3 MPa (43.5 psi) or less...

  • Page 200: Measurement Of Propulsion Motor Case Pressure

    ⑤ With propulsion load at maximum, measure pressure when speed change switch is in “ ” and “ ” and F-R lever is in “N”, “F”, and “R”, respectively. SV540-08010 SV540-08010 Allowable motor case pressure ★ : 0.3 MPa (43.5 psi) or less...

  • Page 201: Measurement Of Propulsion Motor (Rear)

    ⑤ With propulsion load at maximum, measure pressure when speed change switch is in “ ” and “ ” and F-R lever is in “N”, “F”, and “R”, respectively. SV540-08011 SV540-08011 Allowable motor case pressure ★ : 0.3 MPa (43.5 psi) or less...

  • Page 202: Measurement Of Vibrator Motor Case Pressure

    INSPECTION AND ADJUSTMENT 12. MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE 12-1. 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 203: Adjustment Of F-R Lever Linkage

    INSPECTION AND ADJUSTMENT 13. ADJUSTMENT OF F-R LEVER LINkAGE 13-1. Adjustment • In cases such as propulsion hydraulic pump is replaced, control cable is replaced or F-R lever does not move smoothly, make an adjustment in accordance with procedure described below. •...

  • Page 204: Brake Adjustment

    INSPECTION AND ADJUSTMENT 14. BRAkE ADJUSTMENT 14-1. 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 205: Adjustment After Manual Release Of Brake

    INSPECTION AND ADJUSTMENT 14-2. 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 207: Troubleshooting

    TROUBLESHOOTING...

  • Page 209: 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 210: 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 211: 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 212: 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 213 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 214 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 215 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 216 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 217: 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 218 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 219: Fault Codes

    A Cummins supplied grid heater will automatically heat the intake manifold based on the Intake Manifold Temperature when needed prior to engine starting. Intake manifold heating improves engine starting in cold temperatures and reduces white smoke. IDLE FULL n/min MODE ENGINE STOP WARNING WAIT TO START ENGINE CHECK SV540-09007 9-011...

  • Page 220: Flash Out Of Fault Codes

    STOP” lamp. A blink is equivalent to the “ENGINE STOP” lamp being on for 0.5 seconds, and off for 0.5 seconds. A pause between fault code digits has duration of 2 seconds. Diagnostic switch VIEW A SV540-09008 Example Fault Code Sequence Fault Code 214 : Each block represents 0.5 seconds = “WARNING”...

  • Page 221: Fault Code List

    TROUBLESHOOTING 2-2-4. Fault code list Fault code Reason Effect (Lamp) Engine control module critical internal failure Engine may not start. (Red) • Bad intelligent device or component. Engine magnetic crankshaft speed/position lost Fueling to the injectors is disabled and the (Red) both of two signals engine cannot be started.
  • Page 222 TROUBLESHOOTING Fault code Reason Effect (Lamp) Accelerator pedal or lever position sensor 1 Severe derate in power output of the engine. (Red) • Data valid but above normal operational Limp home power only. range. • Most severe level. Engine coolant temperature Progressive power derate increasing in severity (Red) •...
  • Page 223 TROUBLESHOOTING Fault code Reason Effect (Lamp) Sensor supply 3 circuit Possible hard starting and rough running. (Orange) • Voltage above normal or shorted to high source. Wheel based machine speed Engine speed limited to maximum engine (Orange) • Data erratic, intermittent or incorrect. speed without VSS parameter value.
  • Page 224 TROUBLESHOOTING Fault code Reason Effect (Lamp) Electronic control module warning internal Possible no noticeable performance effects, (Orange) hardware failure engine dying or hard starting. Fault information, • Bad intelligent device or component. trip information and maintenance monitor data can be inaccurate. Transmission output shaft speed Engine will run off of a default auxiliary speed.
  • Page 225 TROUBLESHOOTING Fault code Reason Effect (Lamp) Intake manifold 1 temperature Progressive power derate increasing in severity (Orange) • Data valid but above normal operation range. from time of alert. • Moderately severe level. Transmission output shaft speed ECM changes engine speed to a calibration (Orange) •...
  • Page 226 TROUBLESHOOTING Fault code Reason Effect (Lamp) Turbocharger 1 speed Engine power derate. The ECM uses an (Orange) • Data valid but below normal operating range. estimated turbocharger speed. • Moderately severe level. Engine crankshaft speed/position Engine power derate. (Orange) • Data erratic, intermittent or incorrect.
  • Page 227 TROUBLESHOOTING Fault code Reason Effect (Lamp) 1844 Crankcase pressure circuit No engine protection for high crankcase (Orange) • Voltage below normal or shorted to low pressure. source. 1896 EGR valve controller EGR valve actuation will be disabled. (Orange) • Out of calibration 1898 VGT actuator controller Low intake manifold pressure.
  • Page 228 TROUBLESHOOTING Fault code Reason Effect (Lamp) 2349 EGR valve control circuit EGR valve actuation will be disabled. (Orange) • Current below normal or open circuit. 2353 EGR valve control circuit EGR valve actuation will be disabled. (Orange) • Current above normal or grounded circuit. 2357 EGR valve control circuit EGR valve actuation will be disabled.
  • Page 229 TROUBLESHOOTING Fault code Reason Effect (Lamp) 2646 Engine coolant temperature EGR valve actuation will be disabled. (Orange) • Condition exists. 2765 Engine injector bank 1 barcodes None on performance. (None) • Out of calibration. 2961 Exhaust gas recirculation temperature Slight fueling derate to bring EGR temperature (None) •...

  • Page 230: Error Codes

    (Error code can be viewed when using service tool) If more than one error occur at the same time, the sum of the error codes is output. ECO controller ECO controller VIEW A VIEW A Red LED indicator Red LED indicator Green LED indicator Green LED indicator ECO controller ECO controller SV540-09009 SV540-09009 9-022...
  • Page 231 TROUBLESHOOTING Number of Error Error occurred at Description Error bypass action red LED blinks code 1 long, 1 short Signal wire short-circuit Motor proportional solenoid (rear) 1 long, 2 short Signal wire open-circuit Speed is changed to 1st (low speed) immediately. 1 long, 3 short Signal wire short-circuit Motor speed change...
  • Page 232 1.25B 115E41R DIODE UNIT (651CCA) STARTER STARTER LOCKOUT RELAY RELAY(B-6) 71 8BW 59 8W STARTER SWITCH AV60 1.25RW STARTER 1.25RG X 1.25B BATTERY SWITCH 24 1.25BR AV60 STARTER MOTOR The wire size is AVS 0.85 unless otherwise specified. SV540-09001 9-024...

  • Page 233: Engine

    TROUBLESHOOTING 2-4. 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 check lamp must not be lighting. If engine check lamp lights, refer to “Service information” of engine manufacturer.
  • Page 234 1.25B 115E41R DIODE UNIT (651CCA) STARTER STARTER LOCKOUT RELAY RELAY(B-6) 71 8BW 59 8W STARTER SWITCH AV60 1.25RW STARTER 1.25RG X 1.25B BATTERY SWITCH 24 1.25BR AV60 STARTER MOTOR The wire size is AVS 0.85 unless otherwise specified. SV540-09001 9-026...

  • Page 235: Engine Will Not Start (Starter Motor Does Not Run) 2/4

    TROUBLESHOOTING 2-4-1. Engine will not start (Starter motor does not run) 2/4 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). Reference Fig.: 2-4-1 Check point Check/Cause Action...
  • Page 236 1.25B 115E41R DIODE UNIT (651CCA) STARTER STARTER LOCKOUT RELAY RELAY(B-6) 71 8BW 59 8W STARTER SWITCH AV60 1.25RW STARTER 1.25RG X 1.25B BATTERY SWITCH 24 1.25BR AV60 STARTER MOTOR The wire size is AVS 0.85 unless otherwise specified. SV540-09001 9-028...

  • Page 237: Engine Will Not Start (Starter Motor Does Not Run) 3/4

    TROUBLESHOOTING 2-4-1. Engine will not start (Starter motor does not run) 3/4 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). Reference Fig.: 2-4-1 Check point Check/Cause Action...
  • Page 238 1.25B 115E41R DIODE UNIT (651CCA) STARTER STARTER LOCKOUT RELAY RELAY(B-6) 71 8BW 59 8W STARTER SWITCH AV60 1.25RW STARTER 1.25RG X 1.25B BATTERY SWITCH 24 1.25BR AV60 STARTER MOTOR The wire size is AVS 0.85 unless otherwise specified. SV540-09001 9-030...

  • Page 239: Engine Will Not Start (Starter Motor Does Not Run) 4/4

    TROUBLESHOOTING 2-4-1. Engine will not start (Starter motor does not run) 4/4 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). Reference Fig.: 2-4-1 Check point Check/Cause Action...
  • Page 240 TROUBLESHOOTING Fig.: 2-4-2 VIEW B VIEW A DETAIL C SV540-09010 (1) Fuel from supply tank (5) Fuel filter (2) Priming pump (6) Fuel gear pump (3) Fuel to fuel filter (7) Fuel supply to pump (4) Fuel pre-filter 9-032...

  • Page 241: Engine Will Not Start (But Starter Motor Runs)

    TROUBLESHOOTING 2-4-2. 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 242 1.25B 115E41R DIODE UNIT (651CCA) STARTER STARTER LOCKOUT RELAY RELAY(B-6) 71 8BW 59 8W STARTER SWITCH AV60 1.25RW STARTER 1.25RG X 1.25B BATTERY SWITCH 24 1.25BR AV60 STARTER MOTOR The wire size is AVS 0.85 unless otherwise specified. SV540-09001 9-034...

  • Page 243: No Charging

    TROUBLESHOOTING 2-4-3. No charging Reference Fig.: 2-4-1 Check point Check/Cause Action 1. Alternator • After starting engine, measure voltage between alternator Replace alternator or terminal BATTERY wire and chassis ground. battery. Standard voltage : At least intermediate engine speed, 27 to 29 V or more •...
  • Page 244 1.25B 115E41R DIODE UNIT (651CCA) STARTER STARTER LOCKOUT RELAY RELAY(B-6) 71 8BW 59 8W STARTER SWITCH AV60 1.25RW STARTER 1.25RG X 1.25B BATTERY SWITCH 24 1.25BR AV60 STARTER MOTOR The wire size is AVS 0.85 unless otherwise specified. SV540-09001 9-036...

  • Page 245: Engine Speed Cannot Be Switched

    TROUBLESHOOTING 2-4-5. Starter motor runs even when F-R lever is not at “N” and parking brake is not applied Reference Fig.: 2-4-1 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 246 AV60 AV60 BRAKE AV30 SWITCH 5 1.25RB COMBINATION METER 115E41R (651CCA) 1.25B STARTER BATTERY SWITCH RELAY 1.25BR ALTERNATOR STARTER SWITCH 115E41R 28 LgW BATTERY (651CCA) STARTER MOTOR AV60 AV60 The wire size is AVS 0.85 unless otherwise specified. SV540-09002 9-038...

  • Page 247: Propulsion

    TROUBLESHOOTING 2-5. Propulsion Check following items 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 flowing using tester” (P.9-006 to P.9-008). •...
  • Page 248 AV60 AV60 BRAKE AV30 SWITCH 5 1.25RB COMBINATION METER 115E41R (651CCA) 1.25B STARTER BATTERY SWITCH RELAY 1.25BR ALTERNATOR STARTER SWITCH 115E41R 28 LgW BATTERY (651CCA) STARTER MOTOR AV60 AV60 The wire size is AVS 0.85 unless otherwise specified. SV540-09002 9-040...

  • Page 249: Machine Speed Cannot Be Changed 1/5

    TROUBLESHOOTING 2-5-2. Machine speed cannot be changed 1/5 • Engine check lamp must not be lighting. If engine check lamp lights, refer to “Service information” of engine manufacturer. • Check whether ECO controller red LED shows any blink. 1) when red LED shows no blink. Reference Fig.: 2-5-1 Check point Check/Cause...
  • Page 250 AV60 AV60 BRAKE AV30 SWITCH 5 1.25RB COMBINATION METER 115E41R (651CCA) 1.25B STARTER BATTERY SWITCH RELAY 1.25BR ALTERNATOR STARTER SWITCH 115E41R 28 LgW BATTERY (651CCA) STARTER MOTOR AV60 AV60 The wire size is AVS 0.85 unless otherwise specified. SV540-09002 9-042...

  • Page 251: Machine Speed Cannot Be Changed 2/5

    TROUBLESHOOTING 2-5-2. Machine speed cannot be changed 2/5 • Engine check lamp must not be lighting. If engine check lamp lights, refer to “Service information” of engine manufacturer. • Check whether ECO controller red LED shows any blink. 1) when red LED shows no blink. Reference Fig.: 2-5-1 Check point Check/Cause...
  • Page 252 AV60 AV60 BRAKE AV30 SWITCH 5 1.25RB COMBINATION METER 115E41R (651CCA) 1.25B STARTER BATTERY SWITCH RELAY 1.25BR ALTERNATOR STARTER SWITCH 115E41R 28 LgW BATTERY (651CCA) STARTER MOTOR AV60 AV60 The wire size is AVS 0.85 unless otherwise specified. SV540-09002 9-044...

  • Page 253: Machine Speed Cannot Be Changed 3/5

    TROUBLESHOOTING 2-5-2. Machine speed cannot be changed 3/5 • Engine check lamp must not be lighting. If engine check lamp lights, refer to “Service information” of engine manufacturer. • Check whether ECO controller red LED shows any blink. 2) when red LED shows any blink. Reference Fig.: 2-5-1 Number of Check point...
  • Page 254 AV60 AV60 BRAKE AV30 SWITCH 5 1.25RB COMBINATION METER 115E41R (651CCA) 1.25B STARTER BATTERY SWITCH RELAY 1.25BR ALTERNATOR STARTER SWITCH 115E41R 28 LgW BATTERY (651CCA) STARTER MOTOR AV60 AV60 The wire size is AVS 0.85 unless otherwise specified. SV540-09002 9-046...

  • Page 255: Machine Speed Cannot Be Changed 4/5

    TROUBLESHOOTING 2-5-2. Machine speed cannot be changed 4/5 • Engine check lamp must not be lighting. If engine check lamp lights, refer to “Service information” of engine manufacturer. • Check whether ECO controller red LED shows any blink. 2) when red LED shows any blink. Reference Fig.: 2-5-1 Number of Check point...
  • Page 256 AV60 AV60 BRAKE AV30 SWITCH 5 1.25RB COMBINATION METER 115E41R (651CCA) 1.25B STARTER BATTERY SWITCH RELAY 1.25BR ALTERNATOR STARTER SWITCH 115E41R 28 LgW BATTERY (651CCA) STARTER MOTOR AV60 AV60 The wire size is AVS 0.85 unless otherwise specified. SV540-09002 9-048...

  • Page 257: Machine Speed Cannot Be Changed 5/5

    TROUBLESHOOTING 2-5-2. Machine speed cannot be changed 5/5 • Engine check lamp must not be lighting. If engine check lamp lights, refer to “Service information” of engine manufacturer. • Check whether ECO controller red LED shows any blink. 2) when red LED shows any blink. Reference Fig.: 2-5-1 Number of Check point...
  • Page 258 AV60 AV60 BRAKE AV30 SWITCH 5 1.25RB COMBINATION METER 115E41R (651CCA) 1.25B STARTER BATTERY SWITCH RELAY 1.25BR ALTERNATOR STARTER SWITCH 115E41R 28 LgW BATTERY (651CCA) STARTER MOTOR AV60 AV60 The wire size is AVS 0.85 unless otherwise specified. SV540-09002 9-050...

  • Page 259: Brake Cannot Be Released

    TROUBLESHOOTING 2-5-3. Brake cannot be released • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). Reference Fig.: 2-5-1 Check point Check/Cause Action 1. Parking Brake Solenoid • Disconnect harness and measure resistance of coil. Replace parking brake Standard voltage : 45 Ω...
  • Page 260 AV60 AV60 BRAKE AV30 SWITCH 5 1.25RB COMBINATION METER 115E41R (651CCA) 1.25B STARTER BATTERY SWITCH RELAY 1.25BR ALTERNATOR STARTER SWITCH 115E41R 28 LgW BATTERY (651CCA) STARTER MOTOR AV60 AV60 The wire size is AVS 0.85 unless otherwise specified. SV540-09002 9-052...

  • Page 261: Brake Does Not Work

    TROUBLESHOOTING 2-5-4. Brake does not work • Parking brake switch must be applied. • Foot brake switch must be OFF (Brake pedal is depressed). Reference Fig.: 2-5-1 Check point Check/Cause Action 1. Parking Brake Solenoid • Disconnect harness and measure resistance of coil. Replace parking brake Standard resistance : 45 Ω...
  • Page 262 4 5BY BATTERY 1.25RB STARTER SWITCH 115E41R STARTER (651CCA) DIODE UNIT SWITCH AV60 AV60 COMBINATION METER AV60 1.25BR 28 LgW STARTER MOTOR 5 1.25RB AV30 BATTERY ALTERNATOR RELAY 1.25B The wire size is AVS 0.85 unless otherwise specified. SV540-09003 9-054...

  • Page 263: Vibration

    TROUBLESHOOTING 2-6. Vibration Check following items 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 flowing using tester” (P.9-006 to P.9-008). •...
  • Page 264 4 5BY BATTERY 1.25RB STARTER SWITCH 115E41R STARTER (651CCA) DIODE UNIT SWITCH AV60 AV60 COMBINATION METER AV60 1.25BR 28 LgW STARTER MOTOR 5 1.25RB AV30 BATTERY ALTERNATOR RELAY 1.25B The wire size is AVS 0.85 unless otherwise specified. SV540-09003 9-056...

  • Page 265: No Vibration Occurs 2/3

    TROUBLESHOOTING 2-6-1. No vibration occurs 2/3 • Vibration mode change switch must be “CONT” (continuous mode). • Vibration select switch must not be “ ”. • Check whether ECO controller red LED shows any blink. 1) when red LED shows no blink. Reference Fig.: 2-6-1 Check point Check/Cause...
  • Page 266 4 5BY BATTERY 1.25RB STARTER SWITCH 115E41R STARTER (651CCA) DIODE UNIT SWITCH AV60 AV60 COMBINATION METER AV60 1.25BR 28 LgW STARTER MOTOR 5 1.25RB AV30 BATTERY ALTERNATOR RELAY 1.25B The wire size is AVS 0.85 unless otherwise specified. SV540-09003 9-058...

  • Page 267: No Vibration Occurs 3/3

    TROUBLESHOOTING 2-6-1. No vibration occurs 3/3 • Vibration mode change switch must be “CONT” (continuous mode). • Vibration select switch must not be “ ”. • Check whether ECO controller red LED shows any blink. 1) when red LED shows no blink. Reference Fig.: 2-6-1 Check point Check/Cause...
  • Page 268 4 5BY BATTERY 1.25RB STARTER SWITCH 115E41R STARTER (651CCA) DIODE UNIT SWITCH AV60 AV60 COMBINATION METER AV60 1.25BR 28 LgW STARTER MOTOR 5 1.25RB AV30 BATTERY ALTERNATOR RELAY 1.25B The wire size is AVS 0.85 unless otherwise specified. SV540-09003 9-060...

  • Page 269: Amplitude Does Not Change (Remains Either Low Or High) 1/3

    TROUBLESHOOTING 2-6-2. Amplitude does not change (Remains either low or high) 1/3 • Vibration mode change switch must be “CONT” (continuous mode). • Vibration switch must not be “ ”. Reference Fig. : 2-6-1 Check point Check/Cause Action 1. Vibrator Proportional •...
  • Page 270 4 5BY BATTERY 1.25RB STARTER SWITCH 115E41R STARTER (651CCA) DIODE UNIT SWITCH AV60 AV60 COMBINATION METER AV60 1.25BR 28 LgW STARTER MOTOR 5 1.25RB AV30 BATTERY ALTERNATOR RELAY 1.25B The wire size is AVS 0.85 unless otherwise specified. SV540-09003 9-062...

  • Page 271: Amplitude Does Not Change (Remains Either Low Or High) 2/3

    TROUBLESHOOTING 2-6-2. Amplitude does not change (Remains either low or high) 2/3 • Vibration mode change switch must be “CONT” (continuous mode). • Vibration select switch must not be “ ”. Reference Fig. : 2-6-1 Check point Check/Cause Action 4. Throttle switch (1) when starter switch is ON, measure voltage between Replace throttle switch.
  • Page 272 4 5BY BATTERY 1.25RB STARTER SWITCH 115E41R STARTER (651CCA) DIODE UNIT SWITCH AV60 AV60 COMBINATION METER AV60 1.25BR 28 LgW STARTER MOTOR 5 1.25RB AV30 BATTERY ALTERNATOR RELAY 1.25B The wire size is AVS 0.85 unless otherwise specified. SV540-09003 9-064...

  • Page 273: Amplitude Does Not Change (Remains Either Low Or High) 3/3

    TROUBLESHOOTING 2-6-2. Amplitude does not change (Remains either low or high) 3/3 • Vibration mode change switch must be “CONT” (continuous mode). • Vibration select switch must not be “ ”. Reference Fig. : 2-6-1 Check point Check/Cause Action 6. ECO controller (1) when starter switch is ON, measure voltage between Replace ECO controller.
  • Page 274 4 5BY BATTERY 1.25RB STARTER SWITCH 115E41R STARTER (651CCA) DIODE UNIT SWITCH AV60 AV60 COMBINATION METER AV60 1.25BR 28 LgW STARTER MOTOR 5 1.25RB AV30 BATTERY ALTERNATOR RELAY 1.25B The wire size is AVS 0.85 unless otherwise specified. SV540-09003 9-066...

  • Page 275: Vibration Mode Cannot Be Switched

    TROUBLESHOOTING 2-6-3. Vibration mode cannot be switched (F-R lever vibration switch does not work) • Vibration mode change switch must be “ ” (manual mode). • Vibration select switch must not be “ ”. Reference Fig. : 2-6-1 Check point Check/Cause Action 1.
  • Page 276 4 5BY BATTERY 1.25RB STARTER SWITCH 115E41R STARTER (651CCA) DIODE UNIT SWITCH AV60 AV60 COMBINATION METER AV60 1.25BR 28 LgW STARTER MOTOR 5 1.25RB AV30 BATTERY ALTERNATOR RELAY 1.25B The wire size is AVS 0.85 unless otherwise specified. SV540-09003 9-068...

  • Page 277: Vibrator Force Is Low In Eco Mode

    TROUBLESHOOTING 2-6-4. Vibrator force is low in ECO mode • Vibration mode change switch must be “CONT” (continuous mode). • Vibration select switch must not be “ ”. • Throttle switch must be “MID”. • ECO lamp is ON. Reference Fig. : 2-6-1 Check point Check/Cause Action...
  • Page 278 5 1.25RB 115E41R STARTER SWITCH (651CCA) 1.25B STARTER SWITCH BATTERY RELAY 1.25BR 32 BY FUSE AV30 125A 29 LgB 115E41R (651CCA) BATTERY LAMP CHECK RELAY(B-5) STARTER MOTOR AV60 AV60 The wire size is AVS 0.85 unless otherwise specified. SV540-09004 9-070...

  • Page 279: Lighting

    TROUBLESHOOTING 2-7. 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 280 5 1.25RB 115E41R STARTER SWITCH (651CCA) 1.25B STARTER SWITCH BATTERY RELAY 1.25BR 32 BY FUSE AV30 125A 29 LgB 115E41R (651CCA) BATTERY LAMP CHECK RELAY(B-5) STARTER MOTOR AV60 AV60 The wire size is AVS 0.85 unless otherwise specified. SV540-09004 9-072...

  • Page 281: Tachometer Reading Is Abnormal

    TROUBLESHOOTING 2-7-2. Tachometer reading is abnormal Reference Fig. : 2-7-1 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 282 5 1.25RB 115E41R STARTER SWITCH (651CCA) 1.25B STARTER SWITCH BATTERY RELAY 1.25BR 32 BY FUSE AV30 125A 29 LgB 115E41R (651CCA) BATTERY LAMP CHECK RELAY(B-5) STARTER MOTOR AV60 AV60 The wire size is AVS 0.85 unless otherwise specified. SV540-09004 9-074...

  • Page 283: Temperature Meter Is Abnormal

    TROUBLESHOOTING 2-7-4. Temperature meter is abnormal Reference Fig. : 2-7-1 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 284 5 1.25RB 115E41R STARTER SWITCH (651CCA) 1.25B STARTER SWITCH BATTERY RELAY 1.25BR 32 BY FUSE AV30 125A 29 LgB 115E41R (651CCA) BATTERY LAMP CHECK RELAY(B-5) STARTER MOTOR AV60 AV60 The wire size is AVS 0.85 unless otherwise specified. SV540-09004 9-076...

  • Page 285: Hydraulic Oil Filter Warning Lamp Remains On

    TROUBLESHOOTING 2-7-6. Hydraulic oil filter warning lamp remains ON Reference Fig. : 2-7-1 Check point Check/Cause Action 1. Harness • Disconnect connectors between hydraulic oil filter switch Repair or replace 1, 2 and combination meter. harness. • Measure resistance between terminal and chassis ground.
  • Page 286 5 1.25RB 115E41R STARTER SWITCH (651CCA) 1.25B STARTER SWITCH BATTERY RELAY 1.25BR 32 BY FUSE AV30 125A 29 LgB 115E41R (651CCA) BATTERY LAMP CHECK RELAY(B-5) STARTER MOTOR AV60 AV60 The wire size is AVS 0.85 unless otherwise specified. SV540-09004 9-078...

  • Page 287: Engine Oil Pressure Warning Lamp Remains On

    TROUBLESHOOTING 2-7-7. Engine oil pressure warning lamp remains ON • Check whether engine check lamps show no fault code. Reference Fig. : 2-7-1 Check point Check/Cause Action 1. Harness • Disconnect connectors between engine ECM, engine oil Repair or replace pressure switch relay (B-4) and combination meter.
  • Page 288 FUSE BOX 1 FUSE BOX 2 4 5BY BATTERY 1.25RB STARTER SWITCH 115E41R STARTER (651CCA) DIODE UNIT SWITCH AV60 AV60 AV60 1.25BR STARTER MOTOR 5 1.25RB AV30 BATTERY ALTERNATOR RELAY 1.25B The wire size is AVS 0.85 unless otherwise specified. SV540-09005 9-080...

  • Page 289: Vibration Indicator Lamp Does Not Light

    TROUBLESHOOTING 2-7-8. Vibration indicator lamp does not light • Check that vibrator can be operated. Reference Fig. : 2-7-2 Check point Check/Cause Action 1. Harness (1) Measure resistance between vibration select switch Repair or replace terminal 5 wire YB and diode unit terminal E wire YB. harness.
  • Page 290 FUSE BOX 1 FUSE BOX 2 4 5BY BATTERY 1.25RB STARTER SWITCH 115E41R STARTER (651CCA) DIODE UNIT SWITCH AV60 AV60 AV60 1.25BR STARTER MOTOR 5 1.25RB AV30 BATTERY ALTERNATOR RELAY 1.25B The wire size is AVS 0.85 unless otherwise specified. SV540-09005 9-082...

  • Page 291: Parking Brake Indicator Lamp Does Not Light

    TROUBLESHOOTING 2-7-9. Parking brake indicator lamp does not light Reference Fig. : 2-7-2 Check point Check/Cause Action 1. Harness • Measure resistance between parking brake switch Repair or replace terminal 4 wire GR and combination meter connector harness. terminal wire No. 38 wire GR. Standard resistance : 10 Ω...
  • Page 292 FUSE BOX 1 FUSE BOX 2 4 5BY BATTERY 1.25RB STARTER SWITCH 115E41R STARTER (651CCA) DIODE UNIT SWITCH AV60 AV60 AV60 1.25BR STARTER MOTOR 5 1.25RB AV30 BATTERY ALTERNATOR RELAY 1.25B The wire size is AVS 0.85 unless otherwise specified. SV540-09005 9-084...

  • Page 293: Eco Mode Indicator Lamp Does Not Light

    TROUBLESHOOTING 2-7-10. ECO mode indicator lamp does not light • Throttle switch must be “MID”. • Vibration select switch must not be “ ”. Reference Fig. : 2-7-2 Check point Check/Cause Action 1. MID/FULL Speed (1) when starter switch is ON, measure voltage between Replace MID/FULL Control Relay (B-3) MID/FULL speed control relay (B-3) terminal 1 inlet wire...
  • Page 294 4 5BY 1.25RB AV60 DIODE UNIT AV60 AV60 AV30 5 1.25RB 115E41R STARTER SWITCH (651CCA) 1.25B BATTERY RELAY 1.25BR ALTERNATOR STARTER SWITCH 115E41R (651CCA) BATTERY AV60 AV60 STARTER MOTOR The wire size is AVS 0.85 unless otherwise specified. SV540-09006 9-086...

  • Page 295: Horn Does Not Sound

    TROUBLESHOOTING 2-7-11. Horn does not sound Reference Fig. : 2-7-3 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 296: 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 297: Propulsion System

    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 298: 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 299: 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 300: 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 301: Vibrator System

    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 302: Vibrator Frequency Is Too Low

    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 303: Vibrator Does Not Stop

    TROUBLESHOOTING 3-3-4. Vibrator does not stop Check point Cause Check/Action 1. Servo Control Servo control valve spool does not return to • Measure vibrator high/low circuit pressure. Valve neutral position. • If not equal, check and adjust servo control valve or replace it if necessary. 2.

  • Page 304: Steering System

    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 305: Steering Wheel Backlash Or Play Is Large

    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 306 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 2013.11.50 ○ 0418-99045-0-31159-0...

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