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Sakai SV414 Shop Manual

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SV414
SHOP MANUAL
3498-64214-0

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  • Page 1 SV414 SHOP MANUAL 3498-64214-0...
  • 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

    SV414 ○ 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 SV414 ○ 3. ENGINE AND CONTROLS 1. ENGINE 1-1. Engine Mount  3-001 2. FUEL SYSTEM  3-002 3. CONTROL SYSTEM 3-1. Forward-reverse Control  3-004 4. PUMP MOUNT 4-1. Pump Mount   3-005 4-1-1. Installation of pump   3-006 4.
  • Page 7 SV414 ○ 4-4. Description and Operation of Steering System   4-029 4-4-1. Description and operation of steering system   4-029 4-4-2. Structure and operation of Orbitrol   4-030 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...
  • Page 8 SV414 ○ 6. VIBRATORY DRUM • REAR AXLE 1. PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY   6-001 2. VIBRATORY DRUM 2-1. Removal and Installation of Vibratory Drum   6-003 2-1-1. Removal of vibratory drum   6-003 2-1-2. Installation of vibratory drum  6-006 3.
  • Page 9 SV414 ○ 2. MEASUREMENT AND ADJUSTMENT OF PROPULSION CIRCUIT PRESSURE 2-1. Measurement  8-002 2-2. Adjustment   8-003 3. MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT PRESSURE  8-004 3-1. Measurement  8-005 3-2. Adjustment   8-006 4. MEASUREMENT OF PROPULSION SERVO CIRCUIT PRESSURE 4-1.
  • Page 10 SV414 ○ 9. TROUBLESHOOTING 1. TROUBLESHOOTING 1-1. Safety Precautions for Troubleshooting  9-001 1-2. Important Information for Troubleshooting  9-001 1-3. Before Starting  9-002 2. ELECTRICAL SYSTEM TROUBLESHOOTING 2-1. when Performing Electrical System Fault Diagnosis   9-003 2-1-1. Precautions to take during electrical circuit fault diagnosis   9-003 2-1-2.
  • Page 11 SV414 ○ 2-6. Lighting   9-054 2-6-1. Illumination of combination meter does not light  9-054 2-6-2. Combination meter warning lamp or indicator lamp is abnormal   9-056 2-6-3. Hour meter is abnormal   9-058 2-6-4. Fuel meter is abnormal  9-058 2-6-5.

  • 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

    1. SPECIFICATION DATA 1-1. SV414D 102.5 102.5 1700 2655 1475 1300 1905 5035 0421-99005-0-10168-0 Model SAKAI SV414D with ROPS Model & Type Type VIBRATORY SINGLE-DRUM ROLLER without ballast 7,090 kg 15,630 lbs. Operating weight with ballast N/A kg N/A lbs. Maximum weight 7,150 kg 15,765 lbs.

  • Page 27: Sv414D

    SV414D SPECIFICATIONS Centrifugal Low amplitude 93 kN 20,905 lbf. force High amplitude 118 kN 26,525 lbf. Low amplitude 38.0 Hz 2,280 vpm Front Frequency High amplitude 30.0 Hz 1,800 vpm Low amplitude 0.75 mm 0.030 in. Amplitude High amplitude 1.55 mm 0.061 in.

  • Page 28: Sv414T

    SV414T 1-2. SV414T 102.5 102.5 1700 2655 1475 1300 1905 5035 0421-99006-0-10169-0 Model SAKAI SV414T with ROPS Model & Type Type VIBRATORY SINGLE-DRUM ROLLER without ballast 7,090 kg 15,630 lbs. Operating weight with ballast N/A kg N/A lbs. Maximum weight 7,150 kg 15,765 lbs.
  • Page 29 SV414T SPECIFICATIONS Centrifugal Low amplitude 93 kN 20,905 lbf. force High amplitude 118 kN 26,525 lbf. Low amplitude 38.0 Hz 2,280 vpm Front Frequency High amplitude 30.0 Hz 1,800 vpm Low amplitude 0.75 mm 0.030 in. Amplitude High amplitude 1.55 mm 0.061 in.

  • Page 30: Sv414Tf

    SV414TF 1-3. SV414TF 102.5 102.5 1700 2655 1475 1300 1905 5035 0421-99007-0-10170-0 Model SAKAI SV414TF with ROPS Model & Type Type VIBRATORY SINGLE-DRUM ROLLER without ballast 8,320 kg 18,340 lbs. Operating weight with ballast N/A kg N/A lbs. Maximum weight 8,380 kg 18,475 lbs.
  • Page 31 SV414TF SPECIFICATIONS Centrifugal Low amplitude 93 kN 20,905 lbf. force High amplitude 118 kN 26,525 lbf. Low amplitude 38.0 Hz 2,280 vpm Front Frequency High amplitude 30.0 Hz 1,800 vpm Low amplitude 0.50 mm 0.020 in. Amplitude High amplitude 1.00 mm 0.039 in.

  • Page 32: Common Specifications

    SPECIFICATIONS 1-4. Common Specifications Model CUMMINS QSF 2.8 (Diesel, EPA-Tier 4) 4-cycle, water-cooled, 4-cylinder in-line, overhead valve, Type direct injection type, with turbo charger Cylinders - Bore × Stroke 94 mm × 100 mm (3.700 in. × 3.940 in.) Displacement 2.800 L ( 171.0 cu.in.

  • Page 33: Table Of Standard Values

    SPECIFICATIONS 2. TABLE OF STANDARD VALUES 2-1. Engine Item Standard value Remarks CUMMINS QSF 2.8 Engine model Rated output 55/2,400 kW/ min 74/2,400 HP/ min Max. rpm under no load 2,400 rpm 900 rpm Min. rpm under no load 60 N·m 44 lbf·ft Cylinder head Tighten additional 90°...

  • Page 34: 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 140 mm (5.5 in.) Note 1: See dimensions...

  • Page 35: 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 CJ4 SAE15W-40...

  • Page 36: 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 37: Engine And Controls

    ENGINE AND CONTROLS...

  • Page 39: Engine

    ENGINE AND CONTROLS 1. ENGINE 1-1. Engine Mount DETAIL C DETAIL B VIEW A 0421-01801-0-10001-B (1) Bracket (7) Plate (12) Bolt : M16×140 (2) Bracket (8) Damper (13) Plate (3) Engine (9) Shim (14) Damper (4) Bracket (10) Nut : M16 (15) Nut : M16 (5) Bracket...

  • Page 40: Fuel System

    ENGINE AND CONTROLS 2. FUEL SYSTEM 0421-02801-0-10002-B 3-002...
  • Page 41 ENGINE AND CONTROLS Engine Fuel return (engine) Fuel suction (engine) Main filter Fuel cooler Pre-filter Fuel suction (tank) Fuel return (tank) Fuel tank Fuel system diagram SECTION A-A SECTION B-B 0421-02801-0-10002-B (1) Fuel coller (11) Drain plug (2) Hose (Fuel return (engine) → Fuel coller IN) (12) Hose (Main filter OUT →...

  • Page 42: Control System

    ENGINE AND CONTROLS 3. CONTROL SYSTEM 3-1. Forward-reverse Control DETAIL B Apply grease* SECTION A-A 0421-12801-0-10009-0 (1) F-R lever switch (8) Rod end (Apply grease*) (2) Backup buzzer switch (9) Bolt : M16×30 (3) F-R lever (10) Nut : M16 (4) Control cable (11) Spring (Fill grease) (5) Bush (Apply grease*)

  • Page 43: Pump Mount

    ENGINE AND CONTROLS 4. PUMP MOUNT 4-1. Pump Mount SECTION A-A 0421-36801-0-10013-A (1) Bolt : M10×25 (6) Housing (2) Bolt : M10×35 (7) Bolt : M14×45 (3) Retaining ring (8) Pump (4) Hub (9) Bolt : M12×35 (5) Flange N•m (1) Bolt M10×25 : 59 N·m ( 44 lbf·ft )

  • Page 44: Installation Of Pump

    ⑥ Engage hub (4) with flange (5). ⑦ Secure pump (8) to housing (6) with four bolts (7), spring SECTION A-A washers and washers. SV414-03002 (7) Bolt M14×45 : 167 N·m (123 lbf·ft) N•m 3-006...

  • Page 45: Hydraulic Systems

    HYDRAULIC SYSTEMS...

  • Page 48: 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 49 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 51: Hydraulic Circuit Diagram

    HYDRAULIC SYSTEMS 1-2. Hydraulic Circuit Diagram Orbitrol Steering cylinder (R) 70X 35-380 (1/2") (3/8") SRR SRL cc/rev (3/8") SLL SLR Hydraulic oil filter 1 15.0 MPa 70X 35-380 Steering cylinder (L) Parking brake (1/2") (1/2") solenoid valve (1/4") (1/4") (1/4") Servo bypass BPL BPS solenoid valve...

  • Page 53: Propulsion Hydraulic System

    HYDRAULIC SYSTEMS 2. PROPULSION HYDRAULIC SYSTEM 2-1. Propulsion Hydraulic Piping Hose 2-1-1. Propulsion hydraulic piping (F) Hose Hose (FMD VDM) (RB2 FMA) (RA2 FMB) Hose Hydraulic oil tank (ST5 Vibrator motor Hose FMC) (SCA Propulsion motor (R) SECTION B-B SECTION A-A Speed change Parking brake solenoid valve (F)

  • Page 55: Propulsion Hydraulic Piping (R)

    HYDRAULIC SYSTEMS 2-1-2. Propulsion hydraulic piping (R) Hose Hose RB1) (RMD PD1) (PPA Bypass valve Hydraulic oil tank Hose PD1) (RMD Hose RA1) (PPB SECTION A-A Hose Hose Hose PD1) (PDC (PPA RB1) (RMD Hose BV1) (RA3 Hose Hose RA1) BV2) (PPB (RB3...

  • Page 58: Hydraulic Component Specifications

    HYDRAULIC SYSTEMS 2-2. Hydraulic Component Specifications 2-2-1. Hydraulic pump ASSY (propulsion + vibrator + steering • charge) 2-3 1-4 2-10 1-10 1-12 1-13 2-12 2-13 2-11 1-11 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 SV412-04001...
  • Page 59 HYDRAULIC SYSTEMS (1) Propulsion pump (1-1) Multifunction valve (For port A1) (1-2) Charge pressure gauge port 9/16-18UNF (1-3) Charge supply port [PPC] : 7/ 8-14UNF (1-4) Multifunction valve (For port B1) (1-5) Port B1 (Reverse) [PPB] : SAE 1’’ (1-6) Drain port [PD1] : 1 1/16-12UN (1-7) Servo pressure gauge port [SGA] :...

  • Page 60: Propulsion Hydraulic Motor (F)

    HYDRAULIC SYSTEMS 2-2-2. Propulsion hydraulic motor (F) VIEW B Motor circuit diagram Flow of oil   3  6 Clockwise rotation   6  3 Counterclockwise rotation VIEW A SV414-04001 4-008...
  • Page 61 HYDRAULIC SYSTEMS (1) Servo pressure gauge port (High) : 9/16-18UNF (2) Drain port : 7/ 8-14UNF (3) Port B (Reverse) [FMB] : SAE 3/4” (4) Control pressure gauge port [FMC] : 9/16-18UNF (5) Drain port [FMD] : 7/ 8-14UNF (6) Port A (Forward) [FMA] : SAE 3/4”...

  • Page 62: Gear Box

    HYDRAULIC SYSTEMS 2-2-3. Gear box SV410-2-04002 (1) Gear box Specifications • Reduction ratio : 1/47.00 • Weight 90 kg ( 198 lbs. ) 4-010...
  • Page 63 HYDRAULIC SYSTEMS 1) Structure of gear box 1-10 1-11 1-12 1-21 1-13 1-20 1-14 1-14 1-15 1-22 1-16 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...

  • Page 64: Propulsion Hydraulic Motor (R)

    HYDRAULIC SYSTEMS 2-2-4. Propulsion hydraulic motor (R) Motor ciruit diagram Flow of oil   8 7 Clockwise rotation   7 8 Counterclockwise rotation SV505- -04003 4-012...
  • Page 65 HYDRAULIC SYSTEMS (1) Charge pressure relief valve (2) Pilot supply port [RMP] : 9/16-18UNF (3) Drain port [RMD] : 1 1/16-12UN (4) Servo pressure gauge port 9/16-18UNF (5) Speed change solenoid valve (R) (6) Servo pressure gauge port 9/16-18UNF (7) Port B (Forward) [RMB] : SAE 1”...

  • Page 67: Speed Change Solenoid Valve (F)

    HYDRAULIC SYSTEMS 2-2-5. Speed change solenoid valve (F) 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 68: Block (1)

    HYDRAULIC SYSTEMS 2-2-6. Block (1) SECTION A-A R2-4-04006 (1) From propulsion pump port B ([PPB]) [RA1] : 1-1/16-12UNF (2) Body (3) To propulsion motor (F) port B ([FMB]) [RA2] : 1-1/16-12UNF (4) To bypass valve [RA3] : 3/ 4-16UNF (5) To propulsion motor (R) port A )[RMA]) : φ24.9 4-015...

  • Page 69: Block (2)

    HYDRAULIC SYSTEMS 2-2-7. Block (2) SECTION A-A SV414-04002 (1) From propulsion pump port A ([PPA]) [RB1] : 1-1/16-12UNF (2) Body [RB2] : 1-1/16-12UNF (3) To propulsion motor (F) port A ([FMA]) (4) To bypass valve [RB3] : 3/ 4-16UNF (5) To propulsion motor (R) port B ([RMB]) : φ24.9...
  • Page 70 Speed change solenoid valve (F) Parking brake solenoid valve Bypass valve Orbitrol Relief valve Hydraulic oil filter 1 Oil cooler Suction filter Drum Gear box Propulsion motor (F) Speed change valve Flushing valve Low pressure relief valve Servo bypass solenoid valve SV414-04003 4-017...

  • Page 71: Description And Operation Of Propulsion System

    HYDRAULIC SYSTEMS 2-3. Description and Operation of Propulsion System Description • Made up of propulsion pump (3), propulsion motor (R) (6), rear axle ASSY (7), propulsion motor (F) (17), drum (15), speed change solenoid valve (F) (8) and parking brake solenoid valve (9). Rear axle ASSY (7) includes differential (j), final drives (k), tires (m) and brake (n).
  • Page 72 Speed change solenoid valve (F) Parking brake solenoid valve Bypass valve Orbitrol Relief valve Hydraulic oil filter 1 Oil cooler Suction filter Drum Gear box Propulsion motor (F) Speed change valve Flushing valve Low pressure relief valve Servo bypass solenoid valve SV414-04003 4-019...
  • Page 73 HYDRAULIC SYSTEMS Two-step Speed selection (High-Low) From Low to High: • Speed change solenoid valve (F) (8) and propulsion motor (R) (6) is also equipped with speed change solenoid valve (f). • When the changeover switch at the driver’s seat is set in the (Rabbit) position, the oil is output from speed change solenoid valve (F) (8) to speed change valve (p) of propulsion motor (F) (17), moving the swash plate of the motor to the side where the piston stroke decreases.

  • Page 75: Vibrator Hydraulic System

    HYDRAULIC SYSTEMS 3. VIBRATOR HYDRAULIC SYSTEM 3-1. Vibrator Hydraulic Piping Vibrator motor Hydraulic oil tank Hose Hose Coupling LS2) PDV) : High pressure (VD1 (VD2 Hose AD2) (VPB Hose Hose LS2) (VPA AD1) (VD1 SECTION C-C Hose Hose Hose (VPA AD1 ) (VPB AD2)

  • Page 77: Hydraulic Component Specifications

    HYDRAULIC SYSTEMS 3-2. Hydraulic Component Specifications 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 [VDM] : 7/ 8-14UNF (4) Drain port 7/ 8-14UNF...
  • Page 78 Fig.: Vibrator circuit Engine Coupling Propulsion pump Vibrator pump Amplitude select valve Charge relief valve High pressure relief valves Check valves ・ Steering  charge pump Vibrator motor Vibrator Orbitrol Hydraulic oil filter 1 Hydraulic oil filter 2 Oil cooler Suction filter SV414-04004 4-023...

  • Page 79: Description And Operation Of Vibrator System

    HYDRAULIC SYSTEMS 3-3. Description and Operation of Vibrator System Description • Made up of vibrator pump (4), vibrator motor (6) and vibrator (7). Basic function of vibrator pump and motor Vibrator pump: • A piston pump is in use. Varying the pump swashplate angle varies the piston stroke to select low amplitude, neutral and high amplitude.

  • Page 81: Steering System

    HYDRAULIC SYSTEMS 4. STEERING SYSTEM Hydraulic oil tank Hose (SCD 4-1. Steering Hydraulic Piping Hose SLB) (SRL Steering cylinder (R) Hose Suction filter SRR) Orbitrol SECTION A-A SECTION B-B Hose SLL) Hose Hose Hose LS1) (LOP PPC) SCS) Steering cylinder (L) Hose Hose SCS)

  • Page 83: Steering Wheel

    HYDRAULIC SYSTEMS 4-2. Steering Wheel 0418-62813-0-12540-B (1) Steering wheel (4) Nut : M12 P=1.25 (2) Bolt : M10×30 (5) Orbitrol (3) Column shaft N•m (4) Nut M12 P=1.25 : 35 N·m ( 26 lbf·ft ) 4-026...

  • Page 84: Hydraulic Component Specifications

    HYDRAULIC SYSTEMS 4-3. Hydraulic Component Specifications 4-3-1. Orbitrol Hydraulic circuit diagram ORB-SD-04150 (1) Port L [L] : 3/4-16UNF (4) Port P [P] : 3/4-16UNF (2) Port R [R] : 3/4-16UNF (5) Relief valve (3) Port T [T] : 3/4-16UNF Specifications •...
  • Page 86 HYDRAULIC SYSTEMS Fig.: Steering circuit Engine Coupling Propulsion pump Vibrator pump ・ Steering  charge pump Orbitrol Relief valve Check valve Steering cylinders Piston rods Hydraulic oil filter 1 Suction filter SV414-04005 4-028...

  • Page 87: Description And Operation Of Steering System

    HYDRAULIC SYSTEMS 4-4. Description and Operation of Steering System 4-4-1. Description and operation of steering system Description • Made up of steering • charge pump (5), Orbitrol (6), steering cylinders (7) and hydraulic oil filter 1 (8).The steering mechanism is of an articulated type in which the machine frame is articulated at its center. Operation •...

  • Page 88: Structure And Operation Of Orbitrol

    The rotation of rotor (4) is transmitted to the valve section by drive shaft (5), controlling the valve opening according to the steering wheel rotating speed. 1. Spool 5. Drive shaft 2. Sleeve 6. Centering spring 3. Stator 7. Cross pin 4. Rotor 8. Check valve SV414-04006 SV414-04007 4-030...
  • Page 89 (5), and it is fixed also. • When the steering wheel is operated, the turning force is SV414-04009 applied to spool (1), contracting centering spring (6) that has been set in the slit. As a result, the oil groove of spool (1) is aligned with the oil hole of sleeve (2), opening the hydraulic circuit.
  • Page 90 Orbitrol if the displacement angle exists between the spool and sleeve, permitting the rotor to rotate continuously. SV414-04011 This rotation allows the sleeve to catch up with the spool, closing the hydraulic circuit.
  • Page 91 At that time, the rotor functions as a hydraulic pump, preventing the steering wheel from rotating smoothly. 1. Spool 2. Sleeve 6. Centering spring SV414-04012 4-033...

  • Page 93: Electrical System

    ELECTRICAL SYSTEM...

  • Page 95: 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 96: 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 97: System Circuit Diagram

    ELECTRICAL SYSTEM 2. SYSTEM CIRCuIT DIAGRAM FOOT BRAKE SWITCH 2-1. Electrical Circuit Diagram STOP BACKUP BUZZER 38 GR PARKING BRAKE 53 WR SOLENOID 3 51 PARKING BRAKE SWITCH NC NO COM SPEED CHANGE SOLENOID (F) BACKUP 67 BrY BUZZER SPEED SELECT DIODE UNIT TRAVEL MODE...

  • Page 99: Electrical Components

    ELECTRICAL SYSTEM 3. ELECTRICAL CoMPonEnTS Horn relay Fuse relay box assembly (P.5-012) 3-1. Wiring Harness Layout (1) Lamp check relay Diode unit Parking brake solenoid Hydraulic oil filter switch Mark Frame harness(1),(2) Servo bypass solenoid Speed change solenoid (F) (P.5-006),(P.5-022) (P.5-006),(P.5-008) Hydraulic oil filter harness...
  • Page 101 ELECTRICAL SYSTEM 3-2. Wiring Harness Layout (2) Not in use Foot brake switch (R) (Insulation protection) COM(R),NO(LgR) Reserve tank Panel harness Alternator(120A) Coolant level sensor LAMP (P.5-010) (LgB) Terminal B Mark Engine harness (P.5-010),(P.5-024) (P.5-026) Engine harness Ground (P.5-026) VIEW L Diagnostic switch harness Diagnostic switch (P.5-024)

  • Page 102: Frame Harness (2)

    ELECTRICAL SYSTEM 4. wIRInG HARnESSES 4-1. Frame Harness (1) Starter motor Speed change Backup buzzer Vibrator solenoid solenoid harness TMDN harness harness (P.5-022) (P.5-027) (P.5-023) Speed change solenoid (F) 630855-FA LA308 Fuel sensor SWP-2F SWP-2F SWP-2F DT06-2S-CE05 SWP-4F SWP-14M 118 108 BrR GL 1.25WR Twist cable...
  • Page 103 ELECTRICAL SYSTEM CONNECTION CONNECTION CONTACT CONTACT SIZE, COLOR SIZE, COLOR POINTS POINTS #2D3 , 2 , 7M2 , BU , H × 2, R , 8M3 , Servo bypass solenoid, Fuel gauge unit,Ground, Parking brake solenoid Parking brake solenoid, 4 , Ground B, 2B, 3B Servo bypass solenoid, 2WB, 3WB...
  • Page 104 ELECTRICAL SYSTEM 4-2. Frame Harness (2) Twist cable Twist pair cable with shield Twist cable (AVSSCS 0.75) DETAIL A 1421-09039-1-10240-B 5-008...
  • Page 105 ELECTRICAL SYSTEM CONNECTION CONNECTION CONTACT CONTACT SIZE, COLOR SIZE, COLOR POINTS POINTS #2D3 , 2 , 7M2 , BU , H × 2, R , 8M3 , Servo bypass solenoid, Fuel gauge unit,Ground, Parking brake solenoid Parking brake solenoid, 4 , Ground B, 2B, 3B Servo bypass solenoid, 2WB, 3WB...
  • Page 106 ELECTRICAL SYSTEM 4-3. Panel Harness Twist pair cable with shield (AVSSCS 0.75) Horn PB104 LA108 Combination meter (P.5-029) HD14-9-1939P Data link interface with HDC16-9 connector 1.25WR 776164-1 Twist pair cable with shield (AVSSCS 0.75) Hydraulic oil filter harness (P.5-025) CB104 Diagnostic switch harness (P.5-024) SWP-2F...
  • Page 107 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS #2D3 , J , P , Combination meter-3, Ground, Horn, 5D2 , P B,2B Terminating resistor-C 4D1 , Combination meter-30 #4D5 , E #3D4 , P #3D4 , Combination meter-18 5D2 , P 5D2 , B 5D2 , P...

  • Page 108: Fuse・Relay Box Assembly

    ELECTRICAL SYSTEM 4-4. Fuse・Relay Box Assembly Diode unit SWP-14F 7319-3090 1.25WR × Frame harness(1) (P.5-006) 2LgR 58X-4F (gray) × 2LgR 58Y-2F × (black) × SWP-16F Tape Panel harness Marking tape (P.5-010) (color:blue) 1.25RY × SWP-8F 1.25WR × SWP-6F 30 30 Control harness 1.25RY LgW BY...
  • Page 109 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS 2C , 7M2 , Lamp check relay (A9), 4D1 , Relay box-A3 B,2B Relay box-A1, A2, A3, A4, A6, A7 5D2 , Fuse box-5 3C , 8M3 4D1 , Fuse box-3 6M1 ×...

  • Page 110: Battery Relay Harness

    ELECTRICAL SYSTEM 4-5. Battery Relay Harness Frame harness(1) (P.5-006) 58Y-2M 58X-4M 58Y-2M SWP-2M SWP-3M Twist cable Fusible link (gray) (gray) (black) Fuse 10A Fuse 30A (red) (black) (gray) 1.25WR 5R,120 3WL,50 LA308 LA208 (COM) 5RB,120 5BW,50 LA308 LA308 (COM) Starter relay Corrugate Corrugate Corrugate...
  • Page 111 ELECTRICAL SYSTEM CONTACT SIZE, COLOR CONNECTION POINTS 2 , Starter relay 1 , Fusible link 75A 1 , Fusible link 65A 5 , Grid heater relay 3 , Starter relay 3 , Starter relay 2 , Starter relay 2 , Fusible link 45A 5 , Battery relay-BR, Diode-1 4 , Battery relay-Ground, Diode-2 Battery relay-NO, Fusible link 45A...

  • Page 112: Stater Switch Harness

    ELECTRICAL SYSTEM 4-6. Stater Switch Harness 5BY,70 LA305 (B) 5BY,70 BR,70 LCT RL-1A LA105 (BR) Starter switch Tape 2Lg,70 Panel harness LA205 (C) (P.5-010) 1.25LgW,70 LA105 (ACC) 1.25LgW 58X-3M 1404-09077-0-31751-0 CONTACT SIZE, COLOR CONNECTION POINTS E , Starter switch-B E , Starter switch-BR E , Starter switch-C 1.25LgW E , Starter switch-ACC...

  • Page 113: Control Switch Harness

    ELECTRICAL SYSTEM 4-7. Control Switch Harness LR,70 WR,70 Travel mode 53 (2) change switch LW,70 L,70 G,70 Panel harness L,70 Speed select SWP-12M (P.5-010) switch Tape Tape LW,70 BrR,70 LgR,70 BrY,70 67 (2) BrW,70 Parking brake switch GR,70 B,70 X (5) 1421-09020-0-20151-0 CONTACT SIZE, COLOR...

  • Page 114: Throttle Switch Harness

    ELECTRICAL SYSTEM 4-8. Throttle Switch Harness BW,70 WG,70 Panel harness Throttle switch (P.5-010) Tape RY,70 SWP-4M RW,70 1421-09021-0-30152-0 CONTACT SIZE, COLOR CONNECTION POINTS T , Throttle switch-4 T , Throttle switch-3 T , Throttle switch-1 T , Throttle switch-5 5-018...

  • Page 115: Vibration Switch Harness

    ELECTRICAL SYSTEM 4-9. Vibration Switch Harness Y,70 YB,70 Vibration select switch Y,70 YR,70 Panel harness SWP-6M (P.5-010) Tape RW,70 Vibration mode Y,70 change switch RG,70 1421-09022-0-30153-0 CONTACT SIZE, COLOR CONNECTION POINTS B , Vibration select switch-5 B , Vibration select switch-2 B , Vibration mode change switch-2, Vibration select switch-1, -4 B , Vibration mode change switch-3 B , Vibration mode change switch-1...

  • Page 116: Control Harness

    ELECTRICAL SYSTEM 4-10. Control Harness F-R lever switch Backup buzzer switch (COM) (NC) (COM) (NO) CB104 CA104 CB104 CA104 Marking tape (color:white) 58X-2M Marking tape (black) 2B 2Br (color:red) Fuse relay box assembly Tape Tape Corrugate Corrugate (P.5-012) SWP-6M CB104 CA104 (Br,COM) (G,NO)

  • Page 117: F-R Lever Vibration Switch Harness

    ELECTRICAL SYSTEM 4-11. F-R Lever Vibration Switch Harness Br,55 Br,65 (1) COM Control harness G,55 G,65 (2) NO F-R lever vibration switch (P.5-020) PVC Tube ( 6×0.5) W,55 W,65 (3) NC See “Wiring Harness Layout (1), DETAIL E” (P.5-004) 1539-12013-0-30226-0 CONTACT SIZE, COLOR CONNECTION...

  • Page 118: Speed Change Solenoid Harness

    ELECTRICAL SYSTEM 4-12. Speed Change Solenoid Harness LA103 Frame harness (1) Speed change (P.5-006) solenoid Corrugate 7 SWP-2M LA103 1412-09005-0-30074-A CONTACT SIZE, COLOR CONNECTION POINTS R , Speed change solenoid (R) R , Speed change solenoid (R) 5-022...

  • Page 119: Vibrator Solenoid Harness

    ELECTRICAL SYSTEM 4-13. Vibrator Solenoid Harness Vibrator solenoid (a) LA103 LA103 LA103 Frame harness (1) Vibrator (P.5-006) solenoid (b) Corrugate 7 Corrugate 7 LA103 SWP-4M 1402-09020-1-30430-D CONTACT SIZE, COLOR CONNECTION POINTS H × 2, Vibrator solenoid (a), (b) H , Vibrator solenoid (b) H , Vibrator solenoid (a) 5-023...

  • Page 120: Diagnostic Switch Harness

    ELECTRICAL SYSTEM 4-14. Diagnostic Switch Harness Lg,50 LA104 (2) Panel harness Diagnostic switch Tape (P.5-010) SWP-2M B,50 LA104 (3) 1421-09023-1-30154-A CONTACT SIZE, COLOR CONNECTION POINTS J , Diagnostic switch-3 J , Diagnostic switch-2 5-024...

  • Page 121: Hydraulic Oil Filter Harness

    ELECTRICAL SYSTEM 4-15. Hydraulic Oil Filter Harness Panel harness Y,50 LA105 Hydraulic oil filter switch CA104 (P.5-010) Tube 1405-09009-0-40195-0 CONTACT SIZE, COLOR CONNECTION POINTS Hydraulic oil filter switch, Panel harness 5-025...

  • Page 122: Engine Harness

    ELECTRICAL SYSTEM 4-16. Engine Harness TYCO: SWP-2F Alternator Tape 1.25LB 1.25LB 1-967412-2 Frame harness (1) (P.5-006) DELPHI Coolant 1650 SWP-3F PACKARD: level 12110293 sensor Twist cable Twist cable 1421-09042-0-20243-A CONTACT SIZE, COLOR CONNECTION POINTS 1.25LB M , Alternator M , Coolant level sensor M , Coolant level sensor M , Coolant level sensor 5-026...

  • Page 123: Backup Buzzer Harness

    ELECTRICAL SYSTEM 4-17. Backup Buzzer Harness GB,50 LA104 (+) Frame harness (1) Backup buzzer (P.5-006) Corrugate 7 SWP-2M B,50 LA104 (-) 1421-09044-0-30245-0 CONTACT SIZE, COLOR CONNECTION POINTS BU , Backup buzzer (-) BU , Backup buzzer (+) 5-027...

  • Page 124: Electrical Component Specifications

    Engine ECM (BL) (RG) Battery relay (NO) Battery relay (COM) (BY) (R) Battery relay (NO) Starter switch Starter lockout relay (A5) (W) SV414-05001 Harness color codes : White WR : White/Red stripe : Red : Red/Yellow stripe : Brown : Red/Green stripe...

  • Page 125: Combination Meter

    Turn signal (L) ECO mode Vibrator COMBI. meter ILLUMI. Liquid spray Pull down Hour meter Resistor 4.7KΩ x7 High beam Pull down Resistor 4.7KΩ x5 COMBI. meter ILLUMI. Exhaust system high temperature DEF low level Manual regeneration LYS pin ECO mode SV414-05002 5-029...

  • Page 127: Vibratory Drum • Rear Axle

    VIBRATORY DRUM • REAR AXLE...

  • Page 129: 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 130 VIBRATORY DRUM • REAR AXLE 3) Precautions when work is completed • If coolant has been drained, securely retighten the drain valve 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

    Confirm that the surrounding area is safe, and work in a natural, unstrained posture. Also, to firmly secure the machine body, use a support stand of sufficient strength. SV414-06094 2) Supporting rear frame Lift with crane. •...
  • Page 132 Cross member SV414D : 180 kg (397 lbs.) SV414T : 260 kg (573 lbs.) SV414TF : 295 kg (650 lbs.) SV414-06083 WARN ING 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 133 Vibratory drum ASSY SV414D : 2,520 kg (5,556 lbs.) SV414T : 2,495 kg (5,500 lbs.) SV414TF : 3,785 kg (8,344 lbs.) Support stand SV414-06086 6) Put chocks or the like under removed drum (13) to prevent it from moving. Chock SV414-06087...

  • Page 134: 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. (2) Bolts M20×80 : 539 N·m (398 lbf·ft) N•m (Vibrator drum) (4) Bolts M20×90 : 539 N·m (398 lbf·ft)
  • Page 135 VIBRATORY DRUM 3. VIBRATORY DRUM ASSY (1) Drum (51) Nut : M12 3-1. Vibratory Drum ASSY (2) Bolt : M22×70 (52) Holder (3) Bolt : M16×50 (53) Bolt : M16×45 11,12 16,17 (4) Ring (54) Bolt : M 8×16 19,20 (5) Plug (55) Propulsion motor (6) Bolt...

  • Page 137: Vibratory Drum Assy

    • Quantity of gear oil : 21 L (5.5 gal.) • Install plug (14-1) and drain plug (14-2). Drain port 14-2 SV414-06001 W AR N ING Vibratory drum ASSY • When standing the vibratory drum, use wooden blocks of sufficient strength to securely support the drum.
  • Page 138 WARN ING Lifting bolt, nut When installing lifting bolts, secure them with nuts. 4) Install lifting bolts (M20) and nuts to holders (21) and (35). SV414-06004 5) Remove bolts (25). SV414-06005 6) Remove disc SUBASSY. Disc SUBASSY : 135 kg (298 lbs.)
  • Page 139 VIBRATORY DRUM • REAR AXLE 7) Remove sleeve (11). • Remove bolts (13). SV414-06050 8) Lift axle shaft SUBASSY using two pulling bolts (M20×60). Axle shaft Pulling bolt SUBASSY SV414-06051 W AR N ING When installing lifting bolts, screw in the threads fully...
  • Page 140 SUBASSY, tap on the eccentric shaft end with a wooden hammer via a wooden bar during lifting. Axle shaft SUBASSY : 150 kg (331 lbs.) Wooden bar SV414-06053 11) Put axle shaft SUBASSY on wooden blocks. Axle shaft SUBASSY...
  • Page 141 13) Remove eccentric shaft SUBASSY. Eccentric shaft SUBASSY : 135 kg (298 lbs.) (NOTICE) • Put the movable weight at its outmost position. SV414-06008 W AR N ING Drum SUBASSY Be careful because reversing the vibratory drum involves risk. Confirm that the surrounding area is safe, and work in a natural, unstrained posture.
  • Page 142 VIBRATORY DRUM • REAR AXLE 16) Install lifting bolts (M20) and nuts to holders (52) and (59). Lifting bolt, nut SV414-06012 17) Remove bolts (53). SV414-06013 18) Remove disc SUBASSY. Disc SUBASSY Disc SUBASSY : 115 kg (254 lbs.) SV414-06014...
  • Page 143 VIBRATORY DRUM • REAR AXLE 19) Install lifting bolts (M16) to gear box (45). • Remove bolts (3). Lifting bolt SV414-06015 20) Remove gear box (45). (45) Gear box : 120 kg (265 lbs.) SV414-06016 21) Install lifting bolts (M16) to housing SUBASSY.
  • Page 144 VIBRATORY DRUM • REAR AXLE 22) Remove housing SUBASSY. Housing SUBASSY Housing SUBASSY : 100 kg (220 lbs.) SV414-06018 23) Put housing SUBASSY on wooden blocks. Housing SUBASSY Wooden block SV414-06019 24) The right illustration shows axle shaft SUBASSY removed from vibratory drum.
  • Page 145 VIBRATORY DRUM • REAR AXLE 25) Remove bolts (34). • Remove cover (27). SV414-06055 26) Remove bolts (30). • Remove cover (32). • Remove shim (36). SV414-06056 27) Put a piece of wooden board on the end of axle shaft (41) Puller and set a puller on housing (37).
  • Page 146 VIBRATORY DRUM • REAR AXLE 28) Install lifting bolts (M12) to housing SUBASSY. Housing Lifting bolt SUBASSY SV414-06058 29) Remove housing SUBASSY. Housing SUBASSY : 45 kg (99 lbs.) Housing SUBASSY Axle shaft SUBASSY SV414-06059 30) The right illustration shown housing SUBASSY removed from vibratory drum.
  • Page 147 VIBRATORY DRUM • REAR AXLE 31) Remove bolts (54) and seal washers. SV414-06020 32) Remove vibrator bearing (7) using long bolts (M8). Long bolt SV414-06095 6-018...

  • Page 148: Reassembly Of Vibratory Drum

    2) Apply a coat of gear oil to vibrator bearing (7) mounting surface of housing (44). • Drive vibrator bearing into housing. (NOTICE) • Take care not to damage the bearing when installing SV414-06022 3) Apply grease to O-ring (43). • Install O-ring to housing (44). SV414-06023 6-019...
  • Page 149 Apply grease to O-rings for plugs (5). • Install plugs to housing SUBASSY. • Install bolts (54) and seal washers to housing SUBASSY. SV414-06024 W AR N ING Housing When installing lifting bolts, screw in the threads fully Lifting bolt SUBASSY before using.
  • Page 150 Housing SUBASSY (6) Bolts M16×50 : 265 N·m (195 lbf·ft) N•m SV414-06027 8) Reassembly of gear box SUBASSY. • Secure ring (4) to gear box (45) with ten bolts (2) and washers. (2) Bolts M22×70 : 686 N·m (506 lbf·ft) N•m...
  • Page 151 VIBRATORY DRUM • REAR AXLE 10) Lower gear box (45) on mounting surface of housing (44). SV414-06029 11) Secure gear box (45) with eighteen bolts (3) and washers. (3) Bolts M16×50 : 265 N·m (195 lbf·ft) N•m SV414-06030 W AR N ING Lifting bolt, nut When installing lifting bolts, secure them with nuts.
  • Page 152 VIBRATORY DRUM • REAR AXLE 13) Lower disc SUBASSY on mounting surface of gear box Disc (45). SUBASSY Disc SUBASSY : 115 kg (254 lbs.) SV414-06032 (NOTICE) Disc • Disc SUBASSY and propulsion motor mounting holes SUBASSY must be arranged as shown on the right.
  • Page 153 Hole SV414-06035 16) Secure propulsion motor (55) with two bolts (56) and washers. (56) Bolts M16×40 : 265 N·m (195 lbf·ft) N•m SV414-06088...
  • Page 154 18) Secure shaft (9) to eccentric shaft (8) with six bolts (10) and spring washers. (10) Bolts M10×40 : 59 N·m (44 lbf·ft) N•m SV414-06036 19) Install a lifting bolt (M10) to eccentric shaft SUBASSY. Lifting bolt Eccentric shaft SUBASSY...
  • Page 155 Insert eccentric shaft SUBASSY into vibrator bearing (7) while taking care not to tilt the bearing inner race. Inner race SV414-06039 21) Reassembly of axle shaft SUBASSY 21-1) Apply a coat of gear oil to vibrator bearing (42) mounting surface of axle shaft (41).
  • Page 156 Install plugs to axle shaft (41). • Apply sufficient amount of lithium-based grease to rollers of roller bearing (38) inner race. SV414-06062 21-4) Apply a coat of gear oil to roller bearings (38) outer race mounting surface of housing (37). •...
  • Page 157 Housing SUBASSY : 40 kg (88 lbs.) Housing SUBASSY Axle shaft SUBASSY SV414-06065 21-7) Apply a coat of gear oil to roller bearing (38) outer race mounting surface of axle shaft. • Apply sufficient amount of lithium-based grease to rollers of roller bearing inner race.
  • Page 158 Repeat this work several times until tightening torque of bolts no longer fluctuates. (NOTICE) • Tighten the bolts alternately in diagonal directions. SV414-06068 (NOTICE) • Push in the inner race while rotating the bearing. Otherwise, even strongly trying to push the inner...
  • Page 159 VIBRATORY DRUM • REAR AXLE ④  W ithout inserting shim, install cover (32) to axle shaft (41) with four bolts (30) and washers. SV414-06070 ⑤ Using a thickness gauge, measure clearance “A”. Preload adjusting ★ = A + 0.1 mm (0.004 in.)
  • Page 160 Secure cover (32) to axle shaft (41) with eight bolts (30) and washers. (30) Bolts M14×40 : 167 N·m (123 lbf·ft) N•m SV414-06093 21-9) Apply liquid packing to periphery of oil seal (33). • Drive oil seal into cover (27).
  • Page 161 Hole Hole Cover Cover mounting mounting hole hole SV414-06040 22) Install lifting bolts (M16) to axle shaft SUBASSY. Axle shaft Lifting bolt SUBASSY SV414-06075 23) Lift axle shaft SUBASSY. Axle shaft SUBASSY : 150 kg (331 lbs.) Axle shaft SUBASSY •...
  • Page 162 Support the eccentric shaft with a pipe or the like, to prevent tilting of the vibrator bearing inner race during installation. • Take care not to let O-ring to protrude from its groove. SV414-06041 25) Secure axle shaft SUBASSY with sixteen bolts (13) and washers. Axle shaft SUBASSY (13) Bolts M16×50 : 265 N·m (195 lbf·ft)
  • Page 163 27) Slowly lift eccentric shaft SUBASSY with a crane and check that there is an axial play of 1 to 3 mm (0.04 to 0.12 in.). SV414-06079 28) Install lifting bolts and nuts (M20) to holders (21) and (35). Lifting bolt, nut...
  • Page 164 When installing the disc SUBASSY, the breather mounting hole in cover (27) must be perpendicular to the longer edge of the disc(15). SV414-06044 31) Drive two spring pins (12) into sleeve (11). SV414-06080 32) Apply grease to splined portion of sleeve (11) .
  • Page 165 VIBRATORY DRUM • REAR AXLE 33) Apply grease to O-ring (28). • Install O-ring to vibrator motor (29). SV414-06046 34) Secure vibrator motor (29) to cover (27) with two bolts (31) and washers. Ports A and B (29) Vibrator motor : 15 kg (33 lbs.) (31) Bolts M14×40 : 167 N·m (123 lbf·ft)
  • Page 166 Supply port 14-1 • Supply gear oil from oil supply port. • Check that oil drips from gauge port. • Quantity of gear oil : 21 L (5.5 gal.) • Reinstall plugs (14-1) and (14-3). Gauge port 14-3 SV414-06049 6-037...

  • Page 167: Rear Axle

    VIBRATORY DRUM • REAR AXLE 4. REAR AXLE 4-1. Rear Axle ASSY (1) Tire (2) Hub reduction gear (3) Nut : M22 P=1.5 (4) Bolt (brake release) (5) Plug (brake filler and level gauge) (6) Plug (brake drain) (7) Brake (8) Differential (9) Air valve (10) Plug (hub reduction gear filler, level gauge and drain)

  • Page 169: Rear Axle Lubrication

    VIBRATORY DRUM • REAR AXLE 4-2. Rear Axle Lubrication Center housing (differential + brake) Drain Hub reduction gear Supply Drain SV201-1-06094 (1) Filler port (2) Level port (3) Drain gauge • Change oil : Gear oil API-grade GL4 SAE90 (See recommended lubrication.) •...

  • Page 170: Rear Axle Structure

    VIBRATORY DRUM • REAR AXLE 4-3. Rear Axle Structure 4-3-1. Center housing SV201-1K-06002 (1) O-ring (5) Housing (9) Magnet plug (2) Bolt (6) Plug (10) Cover (3) Seal washer (7) Plug (4) Vent (8) Snap ring 6-040...

  • Page 171: Differential

    VIBRATORY DRUM • REAR AXLE 4-3-2. Differential SV400-2-06053 (1) 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) Bolt (9) Ring nut (5) Differential carrier (10) Bearing 6-041...

  • Page 172: Hub Reduction Gear

    VIBRATORY DRUM • REAR AXLE 4-3-3. Hub reduction gear SV414-06089 (1) Half shaft (10) Stud (19) Wheel nit (2) Spring washer (11) Plug (20) Stud (3) Bolt (12) Magnet plug (21) Nut (4) Seal (13) Nut (22) Circlip (5) Seal...
  • Page 173 VIBRATORY DRUM • REAR AXLE 4-3-4. Brake SV201-1K-06003 (1) Spring (6) Dowel (11) Nut (2) O-ring (7) Brake disc (12) Bolt (3) Piston (8) Plug (13) Plug (4) O-ring (9) Seal washer (5) Ring (10) Lock washer 6-043...

  • Page 175: Brake

    BRAKE...

  • Page 177: Brake Pedal

    BRAKE 1. BRAKE PEDAL DETAIL A SECTION B-B 0418-62813-0-12540-B (1) Brake pedal (5) Stopper bolt : M10×50 (2) Foot brake switch (6) Stopper bolt : M10×50 (3) Spring (7) Nut : M10 (4) Nut : M10 7-001...

  • Page 179: Brake Hydraulic Piping

    BRAKE 2. BRAKE HYDRAULIC PIPING Rear axle ASSY Speed change Parking brake solenoid valve (F) solenoid valve Hose Hose (TBR RBR) (LOB BPF) Hose (P.4-004) Hose (BST BTS) VIEW A Propulsion pump Hydraulic oil filter 1 Hose (VBA TVB) Hose (VBA TVB) SECTION B-B...

  • Page 181: Brake System

    (7) Parking brake solenoid valve when brake is ON. (without solenoid excited) Steering charge pump Parking brake solenoid valve when brake is OFF. (with solenoid excited) The arrow ( ) symbol shows the direction of the hydraulic oil flow. SV414-07001 7-003...

  • Page 182: Hydraulic Component Specifications

    BRAKE 4. HYDRAULIC COMPONENT SPECIFICATIONS 4-1. Parking 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...

  • Page 183: Servo Bypass Solenoid Valve

    BRAKE 4-2. 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 185: Inspection And Adjustment

    INSPECTION AND ADJUSTMENT...

  • Page 187: 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 188: Measurement And Adjustment Of Propulsion Circuit Pressure

    ”. ④ Start the engine and set throttle switch to “FUll”. 2 (1-11) 2 (1-11) ⑤ Establish a condition in which machine propulsion load SV414-08001 SV414-08001 becomes maximum. (Pressure does not build up unless propulsion load is applied.) ⑥ With propulsion load at maximum, slowly move F-R lever to the side to be measured.

  • Page 189: 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 (1-1) or (1-4) for evidence of having loosened.

  • Page 190: 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 propulsion charge circuit pressure is within 2-12 2-12...

  • Page 191: Pressure

    ③  A pply parking brake by pressing parking brake switch button. ④  S tart the engine and set throttle switch to “FUll”. ⑤  R ead pressure indicated by pressure gauge. Standard charge relief valve setting ★ SV414-08002 SV414-08002 : 2.5 MPa (363 psi) ± 0.2 ±...

  • Page 192: Adjustment

    : Pressure drop Pressure change rate : 0.39 MPa/turn (57 psi/turn) ③  I f there is no evidence of nut having loosened, remove SV414-08003 SV414-08003 charge relief valve. ④  C heck removed charge relief valve for trapped dirt and scratches on its seat.

  • Page 193: Measurement Of Propulsion Servo Circuit Pressure

    • With parking brake (ON), measured pressures of (1) and (2) are the same. • With parking brake (OFF), measured pressures of (1) and (2) are different. SV414-08004 SV414-08004 Standard charge relief pressure setting ★ : 2.5 MPa (363 psi) ±...

  • Page 194: Measurement Of Machine High/Low Speed Change Circuit Pressure

    MPa (232 psi) ± 0.2 ± 29 SV414-08005 PG001014 • The numbers “1” and “7” appearing in above illustrations are consistent with lead line numbers shown in illustration of propulsion motor (F) in “2-2-2. Propulsion hydraulic motor (F)” (page 4-008).

  • Page 195: Measurement Of Propulsion Motor (R)

    ”. ⑤  S tart the engine and set throttle switch to “FUll”. Propulsion motor (R) Propulsion motor (R) ⑥  R ead pressure indicated by pressure gauge. SV414-08014 SV414-08014 Standard charge relief valve setting ★ : 2.67 MPa (387 psi) ±...

  • Page 196: Measurement Of Parking Brake Release Pressure

    ⑤  R elease parking brake by pressing parking brake switch Parking brake Parking brake button. solenoid valve solenoid valve ⑤  R ead brake release pressure indicated by pressure gauge. SV414-08007 SV414-08007 Brake release pressure : 1.5 to 3.0 MPa (218 to 435 psi) ★ PG002002 8-010...

  • Page 197: Measurement And Inspection Of Vibrator Circuit Pressure

    : 0 to 50 MPa (0 to 7,250 psi) ②  C onfirm that F-R lever is “N”. ③  A pply parking brake by pressing parking brake switch SV414-08008 SV414-08008 button. ④  S et vibration mode change switch to “...

  • Page 198: Inspection

    INSPECTION AND ADJUSTMENT 7-2. Inspection • If measurement results indicate the pressure deviating from maximum circuit pressure range, make an inspection in accordance with procedure described below. ①  R emove plug (3) and valve from high pressure relief valve port (2-1) or (2-5) of vibrator pump.

  • Page 199: Measurement And Adjustment Of Vibrator Charge Circuit

    ① loosen nut (3) from charge relief valve (1-10) on propulsion pump side. ② Tighten adjustment screw (4) by two complete turns. Adjustment screw turned clockwise : Pressure rise SV414-08003 SV414-08003 Adjustment screw turned counterclockwise : Pressure drop Pressure change rate : 0.39 MPa/turn (57 psi/turn) RLV-DD-005 •...

  • Page 200: Pressure

    ③  A pply parking brake by pressing parking brake switch button. ④  S tart the engine and set throttle switch to “FUll”. ⑤  R ead pressure indicated by pressure gauge. Standard charge relief valve setting ★ SV414-08002 SV414-08002 : 2.5 MPa (363 psi) ± 0.2 ±...

  • Page 201: Adjustment

    INSPECTION AND ADJUSTMENT 8-2. 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 (2-12) for evidence of having loosened.

  • Page 202: Measurement Of Vibrator High/Low Change Circuit Pressure

    INSPECTION AND ADJUSTMENT 9. MEASUREMENT OF VIBRATOR HIGH/LOW CHANGE CIRCUIT PRESSURE 9-1. Measurement • Oil temperature during measurement : 50 °C (122 °F) ± 5 ± 9 ① Remove plugs from servo pressure gauge ports (2-3) and (2-10). Attach pressure gauge with the adapter ⓗ . •...

  • Page 203: Measurement And Inspection Of Steering Circuit Pressure

    ⑤ Turn steering wheel to operate relief valve. ⑥  R ead pressure indicated by pressure gauge. Standard maximum circuit pressure ★ (orbitroll relief pressure + charge relief pressure) : 17.5 MPa (2,538 psi) ± 1.0 ± 145 SV414-08009 SV414-08009 PG002003 8-017...

  • Page 204: Inspection

    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 205: Measurement Of Propulsion Pump Case Pressure

    ⑥ Establish a condition in which machine propulsion load becomes maximum. (Pressure does not build up unless propulsion load is applied.) SV414-08010 SV414-08010 ⑦ With propulsion load at maximum, measure pressure when speed select switch is “1 ”, “ 2 ” and “3 ”...

  • Page 206: Measurement Of Propulsion Motor Case Pressure

    ⑥ Establish a condition in which machine propulsion load becomes maximum. (Pressure does not build up unless propulsion load is applied.) SV414-08011 SV414-08011 ⑦ With propulsion load at maximum, measure pressure when speed select switch is “1 ”, “ 2 ” and “3 ”...

  • Page 207: Measurement Of Propulsion Motor (R)

    INSPECTION AND ADJUSTMENT 12-2. Measurement of Propulsion Motor (R) • 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 208: Measurement Of Vibrator Motor Case Pressure

    INSPECTION AND ADJUSTMENT 13. MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE 13-1. 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 209: Adjustment Of F-R Lever Linkage

    ① Set F-R lever in “N”. ② Attach both ends of control cable (2). Specified dimension a : 210 mm (8.27 in.) ★ SV414-08012 ③ Confirm the strokes of propulsion pump control lever (3). Specified dimension b : 212 mm ( 8.35 in.) ★...

  • Page 210: Brake Adjustment

    INSPECTION AND ADJUSTMENT 15. BRAKE ADJUSTMENT 15-1. 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 211: Adjustment After Manual Release Of Brake

    INSPECTION AND ADJUSTMENT 15-2. 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 213: Troubleshooting

    TROUBLESHOOTING...

  • Page 215: 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 216: 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 217: 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 218: 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 Signal from Power to of equipment B equipment A equipment A equipment A Battery Equipment B...
  • Page 219 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 220 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 221 TROUBLESHOOTING Measurement using a test harness Test harness Equipment A Equipment B Measurement on a lead cable Measurement from the backside of connector Test probe Wire Connector Needle Lead cable TS-10006 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 222 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 223: 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 224 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 225: Fault Codes

    TROUBLESHOOTING 2-2. Fault Codes 2-2-1. Fault code list Fault Cummins Description Effect Code Engine Control Module Critical Internal Engine may not start or may be difficult to Failure start. • Bad Intelligent Device or Component Engine Magnetic Speed/Position Lost Both of The engine will shut down or will not start.
  • Page 226 TROUBLESHOOTING Fault Cummins Description Effect Code Accelerator Pedal or Lever Position Sensor 1 Severe derate in power output of the engine. • Data valid but above normal operational Limp home power only. range • Most Severe Level Engine Coolant Temperature Progressive power derate increasing in •...
  • Page 227 TROUBLESHOOTING Fault Cummins Description Effect Code Sensor Supply 3 Circuit Engine may run rough, may stop running, 3511 • Voltage below normal, or shorted to low may not start, or may be difficult to start. source Sensor Supply 3 Circuit Engine may run rough, may stop running, 3511 •...
  • Page 228 TROUBLESHOOTING Fault Cummins Description Effect Code Injector Solenoid Driver Cylinder 4 Circuit Possible reduced engine performance. • Current below normal or open circuit Engine Control Module Warning Internal Possible no noticeable performance Hardware Failure effects or engine dying or hard starting. •...
  • Page 229 TROUBLESHOOTING Fault Cummins Description Effect Code Auxiliary Intermediate (PTO) Speed Switch Intermediate speed control switch may not Validation operate correctly. • Data erratic, intermittent or incorrect Auxiliary Input/Output 2 Circuit None on performance. • Voltage above normal, or shorted to high source Auxiliary Alternate Torque Validation Switch Torque curve setting defaults to default curve.
  • Page 230 TROUBLESHOOTING Fault Cummins Description Effect Code Turbocharger 1 Compressor Intake Pressure Possible reduced engine performance. Circuit 1176 • Voltage Above Normal or Shorted to High Source Turbocharger 1 Compressor Intake Pressure Possible reduced engine performance. Circuit 1176 • Voltage Below Normal or Shorted to Low Source Turbocharger 1 Compressor Intake Pressure Possible reduced engine performance.
  • Page 231 TROUBLESHOOTING Fault Cummins Description Effect Code Sensor Supply 4 Circuit Engine will only idle. 2186 3512 • Voltage below normal, or shorted to low source EGR Valve Position Circuit EGR valve actuation will be disabled. 2271 • Voltage above normal, or shorted to high source EGR Valve Position Circuit Possible reduced engine performance.
  • Page 232 TROUBLESHOOTING Fault Cummins Description Effect Code Injector Solenoid Driver Cylinder 3 Possible reduced engine performance. 2444 • Out of Calibration Injector Solenoid Driver Cylinder 4 Possible reduced engine performance. 2445 • Out of Calibration Coolant Level None on performance. • Data Valid But Below Normal Operating 2448 Range...
  • Page 233 TROUBLESHOOTING Fault Cummins Description Effect Code Wheel-Based Vehicle Speed Engine speed limited to Maximum Engine • Received Network Data In Error Speed without VSS parameter value. Cruise 3525 Control, Gear-Down Protection, and Road Speed Governor will not work. Wheel-Based Vehicle Speed None on performance.
  • Page 234 TROUBLESHOOTING Fault Cummins Description Effect Code Engine Fan Blade Pitch Position Sensor None on performance. Circuit 5183 6799 • Voltage Above Normal or Shorted to High Source Engine Fan Blade Pitch Position Sensor None on performance. Circuit 5184 6799 • Voltage Below Normal or Shorted to Low Source Engine Fan Blade Pitch...
  • Page 236 ISC 1 SW(FULL) GROUND ECM RETURN(SWITCHES) STARTER LOCKOUT TO LAMP 29 1.25LB ECM RETURN(GENERAL) CHECK INTAKE AIR HEATER(+) RELAY(A9) ALTERNATOR(120A) FUSE 112 15B 112 15B AV20 AV20 125A GROUND 7 WG 108 GB GRID HEATER GRID HEATER SV414-09003 RELAY 9-021...

  • Page 237: Engine

    TROUBLESHOOTING 2-3. 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 or engine stop lamp must not be lighting. If engine warning lamp or engine stop lamp lights, refer to troubleshooting of engine manufacturer.
  • Page 238 ISC 1 SW(FULL) GROUND ECM RETURN(SWITCHES) STARTER LOCKOUT TO LAMP 29 1.25LB ECM RETURN(GENERAL) CHECK INTAKE AIR HEATER(+) RELAY(A9) ALTERNATOR(120A) FUSE 112 15B 112 15B AV20 AV20 125A GROUND 7 WG 108 GB GRID HEATER GRID HEATER SV414-09003 RELAY 9-023...

  • Page 239: Engine Will Not Start (Starter Motor Does Not Run) 2/3

    TROUBLESHOOTING 2-3-1. Engine will not start (Starter motor does not run) 2/3 • F-R lever must be in “N”. • Parking brake switch must be applied. • Brake pedal is not depressed. Reference Fig.: 2-3-1 Check point Check/Cause Action 5. Battery Relay (1) When starter switch is OFF, measure voltage between Replace battery relay.
  • Page 240 ISC 1 SW(FULL) GROUND ECM RETURN(SWITCHES) STARTER LOCKOUT TO LAMP 29 1.25LB ECM RETURN(GENERAL) CHECK INTAKE AIR HEATER(+) RELAY(A9) ALTERNATOR(120A) FUSE 112 15B 112 15B AV20 AV20 125A GROUND 7 WG 108 GB GRID HEATER GRID HEATER SV414-09003 RELAY 9-025...

  • Page 241: Engine Will Not Start (Starter Motor Does Not Run) 3/3

    TROUBLESHOOTING 2-3-1. Engine will not start (Starter motor does not run) 3/3 • F-R lever must be in “N”. • Parking brake switch must be applied. • Brake pedal is not depressed. Reference Fig.: 2-3-1 Check point Check/Cause Action 9. Parking Brake Switch (1) When starter switch is ON, measure voltage between Replace parking brake parking brake switch terminal 1 inlet wire LgR and...
  • Page 242 ISC 1 SW(FULL) GROUND ECM RETURN(SWITCHES) STARTER LOCKOUT TO LAMP 29 1.25LB ECM RETURN(GENERAL) CHECK INTAKE AIR HEATER(+) RELAY(A9) ALTERNATOR(120A) FUSE 112 15B 112 15B AV20 AV20 125A GROUND 7 WG 108 GB GRID HEATER GRID HEATER SV414-09003 RELAY 9-027...

  • Page 243: No Charging

    TROUBLESHOOTING 2-3-2. No charging Reference Fig.: 2-3-1 Check point Check/Cause Action 1. Alternator • After starting engine, measure voltage between alternator Replace alternator or terminal B+ and chassis ground. battery. Standard voltage : At least intermediate engine speed, 14 V or more •...
  • Page 244 ISC 1 SW(FULL) GROUND ECM RETURN(SWITCHES) STARTER LOCKOUT TO LAMP 29 1.25LB ECM RETURN(GENERAL) CHECK INTAKE AIR HEATER(+) RELAY(A9) ALTERNATOR(120A) FUSE 112 15B 112 15B AV20 AV20 125A GROUND 7 WG 108 GB GRID HEATER GRID HEATER SV414-09003 RELAY 9-029...

  • Page 245: Starter Motor Runs Even When F-R Lever Is Not At "N

    TROUBLESHOOTING 2-3-4. Starter motor runs even when F-R lever is not at “N” and parking brake is not applied Reference Fig. : 2-3-1 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 TRAVEL MODE CHANGE SWITCH MODE CONNECTION REVERSE SLOPE OPERATION FORWARD SLOPE OPERATION FUSE BOX F.L. 75A 3 8R 76 8WR STARTER SWITCH F.L. 65A 4 5BY 77 5BW STARTER SWITCH AV60 24 BR BATTERY RELAY RC:185MIN BATTERY CCA:1000A AV60 SV414-09004 9-031...

  • Page 247: Propulsion

    TROUBLESHOOTING 2-4. 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 TRAVEL MODE CHANGE SWITCH MODE CONNECTION REVERSE SLOPE OPERATION FORWARD SLOPE OPERATION FUSE BOX F.L. 75A 3 8R 76 8WR STARTER SWITCH F.L. 65A 4 5BY 77 5BW STARTER SWITCH AV60 24 BR BATTERY RELAY RC:185MIN BATTERY CCA:1000A AV60 SV414-09004 9-033...

  • Page 249: Machine Moves Neither Forward Nor Backward 2/2

    TROUBLESHOOTING 2-4-1. Machine moves neither forward nor backward 2/2 • Parking brake switch must be released. • Brake pedal is not depressed. Reference Fig.: 2-4-1 Check point Check/Cause Action 5. Diode Unit (1) When starter switch is ON and F-R lever is “N”, Replace diode unit.
  • Page 250 TRAVEL MODE CHANGE SWITCH MODE CONNECTION REVERSE SLOPE OPERATION FORWARD SLOPE OPERATION FUSE BOX F.L. 75A 3 8R 76 8WR STARTER SWITCH F.L. 65A 4 5BY 77 5BW STARTER SWITCH AV60 24 BR BATTERY RELAY RC:185MIN BATTERY CCA:1000A AV60 SV414-09004 9-035...

  • Page 251: Machine Speed Cannot Be Changed

    TROUBLESHOOTING 2-4-2. Machine speed cannot be changed • Speed select switch must be “ ”. Reference Fig.: 2-4-1 Check point Check/Cause Action 1. Speed Change • Disconnect harness and measure resistance of coil. Replace speed change Solenoid (F) Standard resistance : 12.3 ±...
  • Page 252 TRAVEL MODE CHANGE SWITCH MODE CONNECTION REVERSE SLOPE OPERATION FORWARD SLOPE OPERATION FUSE BOX F.L. 75A 3 8R 76 8WR STARTER SWITCH F.L. 65A 4 5BY 77 5BW STARTER SWITCH AV60 24 BR BATTERY RELAY RC:185MIN BATTERY CCA:1000A AV60 SV414-09004 9-037...

  • Page 253: Travel Mode Cannot Be Changed 1/2

    TROUBLESHOOTING 2-4-3. Travel mode cannot be changed 1/2 Reference Fig.: 2-4-1 Check point Check/Cause Action 1. Speed Change • Disconnect harness and measure resistance of coil. Replace speed change Solenoid (F) Standard resistance : 12.3 ± 1.2 Ω solenoid (F). •...
  • Page 254 TRAVEL MODE CHANGE SWITCH MODE CONNECTION REVERSE SLOPE OPERATION FORWARD SLOPE OPERATION FUSE BOX F.L. 75A 3 8R 76 8WR STARTER SWITCH F.L. 65A 4 5BY 77 5BW STARTER SWITCH AV60 24 BR BATTERY RELAY RC:185MIN BATTERY CCA:1000A AV60 SV414-09004 9-039...

  • Page 255: Travel Mode Cannot Be Changed 2/2

    TROUBLESHOOTING 2-4-3. Travel mode cannot be changed 2/2 Reference Fig.: 2-4-1 Check point Check/Cause Action 4. Travel Mode Relay (1) When starter switch is ON and travel mode select Replace travel mode (A7) switch is “TRAVEL MODE”, measure voltage between relay (A7).
  • Page 256 TRAVEL MODE CHANGE SWITCH MODE CONNECTION REVERSE SLOPE OPERATION FORWARD SLOPE OPERATION FUSE BOX F.L. 75A 3 8R 76 8WR STARTER SWITCH F.L. 65A 4 5BY 77 5BW STARTER SWITCH AV60 24 BR BATTERY RELAY RC:185MIN BATTERY CCA:1000A AV60 SV414-09004 9-041...

  • Page 257: Brake Cannot Be Released 1/2

    TROUBLESHOOTING 2-4-4. Brake cannot be released 1/2 • Parking brake switch must be released. • Brake pedal is not depressed. Reference Fig.: 2-4-1 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 258 TRAVEL MODE CHANGE SWITCH MODE CONNECTION REVERSE SLOPE OPERATION FORWARD SLOPE OPERATION FUSE BOX F.L. 75A 3 8R 76 8WR STARTER SWITCH F.L. 65A 4 5BY 77 5BW STARTER SWITCH AV60 24 BR BATTERY RELAY RC:185MIN BATTERY CCA:1000A AV60 SV414-09004 9-043...

  • Page 259: Brake Cannot Be Released 2/2

    TROUBLESHOOTING 2-4-4. Brake cannot be released 2/2 • Parking brake switch must be released. • Brake pedal is not depressed. Reference Fig.: 2-4-1 Check point Check/Cause Action 5. Parking Brake Switch (1) When starter switch is ON, measure voltage between Replace parking brake parking brake switch terminal 1 inlet wire LgR and switch.
  • Page 260 TRAVEL MODE CHANGE SWITCH MODE CONNECTION REVERSE SLOPE OPERATION FORWARD SLOPE OPERATION FUSE BOX F.L. 75A 3 8R 76 8WR STARTER SWITCH F.L. 65A 4 5BY 77 5BW STARTER SWITCH AV60 24 BR BATTERY RELAY RC:185MIN BATTERY CCA:1000A AV60 SV414-09004 9-045...

  • Page 261: Brake Does Not Work

    TROUBLESHOOTING 2-4-5. Brake does not work • Parking brake switch must be applied. • Brake pedal is depressed. Reference Fig.: 2-4-1 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 262 SOLENOID VIBRATION SELECT SWITCH VIBRATION CONNECTION (LOW) 1-2,4-6 1-3,4-6 (HIGH) 1-3,4-5 FUSE BOX F.L. 75A 3 8R 76 8WR STARTER SWITCH F.L. 65A 4 5BY 77 5BW STARTER SWITCH AV60 24 BR BATTERY RELAY RC:185MIN BATTERY CCA:1000A AV60 SV414-09005 9-047...

  • Page 263: Vibration

    TROUBLESHOOTING 2-5. Vibration Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. • Throttle switch must be “FULL”. • Check any ground circuit which belongs to components to be checked. 2-5-1. No vibration occurs •...
  • Page 264 SOLENOID VIBRATION SELECT SWITCH VIBRATION CONNECTION (LOW) 1-2,4-6 1-3,4-6 (HIGH) 1-3,4-5 FUSE BOX F.L. 75A 3 8R 76 8WR STARTER SWITCH F.L. 65A 4 5BY 77 5BW STARTER SWITCH AV60 24 BR BATTERY RELAY RC:185MIN BATTERY CCA:1000A AV60 SV414-09005 9-049...

  • Page 265: Amplitude Does Not Change (Remains Either Low Or High)

    TROUBLESHOOTING 2-5-2. Amplitude does not change (Remains either Low or High) • Vibration mode change switch must be “CONT”. Reference Fig.: 2-5-1 Check point Check/Cause Action 1. Vibrator Solenoid • Disconnect harness and measure resistance of coil. Replace vibrator Standard resistance : 5.1 Ω solenoid.
  • Page 266 SOLENOID VIBRATION SELECT SWITCH VIBRATION CONNECTION (LOW) 1-2,4-6 1-3,4-6 (HIGH) 1-3,4-5 FUSE BOX F.L. 75A 3 8R 76 8WR STARTER SWITCH F.L. 65A 4 5BY 77 5BW STARTER SWITCH AV60 24 BR BATTERY RELAY RC:185MIN BATTERY CCA:1000A AV60 SV414-09005 9-051...

  • Page 267: Vibration Mode Cannot Be Switched

    TROUBLESHOOTING 2-5-3. 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.: 2-5-1 Check point Check/Cause Action 1.
  • Page 268 HYD. oil filter warning Liquid spray Parking brake Vibrator Flood lamp +BAT High beam Exhaust system high temperature Turn signal (R) Head lamp Turn signal (L) ECO mode COMBI. meter ILLUMI. Pull down Hour meter Resistor 4.7KΩ x7 Pull down Resistor 4.7KΩ x5 SV414-09006 9-053...

  • Page 269: Lighting

    TROUBLESHOOTING 2-6. Lighting 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 270 HYD. oil filter warning Liquid spray Parking brake Vibrator Flood lamp +BAT High beam Exhaust system high temperature Turn signal (R) Head lamp Turn signal (L) ECO mode COMBI. meter ILLUMI. Pull down Hour meter Resistor 4.7KΩ x7 Pull down Resistor 4.7KΩ x5 SV414-09006 9-055...

  • Page 271: Combination Meter Warning Lamp Or Indicator Lamp Is Abnormal

    TROUBLESHOOTING 2-6-2. Combination meter warning lamp or indicator lamp is abnormal Reference Fig. : 2-6-1 Check point Check/Cause Action 1. Harness • Disconnect connectors between combination meter and Repair or replace lamp check relay. harness. • Measure resistance between terminals and chassis ground.
  • Page 272 HYD. oil filter warning Liquid spray Parking brake Vibrator Flood lamp +BAT High beam Exhaust system high temperature Turn signal (R) Head lamp Turn signal (L) ECO mode COMBI. meter ILLUMI. Pull down Hour meter Resistor 4.7KΩ x7 Pull down Resistor 4.7KΩ x5 SV414-09006 9-057...

  • Page 273: Hour Meter Is Abnormal

    TROUBLESHOOTING 2-6-3. Hour meter is abnormal Reference Fig. : 2-6-1 Check point Check/Cause Action 1. Combination Meter (1) When starter switch is ON, measure voltage between Replace combination (Hour meter) combination meter terminal wires and ground terminal meter. wire. • Continuous power (+) terminal wire No.70 inlet wire WR and ground (-) terminal wire No.X wire B •...
  • Page 274 HYD. oil filter warning Liquid spray Parking brake Vibrator Flood lamp +BAT High beam Exhaust system high temperature Turn signal (R) Head lamp Turn signal (L) ECO mode COMBI. meter ILLUMI. Pull down Hour meter Resistor 4.7KΩ x7 Pull down Resistor 4.7KΩ x5 SV414-09006 9-059...

  • Page 275: Hydraulic Oil Filter Warning Lamp Remains On

    TROUBLESHOOTING 2-6-5. Hydraulic oil filter warning lamp remains ON Reference Fig. : 2-6-1 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 276 HYD. oil filter warning Liquid spray Parking brake Vibrator Flood lamp +BAT High beam Exhaust system high temperature Turn signal (R) Head lamp Turn signal (L) ECO mode COMBI. meter ILLUMI. Pull down Hour meter Resistor 4.7KΩ x7 Pull down Resistor 4.7KΩ x5 SV414-09007 9-061...

  • Page 277: Vibration Indicator Lamp Does Not Light

    TROUBLESHOOTING 2-6-6. Vibration indicator lamp does not light • Check that vibrator can be operated. • Vibration mode change switch must be “CONT”. Reference Fig. : 2-6-2 Check point Check/Cause Action 1. Harness (1) Measure resistance between vibration select switch Repair or replace terminal 5 wire YR and diode unit terminal E wire YR.
  • Page 278 HYD. oil filter warning Liquid spray Parking brake Vibrator Flood lamp +BAT High beam Exhaust system high temperature Turn signal (R) Head lamp Turn signal (L) ECO mode COMBI. meter ILLUMI. Pull down Hour meter Resistor 4.7KΩ x7 Pull down Resistor 4.7KΩ x5 SV414-09007 9-063...

  • Page 279: Parking Brake Indicator Lamp Does Not Light

    TROUBLESHOOTING 2-6-7. Parking brake indicator lamp does not light Reference Fig. : 2-6-2 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 280 BACKUP BUZZER SWITCH BACKUP BUZZER HORN 1.25RY HORN RELAY(A8) HORN SWITCH FUSE BOX F.L. 75A 3 8R 76 8WR STARTER SWITCH F.L. 65A 4 5BY 77 5BW STARTER SWITCH AV60 24 BR BATTERY RELAY RC:185MIN BATTERY CCA:1000A AV60 SV414-09008 9-065...

  • Page 281: Horn Does Not Sound

    TROUBLESHOOTING 2-6-8. Horn does not sound Reference Fig. : 2-6-3 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 282: 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 283: 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 284: 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 285: 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 286: 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 287: 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 288: 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 289: Vibrator Does Not Stop

    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 290: 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 291: 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 294 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 © 2018 SAKAI HEAVY INDUSTRIES, LTD. All Rights Reserved. Printed in Japan 2018.02.10 ○ 0421-99003-0-30026-0...

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