Sakai SW880-1 Shop Manual
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Sakai SW880-1 Shop Manual

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SW880
/990
-1
-1
SHOP MANUAL
3498-6568A-0

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Summary of Contents for Sakai SW880-1

  • Page 1 SW880 /990 SHOP MANUAL 3498-6568A-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

    SW880 /990 ○ 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 SW880 /990 ○ 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  3-003 4. PUMP MOUNT 4-1. Pump Mount   3-004 4-1-1. Installation of pump   3-005 4.
  • Page 7 SW880 /990 ○ 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 SW880 /990 ○ 6. VIBRATORY DRUM 1. PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY   6-001 2. REMOVAL AND INSTALLATION OF VIBRATORY DRUM 2-1. Removal of Vibratory Drum  6-003 2-2. Installation of Vibratory Drum   6-008 3. VIBRATORY DRUM ASSEMBLY 3-1.
  • Page 9 SW880 /990 ○ 3. MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT PRESSURE 3-1. Measurement  1 0-005 3-2. Adjustment   1 0-006 4. MEASUREMENT OF PROPULSION SERVO CIRCUIT PRESSURE 4-1. Measurement  1 0-007 5. MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE 5-1.
  • Page 10 SW880 /990 ○ 11. TROUBLESHOOTING 1. TROUBLESHOOTING 1-1. Safety Precautions for Troubleshooting  1 1-001 1-2. Important Information for Troubleshooting  1 1-001 1-3. Before Starting  1 1-002 1-4. wire Number and Color Code    1 1-002 2.
  • Page 11 SW880 /990 ○ 2-4-3. No charging   1 1-061 2-4-4. Grid heater does not work (Engine starting performance is bad in cold weather)  1 1-061 2-4-5. Starter motor runs even when F-R lever is not at “N” and parking brake is not applied...
  • Page 12 SW880 /990 ○ 2-6. Vibration  1 1-129 2-6-1. No vibration occurs 1/3  1 1-129 2-6-1. No vibration occurs 2/3  1 1-131 2-6-1. No vibration occurs 3/3  1 1-133 2-6-2. Vibration frequency cannot be switched 1/3  1 1-135 2-6-2.
  • Page 13 SW880 /990 ○ 2-9-5. Temperature meter is abnormal  1 1-191 2-9-6. Fuel meter is abnormal  1 1-191 2-9-7. Hydraulic oil filter warning lamp remains ON  1 1-193 2-9-8. Engine oil pressure warning lamp remains ON   1 1-195 2-9-9.

  • Page 15: Safety

    SAFETY...

  • Page 17: 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 18: 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 19: 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 20: 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 21: 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 22 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 23: 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 25: Specifications

    SPECIFICATIONS...

  • Page 28: Specification Data

    SPECIFICATIONS 1. SPECIFICATION DATA 1-1. SW880 2195 2000 2000 1200 3540 5940 0568-99011-0-11446-0 Model SAKAI SW880 with ROPS Model & Type Type VIBRATORY TANDEM ROLLER without ballast 12,870 kg 28,375 lbs. Operating weight with ballast N/A kg N/A lbs. Maximum weight 13,590 kg 29,960 lbs.
  • Page 29 SPECIFICATIONS 4,000 vpm 160 kN 35,970 lbs. 3,000 vpm 90 kN 20,230 lbs. amplitude Centrifugal 2,500 vpm 63 kN 14,160 lbs. force High 3,000 vpm 177 kN 39,790 lbs. amplitude 2,500 vpm 123 kN 27,650 lbs. 66.7 Hz 4,000 vpm Front Low amplitude 50.0 Hz...
  • Page 30 SPECIFICATIONS Name CUMMINS QSB4.5 (Diesel, EPA-Interim Tier 4) 4-cycle, Water-cooled, 4-cylinder in-line, overhead valve, Model direct injection type, with turbo charger Bore × Stroke 107 mm × 124 mm (4.213 in. × 4.882 in.) Displacement 4.457 L ( 272.0 cu.in Rated speed 2,500 min ( 2,500 rpm...

  • Page 32: Sw990

    SPECIFICATIONS 1-2. SW990 2195 2130 2130 1200 3540 5940 0569-99004-0-10843-0 Model SAKAI SW990 with ROPS Model & Type Type VIBRATORY TANDEM ROLLER without ballast 13,250 kg 29,210 lbs. Operating weight with ballast N/A kg N/A lbs. Maximum weight 13,980 kg 30,820 lbs.
  • Page 33 SPECIFICATIONS 4,000 vpm 173 kN 38,890 lbs. 3,000 vpm 98 kN 22,030 lbs. amplitude Centrifugal 2,500 vpm 68 kN 15,285 lbs. force High 3,000 vpm 185 kN 41,590 lbs. amplitude 2,500 vpm 128 kN 28,775 lbs. 66.7 Hz 4,000 vpm Front Low amplitude 50.0 Hz...
  • Page 34 SPECIFICATIONS Name CUMMINS QSB4.5 (Diesel, EPA-Interim Tier 4) 4-cycle, Water-cooled, 4-cylinder in-line, overhead valve, Model direct injection type, with turbo charger Bore × Stroke 107 mm × 124 mm (4.213 in. × 4.882 in.) Displacement 4.457 L ( 272.0 cu.in Rated speed 2,500 min ( 2,500 rpm...

  • Page 35: Table Of Standard Values

    SPECIFICATIONS 2. TABLE OF STANDARD VALUES 2-1. Engine Standard value Remarks Item SW880 SW990 CUMMINS QSB4.5 (Diesel, EPA-Interim Tier4) Engine model 107.6/2,500 kw/min 122.0/2,500 kw/min Rated output 144/2,500 HP/rpm 164/2,500 HP/rpm 2,500 rpm Maximum rpm under no load Minimum rpm under no load 700 rpm 90 N·m 66 lbf·ft...

  • Page 36: 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 137 mm (5.4 in.)

  • Page 37: 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 38: 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 39: Engine And Controls

    ENGINE AND CONTROLS...

  • Page 41: Engine

    ENGINE AND CONTROLS 1. ENGINE 1-1. Engine Mount DETAIL A DETAIL B 0568-01803-0-11414-A (1) Bracket (9) Damper (2) Bracket (10) Nut : M12 (3) Base (11) Bolt : M 8×20 (4) Base (12) Bracket (5) Engine (13) Bolt : M12×35 (6) Bolt : M12×35 (14) Bolt...

  • Page 42: Fuel System

    ENGINE AND CONTROLS 2. FUEL SYSTEM Drain Return Suction VIEW A SECTION B-B 0568-02804-0-11317-A (1) Hose (Fuel gear pump drain → Fuel tank return) (8) Fuel pre-filter (2) Fuel unit (9) Fuel tank (3) Hose (Fuel tank suction → Fuel pre-filter IN) (10) Plug (4) Hose (Fuel pre-filter OUT →...

  • Page 43: Control System

    ENGINE AND CONTROLS 3. CONTROL SYSTEM 3-1. Forward-reverse Control Apply grease *1 Black face Apply grease *1 Apply grease *1 SECTION A-A Apply grease *1 Apply grease *2 SECTION B-B 0568-12805-0-11265-A (1) F-R lever switch (6) Washer (11) F-R lever potentiometer 1 (2) F-R lever (7) Nut (12) Spring pin...

  • Page 44: Pump Mount

    ENGINE AND CONTROLS 4. PUMP MOUNT 4-1. Pump Mount SECTION A-A VIEW B 0568-36808-0-11256-0 (1) Bolt : M10×50 (5) Housing : M12×80 (2) Bolt : 3/8-16UNC×22 (6) Bolt : M20×45 (3) Hub (7) Pump (4) Flange (8) Bolt : M12×35 N•m (1) Bolt M10×50 60 N·m (...

  • Page 45: Installation Of Pump

    ENGINE AND CONTROLS 4-1-1. Installation of pump • When the pump has been removed from the engine for repair or replacement, reinstall it in accordance with the following procedure. ① Apply adequate amount of lithium-based grease to pump (7) and hub (3) splines. ②...

  • Page 47: Hydraulic Systems

    HYDRAULIC SYSTEMS...

  • Page 50: 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 51 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 53: Hydraulic Circuit Diagram

    2.5 MPa 1.5 MPa (2500 rpm) 16.0 65.7 i=39.000 cc/rev cc/rev (3/4") 34.0 Vibration HI (1/2") (1/2") (3000 rpm) 2000 (SW880-1) (2500 rpm) 2130 (SW990-1) (1/2") (1/4") (1/2") Vibrator Valve block (Rear) motor Propulsion motor (Rear) (Rear) Vibration LO (1/2") (1/2") (1/2")

  • Page 55: Propulsion Hydraulic System

    HYDRAULIC SYSTEMS 2. PROPULSION HYDRAULIC SYSTEM 2-1. Propulsion Hydraulic Piping 2-1-1. Propulsion hydraulic piping (1) Coupling Hydraulic oil tank Hose Hose (PDT (Hydraulic oil tank Drain) Hose (PDT VIEW A SECTION B-B Coupling : Coupling : (Forward side gauge port) (Reverse side gauge port) Valve block Hose...

  • Page 57: Propulsion Hydraulic Piping (2)

    HYDRAULIC SYSTEMS 2-1-2. Propulsion hydraulic piping (2) Hose (PVR FMP) Propulsion motor (Rear) Front : FMP Rear : RMP Front : FMD Rear : RMD Front : FMA Hose Rear : RMA (PVR BSP) Front : FMB Rear : RMB VIEW B DETAIL C VIEW A...

  • Page 60: Hydraulic Component Specifications

    HYDRAULIC SYSTEMS 2-2. Hydraulic Component Specifications 2-2-1. Hydraulic pump assembly (propulsion + vibrator) 2-5 (back of 2-6) 1-6 (back of 1-7) 1-10 1-11 1-12 2-10 2-11 2-12 2-13 1-16 1-15 1-14 1-13 2-16 2-15 2-14 1-16 1-10 1-12 1-6 2-10 2-13 2-8 1-13 Pump circuit diagram...
  • Page 61 HYDRAULIC SYSTEMS (1) Propulsion pump (1-1) Drain port [PT1] : 1 1/16-12UN (1-2) Servo pressure gauge port [PX1] : 9/16-18UNF (1-3) Propulsion pump proportional solenoid valve a (Reverse) (1-4) Cut off valve (1-5) Charge supply port [PF1] : 1 1/16-12UN (1-6) Port B (Forward) [PBF, PBR] : SAE 1”...

  • Page 62: Propulsion Hydraulic Motor (Front)

    (11) Charge pressure gauge port : 7/16-20UNF (6) High pressure gauge port (For Port A) : 9/16-18UNF Flow of oil   1 2 Clockwise rotation   2 1 Counterclockwise rotation Motor circuit diagram SW880-1-04002 Motor specifications • Displacement : 65.7 cm /rev ( 4.0 cu.in./rev ) •...
  • Page 63 HYDRAULIC SYSTEMS 1) Internal structure of propulsion hydraulic motor (front) SECTION A-A 7-11 7-10 SW800- -04006 (7) Motor (8) Reduction gear (7-1) Cylinder block kit (8-1) Floating seal kit (7-2) Bearing (8-2) Angular bearing (7-3) Oil seal (8-3) Planetary gear 2nd (7-4) Shaft (8-4) Needle roller (7-5) Swash plate assembly...

  • Page 64: Propulsion Hydraulic Motor (Rear)

    **Rotation direction output **Rotation direction is as seen Lo : *8.5 3.5% from A. SW880-1-04001 (1) Port B (Forward) [RMB] : SAE 1” (7) Motor (2) Port A (Reverse) [RMA] : SAE 1” (8) Reduction gear (3) Parking brake pilot port...
  • Page 65 HYDRAULIC SYSTEMS 1) Internal structure of propulsion hydraulic motor (rear) 7-11 7-10 SW880-04004 (7) Motor (8) Reduction gear (7-1) Cylinder block kit (8-1) Floating seal kit (7-2) Bearing (8-2) Angular bearing (7-3) Oil seal (8-3) Planetary gear 2nd (7-4) Shaft (8-4) Needle roller (7-5) Swash plate assembly (8-5) Carrier...

  • Page 66: Valve Block

    HYDRAULIC SYSTEMS 2-2-4. Valve block (−) (＋) Wire color Wire color:red :black (＋) (−) 10 11 6 13 Connection diagram Valve block circuit diagram SW880-04005 (1) Body (9) Brake solenoid valve (2) Port B [PVR] : 9/16-18UNF (10) Port P [PVP] : 9/16-18UNF (3) Port X2 [VX2] : 9/16-18UNF...

  • Page 67: Vibrator Hydraulic System

    HYDRAULIC SYSTEMS 3. VIBRATOR HYDRAULIC SYSTEM 3-1. Vibrator Hydraulic Piping 3-1-1. Vibrator hydraulic piping (1) Vibrator valve block Vibrator valve block (Rear) (Front) VIEW A Hydraulic oil tank Hose (Hydraulic oil tank VPS) Hydraulic oil filter 2 Hose (VF1 LS2) Coupling Coupling Hose...

  • Page 69: Vibrator Hydraulic Piping (2)

    HYDRAULIC SYSTEMS 3-1-2. Vibrator hydraulic piping (2) Coupling Coupling (Front drum (Front drum Hose Hose low amplitude side high amplitude side (FM2 FVB) (FM1 FVA) gauge port) gauge port) Vibrator motor (Front) VIEW C Vibrator valve block (Front) Hose Hose Hose (VFT FD2)

  • Page 71: Vibrator Hydraulic Piping (3)

    HYDRAULIC SYSTEMS 3-1-3. Vibrator hydraulic piping (3) Coupling Coupling (Rear drum (Rear drum low amplitude side high amplitude side gauge port) gauge port) Hose (BSF RD2) Hose Hose (BSL RVA) (BSH RVB) Hose SECTION B-B (RD1 TVD) Vibrator valve block (Rear) Hose (RM2...

  • Page 73: Hydraulic Component Specifications

    HYDRAULIC SYSTEMS 3-2. Hydraulic Component Specifications 3-2-1. Vibrator hydraulic motor Motor circuit diagram Flow of oil VIEW A 3 Clockwise rotation 4 Counterclockwise rotation SW800-04015 (1) Drain port (T1) [FD1, RD1] : G1/2 (2) Drain port (T2) [FD2, RD2] : M12×1.5 (3) Port B [FVB, RVB] : 1 1/16-12UN-2B (4) Port A...

  • Page 74: Vibrator Valve Block

    HYDRAULIC SYSTEMS 3-2-2. Vibrator valve block Sol.a Sol.b 13 (back of 14) (G1) Electrical circuit diagram Sol.c Valve block circuit diagram 3-1,10-1 12-1 4-1,9-1 3-2,10-2 12-2 7/8-14UNF-2A 7/8-14UNF-2A (3),(10) Vibrator solenoid valve (a,b) (12) Vibrator solenoid valve (c) (4),(9) Relief valve (R1,R2) SW880-04006 4-017...
  • Page 75 HYDRAULIC SYSTEMS (1) Body (2) Port V1 [VF1, VR1] : 3/4-16UNF (3) Vibrator solenoid valve (a) : G1 (3-1) Nut (3-2) Nut (4) Relief valve R2 : 7/8-14UNF (4-1) Nut (5) Flushing valve R3 (5-1) Bolt : M6×30 (6) Port M1 [FM1, RM1] : 3/4-16UNF (7) Port T [VFT, VRT] : 3/4-16UNF...

  • Page 77: Steering System

    HYDRAULIC SYSTEMS 4. STEERING SYSTEM 4-1. Steering Hydraulic Piping Hose Steering cylinder (R) (BSS Orbitrol Steering  Charge pump Hose (SRF SLD) DETAIL A VIEW B Hose (SLG SRD) (From steering  charge pump) (To hydraulic oil filter 1) (From orbitrol T port) (To orbitrol P port) Hose Steering cylinder (L)

  • Page 79: Steering Wheel

    HYDRAULIC SYSTEMS 4-2. Steering Wheel 0431-32801-0-10036-A (1) Tilt lock handle (6) Bolt : M10×35 (2) Tilt ASSY (7) Orbitrol (3) Column shaft (8) Bolt : M10×25 (4) Nut : M12 P=1.25 (9) Bolt : M10×25 (5) Steering wheel (4) Nut M12 P=1.25 64 N·m ( 47 lbf·ft ) (6) Bolt M10×35 49 N·m ( 36 lbf·ft )

  • Page 80: Hydraulic Component Specifications

    HYDRAULIC SYSTEMS 4-3. Hydraulic Component Specifications 4-3-1. Orbitrol Orbitrol circuit diagram SW880-04007 (1) Port L : 3/4-16UNF (2) Port R : 3/4-16UNF (3) Port P : 3/4-16UNF (4) Port T : 3/4-16UNF (5) Relief valve Specifications • Displacement 400 cm /rev ( 24.4 cu.in./rev ) •...

  • Page 81: 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 83: Electrical System

    ELECTRICAL SYSTEM...

  • Page 85: 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 86: 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 87: System Circuit Diagram

    AV60,B AV60,B 5_12P VIBRATION FREQUENCY 189 BrR 171 BW 171 3BW 172 3BY FUSE 6_12P SELECT SWITCH IPF SELECT SWITCH WITH SW880-1 TORQUE WAIT TO START 190 L 171 BW TERMINATING CONTROL BOX 7_12P FREQUENCY CONNECTION F-R LEVER WATER TERMINATING LAMP 1.0k...

  • Page 89: Electrical Components

    ELECTRICAL SYSTEM 3. ELECTRICAL COMPONENTS 3-1. Battery Layout VIEW A 0568-09814-0-11304-0 (1) Battery (9) Cord (Grid heater relay (terminal 5) – Grid heater) (2) Cord (Battery (-) – Ground) (3) Cord (Battery (+) – Battery relay (COM)) (10) Alternator (4) Grid heater relay (11) Cord (Starter motor (Ground) –...

  • Page 91: Wiring Harness Layout (1)

    ELECTRICAL SYSTEM 3-2. Wiring Harness Layout (1) Ground Water spray pump (R,2) ( RP2 , 2B2 Engine harness Battery harness Engine harness Water spray pump (R,1) Water spray pump (R) harness (P.5-014) (P.5-016) (P.5-014) (P.5-030) ( RP1 , 2B1 Mark RES2 Resistor unit (P.5-006) Mark E4 Ground G...

  • Page 93: Wiring Harness Layout (2)

    ELECTRICAL SYSTEM 3-3. Wiring Harness Layout (2) ENGINE STOP lamp Emergency switch Panel harness (L) Water spray pump switch (F) FP Water spray mode select switch (LgW),(RB) 1(WR),2(WY),3(WL) (P.5-022) 1(LW),2(W),3(G),4(RG),5(Y) Vibration mode select switch (GW), (GL), (O), (GL) WARNING lamp Panel harness (R) Water spray pump switch (R) RP 1(YW),3(GB),4(YW),5(YL)

  • Page 95: Wiring Harness Layout (3)

    ELECTRICAL SYSTEM 3-4. Wiring Harness Layout (3) EGT WARNING lamp relay Lamp check relay 1(G),2(GW),3(WL),5(R) 1(LgW),2(LgB),3(YG),5(B) EXACT meter relay Throttle stop relay *1Relay connector 1(G),2(GW),3(RW),4(LgY) 1(LgY),2(LgB),3(LgY),4(LgR),5(BW) Engine oil pressure switch relay Starter switch relay 1(LW),2(GW),3(Lg),5(B) 1(1.25BR),2(B),3(LgR),5(GB) Starter lockout relay Main haness Propulsion pump neutral holding relay 1(LR),2(GW),3(1.25BY),5(1.25BR) (P.5-008,010)

  • Page 96: Wiring Harnesses

    ELECTRICAL SYSTEM 4. WIRING HARNESSES F-R lever harness Panel harness (L) Twist pair cable 4-1. Main Harness (1) (P.5-020) (P.5-022) (with shield AVSSCS 0.75) SWP-12F SWP-8M 58X-4F 58X-4M SWP-16F SWP-16M Working Tape 0.5Lg 0.5Br 0.5YL 0.5WR 0.5W MC024B controller 77 25 25 Tape Engine (C2)
  • Page 97 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS COM -16M × 4, DC12V , DIS , L3 , LH , MC024A , MC050 × 2, M1 , L, 0.5L LH , MC050 , RES1 B, 0.5B, 1.25B, P/C , RES1 , RH1 , Fuel unit, Ground bolt, Terminating resistor (120Ω) Br, 0.5Br FRONT ROLL , LH , MC050 , RES1...

  • Page 98: Main Harness (2)

    ELECTRICAL SYSTEM 4-1. Main Harness (2) F-R lever harness Panel harness (L) Twist pair cable (P.5-020) (P.5-022) (with shield AVSSCS 0.75) SWP-12F SWP-8M 58X-4F 58X-4M SWP-16F SWP-16M Working Tape 0.5Lg 0.5Br 0.5YL 0.5WR 0.5W controller MC024B 77 25 25 Tape (C2) Engine 0.5B...
  • Page 99 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS M7 , SPR LgB, 0.5LgB DIS , M3 , MC024B E6 , M6 L4 , M3 COM -16M, E2 L1 , M4 G, 0.5G E1 , MC050 L1 , M4 B, 0.5B E1 , MC024B FRONT ROLL , LH...

  • Page 100: Fuse • Relay Harness

    ELECTRICAL SYSTEM 4-2. Fuse • Relay Harness SWP-8F Corrugate Tape Starter switch EXACT meter Lamp check EGT WARNING Throttle Engine oil pressure Starter 1.25B relay lamp relay stop relay switch relay relay relay lockout relay 1.25BY 1.25BR 1.25BR Relay box 1 SWP-12M Tape 1.25BR...
  • Page 101 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS M1 , Relay box 1-1-2, 1-3-5, 1-6-5, 2-8-2, 2-9-2, 2-10-2, 2-12-2, 2-13-2, M5 , Relay box 3-15-5 B,1.25B 2-14-2, 3-15-2, 3-16-2, 3-17-2, 3-18-2 M5 , Relay box 3-16-5 M5 , Fuse box-F3 M7 , Relay box 3-17-3 1.25GY...

  • Page 102: Engine Harness

    ELECTRICAL SYSTEM 4-3. Engine Harness Front frame harness (P.5-018) SWP-16F Twist cable (Cap) Engine ECM J3 (60pin) connector SWP-6M SWP-6M SWP-6F 58X-3F Twist pair cable Twist cable (with shield AVSSCS 0.75) Engine coolant level sensor 12110293 Propulsion pump Battery Twist cable Battery proportional solenoid harness...
  • Page 103 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS B, 2B, 3B EME × 2, F2 , S2 , Tachometer sensor, Terminating resistor (120Ω) B, 3B Engine ECM J3 (60pin) connector-21, 22, 31, 32, Engine stud bolt B3 , E6 E3 , Engine ECM J3 (60pin) connector-3 E1 , EME...

  • Page 104: Battery Harness

    ELECTRICAL SYSTEM 4-4. Battery Harness Battery relay Engine harness (NO) (NO) (NO) (COM) (COM) (COM) (COM) (COM) (COM) (BR) (Ground) (P.5-014) LA208 LA308 LA308 LA308 LA308 LA308 LA308 LA208 LA108 LE104 LE104 58Y-2F 7322-4123-30 65A (black) Tape 7322-4123-30 65A (black) Fusible link Tape 7322-4123-30...
  • Page 105 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS E , Diode B2 , Fusible link 65A B3 , Fusible link 65A NO , Fusible link 65A NO , Fusible link 65A B3 , Fusible link 65A B4 , Fuse 15A B5 , Fuse 5A CO , Fusible link 65A...

  • Page 106: Front Frame Harness

    ELECTRICAL SYSTEM 4-5. Front Frame Harness SWP-2F Parking brake solenoid Tape Water spray Water spray pump (F,1) pump (F,2) SWP-2F Neutral solenoid Tape Vibrator pump proportional solenoid Twist cable CB104 CA104 CA104 CB104 W2S-PO12 DT06-2S-CE05 Fuel senser Tape b (Lo) a (Hi) Tape SWP-6F...
  • Page 107 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS F2 , FBR , NEU , Va , Vb , Ground bolt, Vibrator solenoid (F) × 3, F1 , Fuel sensor B, 3B Twist cable Vibrator solenoid (R) × 3 F1 , Fuel sensor 2B, 5B 2B1 , 2B2 , Ground bolt...

  • Page 108: F-R Lever Harness

    ELECTRICAL SYSTEM 4-6. F-R Lever Harness Water spray Water spray Water spray pump switch (R) pump switch (F) timer switch Water spray mode select switch 79 81 159 80 Water spray timer RB4B-SL 58X-4F Tape 58X-4M Tape Main harness 1050 (P.5-008,010) Corrugate SWP-8F...
  • Page 109 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS L3 , TIM FP , L2 L4 , RNO L2 , RP L4 , RCOM L4 , POT1 , POT2 FNC , L4 L4 , POT1 , POT2 FCOM , L4 L4 , POT1 L3 , TIM ×...

  • Page 110: Panel Harness (L)

    ELECTRICAL SYSTEM 4-7. Panel Harness (L) Vibration Vibration mode Vibration frequency Vibration drum change switch select switch select switch select switch YW,100 (1) R1.25-3.5 GW,100 (2) R1.25-3.5 40 YW,100 (3) R1.25-3.5 Main harness IPF select switch SWP-16M (P.5-008,010) LW,100 Tape Corrugate (4) R1.25-3.5 YW,100...
  • Page 111 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS AUT , LH C/A - 3 , LH F/R - 2 , LH C/A - 5 , LH F/R - 5 , LH IPF - 2 , LH C/A - 1 , - 4 , FRQ - 1 , - 4 , F/R - 1 , - 4 , IPF - 1 , - 3 , - 5 , LH , IPF - 4 , LH L/H - 1...

  • Page 112: Panel Harness (R)

    ELECTRICAL SYSTEM 4-8. Panel Harness (R) Speed change Emergency switch switch Parking brake switch LA104 LA104 LA104 RW,70 SWP-8M Tape YR,70 1.25LB 1.25BR YR,70 Throttle switch Tape L,70 SWP-14M BrR,70 Tape 189 (6) Main harness (P.5-008,010) 5L,70 LE305 (B) 1.25BR,70 52 LE205 (BR) 58X-4M Starter switch...
  • Page 113 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS EGT , PAR - 5 , RH1 EME - 1 , RH2 LIT - 3 , RH3 EME - 3 , RH2 LIT - 1 , RH3 LIT - 4 , RH3 LIT - 5 , RH3 PAR - 2 , RH2 PAR - 1 , RH1...

  • Page 114: Floor Bord Harness

    ELECTRICAL SYSTEM 4-9. Floor Bord Harness 2750 2350 DT06-2S-EP06 DT06-2S-EP06 Tape Corrugate Corrugate Tape 58X-3M Main Tape Flood lamp Head lamp harness (P.5-008,010) RY,100 CA104 2330 2350 DT06-2S-EP06 W2S-PO12 Tape Corrugate Corrugate Corrugate Tape LA208 CB104 Ground bolt Backup buzzar 1568-09193-0-21395-0 5-026...
  • Page 115 ELECTRICAL SYSTEM CONTACT SIZE, COLOR CONNECTION POINTS 2B, 3B FL1 , Flood lamp (L), (R), Ground bolt, Head lamp (L), (R) FL1 , Head lamp (L), (R) FL1 , Flood lamp (L), (R) FL2 , Backup buzzer 5-027...

  • Page 116: Starter Relay Harness

    ELECTRICAL SYSTEM 4-10. Starter Relay Harness 5W,150 LA308 5BW,130 58Y-2M LA308 Tape Engine harness Starter relay (P.5-014) Corrugate 2BR,100 58X-2M LA205 Tape 2B,100 LA205 1568-09196-0-31409-0 CONTACT SIZE, COLOR CONNECTION POINTS S2 , Starter relay S2 , Starter relay S1 , Starter relay S1 , Starter relay 5-028...

  • Page 117: Torque Control Box Harness

    ELECTRICAL SYSTEM 4-11. Torque Control Box Harness Fuse 7124-9681 Twist pair cable (with shield AVSSCS 0.75) Twist pair cable (with shield AVSSCS 0.75) DT06-4S Tape Main harness Torque control box SWP-6M Tape (P.5-008,010) DT04-2P Tape 1568-09186-0-31330-0 CONTACT SIZE, COLOR CONNECTION POINTS TRQ , Fuse 5A Fuse 5A, Torque control box...

  • Page 118: Water Spray Pump (R) Harness

    ELECTRICAL SYSTEM 4-12. Water Spray Pump (R) Harness 5B,50 2L,100 58Y-1F 83 CB104 Water spray pump (R,1) 2B,100 CA104 1300 1800 58X-2M Main Tape Corrugate Corrugate 2B,100 harness X1 CA104 (P.5-008,010) Water spray pump (R,2) 2LW,100 CB104 SWP-4M Tape Speed sensor Corrugate DTM06-6S 1568-09194-0-31406-0...

  • Page 119: Electrical Component Specifications

    Black ・Red, white and black 　indicate harness colors Black VIEw A Starting shaft position 120° ±５° Mechanical travel Stop position with return spring Output characteristics Output (％) （％） Angle (°) Electrical travel Total electrical travel Shaft return direction SW880-1-05018 5-031...

  • Page 120: Exact Meter

    ELECTRICAL SYSTEM 5-2. Exact Meter SwP-8M SwP-6F SwP-6M (Cap) Harness side 25 X SwP-8F SW880-1-05017 Wire Function CAN + CAN - CAN GND +12 V OUT +12 V Exact meter relay — — 5-032...

  • Page 121: Resistor Unit

    SwP12F-4 300Ω SwP12F-5 300Ω SwP3F-1 SwP12F-6 300Ω 5.6Ω SwP12F-7 300Ω SwP12F-8 5.6Ω 300Ω SwP12F-9 300Ω SwP12F-10 5.6Ω SwP3F-3 300Ω SwP12F-11 SwP12F-12 SW880-1-05015 (1) Case (2) Cement resistor : 5.6 Ω 10 w (3) Resistor : 300 Ω 3 w 5-033...

  • Page 122: Lever Switch

    ELECTRICAL SYSTEM 5-4. Lever Switch Harness side Electrical circuit SW880-1-05019 (1) F-R lever auto speed set switch (white) (2) F-R lever vibration switch (Green) (3) F-R lever water spray switch (Blue) (4) Handle 5-034...

  • Page 123: Fuse Box

    Harness color codes Fuse box BY : Black/Yellow stripe WY : white/Yellow stripe BR : Black/Red stripe WG : white/Green stripe SW880-1-05012 : white GY : Green/Yellow stripe WR : white/Red stripe GB : Green/Black stripe WB : white/Black stripe...

  • Page 124: Combination Meter

    Hydraulic oil filter Engine oil pressure warning indicator warning Preheating indicator Hydraulic oil filter warning SWP-12F Lamp check Coolant temp. SEL.1 Coolant temp. SEL.2 System configuration diagram Note: The circuit in the dashed box is not mounted. SW880-1-05016 5-036...

  • Page 125: Vibratory Drum

    VIBRATORY DRUM...

  • Page 127: Precautions For Disassembly And Reassembly

    VIBRATORY DRUM 1. PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY • When removing, installing, disassembling or reassembling the unit, observe the general precautions described below. 1) Precautions for removal work • Coolant that contains antifreeze should be treated as a chemical, and must not be drained carelessly on the ground.
  • Page 128 VIBRATORY DRUM 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 129: Removal And Installation Of Vibratory Drum

    VIBRATORY DRUM 2. REMOVAL AND INSTALLATION OF VIBRATORY DRUM 2-1. Removal of Vibratory Drum 1) Prior to disassembly of vibratory drum, completely drain water spray tank. Water spray tank : 600 L×2 ( 159 gal.×2 ) 2) Joint front frame and rear frame with steering lock bar (1). SW880-06001 SW880-06001 W AR N ING...
  • Page 130 VIBRATORY DRUM 5) Loosen the hose clamps (3) and remove the water spray hoses (4). SW880-06004 SW880-06004 6) Remove the hose clamp (5). • Remove the two bolts (6) (left and right). • Pull out the tank stoppers (7) (left and right). SW880-06005 SW880-06005 7) Lift the member (8) and water spray pipe cover (9) with a...
  • Page 131 VIBRATORY DRUM 8) Loosen the hose clamp (12) at the outlet of the water tank. • Disconnect the water spray hose (13). SW880-06007 SW880-06007 9) Remove the bolt (14) fixing the drain cap chain. • Remove the four cover fixing bolts (15) (left and right). •...
  • Page 132 VIBRATORY DRUM 11) Lift the water tank (19) with a crane and remove it from the frame. Water supply port Water supply port (NOTICE) • Lift the water tank at the water supply port so as not to damage the tank. (19) water tank : 50 kg (110 lbs.) SW880-06010 SW880-06010...
  • Page 133 VIBRATORY DRUM ② Vibrator motor piping • Remove the hydraulic hose clamp (31). • Disconnect the four hydraulic hoses (27), (28), (29) and (30) connecting to the vibrator motor. (NOTICE) • Plug both ends of the disconnected hoses or implement other actions to prevent entry of foreign matter.

  • Page 134: Installation Of Vibratory Drum

    VIBRATORY DRUM 2-2. Installation of Vibratory Drum 1) Install the vibratory drum in the reverse order in which it was removed. • Tightening torques for the bolts where particular care is required when installing the vibratory drum (21) Bolts M20×70 : 539 N·m (398 lbf·ft) N•m Cross member (33) Bolts M22×90 : 685 N·m (506 lbf·ft)
  • Page 135 VIBRATORY DRUM 3. VIBRATORY DRUM ASSEMBLY 3-1. Vibratory Drum Assembly (1) Bolt (M20×60) (31) Bolt (M22×90) (2) Housing (32) Bracket (3) Vibrator bearing (33) Shim (4) Eccentric shaft (34) O-ring (5) Vibrator bearing (35) Cover (6) Sleeve (36) Bolt (M12×40) (7) Spring pin (37) Roller bearing (8) Housing...

  • Page 137: Vibratory Drum Assembly

    VIBRATORY DRUM 4. DISASSEMBLY AND REASSEMBLY OF VIBRATORY DRUM • The lead line numbers shown in the illustrations below are consistent with the part numbers of the vibratory drum 39-1 39-1 shown on page 6-009. 4-1. Disassembly of Vibratory Drum 1) Remove the plugs (39-1) and (39-2).
  • Page 138 VIBRATORY DRUM 4) Install lifting bolts and nuts (M22) as shown on the right. Lifting bolt Lifting bolt SW880-06020 SW880-06020 5) Remove the sixteen bolts (23). • Lift the brackets (22) and (32), damper (18) and bracket (16) together with a crane and remove them. (NOTICE) •...
  • Page 139 VIBRATORY DRUM 7) Using the two pulling bolts (M16×50), lift the axle shaft (13). Pulling bolt Pulling bolt SW800-06018 SW800-06018 W AR N ING Lifting bolt Lifting bolt When attaching the lifting bolts, screw in the threads fully before using. 8) Install lifting bolts (M16) on the axle shaft (13).
  • Page 140 VIBRATORY DRUM 10) Attach a lifting bolt (M8) to the end of the eccentric shaft (11) and lift the eccentric shaft to remove it. Lift with crane. Lift with crane. (11) Eccentric shaft : 60 kg (132 lbs.) Lifting bolt Lifting bolt SW800-06022 SW800-06022...
  • Page 141 VIBRATORY DRUM 13) Install lifting bolts (M16) on the housing (8). Lifting bolt Lifting bolt SW800-06025 SW800-06025 14) Lift the housing subassembly with a crane to remove it. Lift with crane. Lift with crane. (8) and (4) Total weight of parts to be lifted : 100 kg (220 lbs.) Housing Housing...
  • Page 142 VIBRATORY DRUM 16) Install lifting bolts and nuts (M22) as shown on the right. Lifting bolt Lifting bolt SW880-06025 SW880-06025 17) Remove the sixteen bolts (54). • Lift the brackets (48) and (56), damper (59) and plate (55) together with a crane to remove them. (NOTICE) •...
  • Page 143 VIBRATORY DRUM 19) Install lifting bolts (M20) on the propulsion motor (53). Lifting bolt Lifting bolt SW880-06028 SW880-06028 20) Lift the propulsion motor (53) with a crane to remove it. Lift with crane. Lift with crane. (53) Propulsion motor : 200 kg (441 lbs.) SW880-06029 SW880-06029 21) Remove the sixteen bolts (1).
  • Page 144 VIBRATORY DRUM 22) Using two pulling bolts (M20×50), lift the housing (2). Pulling bolt Pulling bolt SW880-06031 SW880-06031 23) Install lifting bolts (M20) on the housing (2). Lifting bolt Lifting bolt SW880-06032 SW880-06032 24) Lift the housing (2) with a crane to remove it. (2) Housing : 80 kg (176 lbs.) Lift with crane.
  • Page 145 VIBRATORY DRUM 25) Shown on the right is the axle shaft subassembly removed from the vibratory drum. • Remove the six bolts (36). • Remove the cover (35). SW800-06037 SW800-06037 26) Remove the eight bolts (28). • Remove the cover (29) and shim (26). SW800-06038 SW800-06038 27) Place a protection plate on the end face of the axle shaft...
  • Page 146 VIBRATORY DRUM 28) Install lifting bolts (M12) on the housing (15). Lifting bolt Lifting bolt SW800-06040 SW800-06040 29) Lift the housing (15) with a crane to separate it from the axle shaft (13). Lift with crane. Lift with crane. (15) Housing : 50 kg (110 lbs.) SW800-06041 SW800-06041 30) Put the housing subassembly on a stand as shown.
  • Page 147 VIBRATORY DRUM 31) Set up a bearing puller on the stand. Bearing puller Bearing puller 4- 18 4- 18 t 16 t 16 Plate Plate Puller Puller M16 2.0 M16 2.0 M16 2.0 M16 2.0 φ16 φ16 M16 2.0 M16 2.0 Two shafts Two shafts SW800-06043...
  • Page 148 VIBRATORY DRUM 34) Install lifting bolts (M16) and lift the housing (8) with a crane. Lift with crane. Lift with crane. (8) Housing : 95 kg (209 lbs.) Lifting bolt Lifting bolt SW800-06046 SW800-06046 35) Put the housing (8) and eccentric shaft (4) lifted with a crane on wooden blocks.
  • Page 149 VIBRATORY DRUM 37) Lift the housing (8) with a crane to separate it from the eccentric shaft (4). Lift with crane. Lift with crane. (8) Housing : 40 kg (88 lbs.) SW880-06034 SW880-06034 38) Put the housing (8) on wooden blocks. Wooden block Wooden block SW800-06050...

  • Page 150: Reassembly Of Vibratory Drum

    VIBRATORY DRUM 4-2. Reassembly of Vibratory Drum (NOTICE) • Before reassembling, clean the disassembled parts well and check that there is no abnormality. O-ring fitting groove O-ring fitting groove 1) Housing subassembly ① Apply a thin coat of gear oil to the surface to which the vibrator bearing (3) will be press-fitted.
  • Page 151 VIBRATORY DRUM 3) Lift the housing subassembly with a crane and install it in the vibratory drum. (NOTICE) • When installing the housing subassembly, take care not to allow the O-ring to protrude from the fitting groove. Housing Housing subassembly subassembly Housing subassembly : 80 kg (176 lbs.) SW800-06055...
  • Page 152 • The side on which a weld bead is installed is the vibrator motor side. Wooden block Wooden block (46) Drum SW880-1-06001 SW880-1-06001 SW880 : 2,150 kg (4,740 lbs.) SW990 : 2,250 kg (4,960 lbs.) 8) Put the eccentric shaft (11) (vibrator motor side) on wooden blocks with its splined portion facing up.
  • Page 153 VIBRATORY DRUM 9) Eccentric shaft subassembly ① Apply a thin coat of gear oil to the surface to which the vibrator bearing (5) will be press-fitted. • Drive the vibrator bearing (5) into the housing (8). • Apply a thin coat of gear oil to the inner surface of the bearing (5).
  • Page 154 VIBRATORY DRUM ④ Apply a thin coat of gear oil to the bearing mounting surface of the eccentric shaft (4). • Lift the housing subassembly with a crane and install it on Lift with crane. Lift with crane. the eccentric shaft (4). (NOTICE) •...
  • Page 155 VIBRATORY DRUM ⑦ Apply a thin coat of gear oil to the surface to which the vibrator bearing (10) will be press-fitted. • Drive the vibrator bearing (10) into the housing (8). (NOTICE) • Take care not to damage the bearing when installing SW800-06066 SW800-06066 ⑧...
  • Page 156 VIBRATORY DRUM 10) Attach a lifting jig to the eccentric shaft subassembly. Eccentric shaft Eccentric shaft subassembly subassembly 2-M16 2.0 2-M16 2.0 Eyebolt Eyebolt 4- 18 4- 18 (M16 2.0) (M16 2.0) Lifting jig Lifting jig Bracket Bracket Two shafts Two shafts Lifting jig Lifting jig...
  • Page 157 VIBRATORY DRUM 13) Axle shaft subassembly 13-1) Apply a thin coat of gear oil to the surface of the outer race of the roller bearing (37) to be press-fitted. • Drive the outer race of the roller bearing (37) into the housing (15).
  • Page 158 VIBRATORY DRUM 13-4) Install the plugs (39) on the axle shaft subassembly. • Apply sufficient amount of lithium-based grease to the roller surface of the roller bearing (37). Axle shaft subassembly Axle shaft subassembly SW800-06076 SW800-06076 13-5) Install lifting bolts (M12) on the housing subassembly and lift it with a crane to joint it with the axle shaft Lifting bolt Lifting bolt...
  • Page 159 VIBRATORY DRUM 13-7) Preload adjustment of roller bearing ① Install a shim (26) of about 1 mm (0.08 in.) on the axle shaft and install the cover (29). The shim provides a clearance between the end face of the axle shaft and the inner surface of the cover (29).
  • Page 160 VIBRATORY DRUM ③ without inserting shim, install the cover (29). • Install washers to the four bolts (28) and tighten. There must be no gap There must be no gap • Using a thickness gauge, measure the gap at dimension “A”.
  • Page 161 VIBRATORY DRUM ⑥ Secure the cover (35) to the housing (15) with the six bolts (36) and spring washers. (36) Bolts M12×40 : 108 N·m (80 lbf·ft) N•m SW800-06085 SW800-06085 14) Install lifting bolts (M16) on the axle shaft subassembly. Lifting bolt Lifting bolt Axle shaft subassembly...
  • Page 162 (39-1) and (39-2). 39-1 39-1 39-2 39-2 SW880-1-06002 SW880-1-06002 17) Secure the axle shaft subassembly to the drum with the sixteen bolts (14). (14) Bolts M16×50 : 265 N·m (195 lbf·ft) N•m...
  • Page 163 VIBRATORY DRUM 18) Install a lifting bolt (M8) on the shaft end of the eccentric shaft (11). Lifting bolt Lifting bolt SW800-06091 SW800-06091 19) Slowly lift the eccentric shaft with a crane and check that there is an axial play of 1 to 2 mm (0.04 to 0.08 in.). Lift with crane.
  • Page 164 VIBRATORY DRUM 21) Lift the bracket subassembly with a crane. Lift with crane. Lift with crane. Bracket subassembly : 290 kg (639 lbs.) SW880-06043 SW880-06043 22) Lower the bracket subassembly while keeping it level and install it on the spigot joint of the housing. Breather Breather Align...
  • Page 165 VIBRATORY DRUM 24) Apply molybdenum-based grease to the splined portion of the sleeve (42). • Fit the sleeve (42) to the splined shaft on the eccentric shaft end. SW880-06046 SW880-06046 25) Apply a thin coat of grease to the O-ring (34). •...
  • Page 166 VIBRATORY DRUM WARN ING Be careful because reversing the vibratory drum is dangerous work. Confirm that the surrounding area is safe, and work in a natural, unstrained posture. 27) Lift the drum (46) with a crane and reverse it. Then, stand the drum with the propulsion motor side facing up.
  • Page 167 VIBRATORY DRUM 30) Slowly lift the eccentric shaft with a crane and check that there is an axial play of 1 to 2 mm (0.04 to 0.08 in.). Lift with crane. Lift with crane. SW800-06103 SW800-06103 31) Apply a thin coat of grease to the O-ring (52). •...
  • Page 168 VIBRATORY DRUM 33) Slowly lift the propulsion motor (53) with a crane and install it in the drum. Lift with Lift with crane. crane. (NOTICE) • When installing the propulsion motor, take care not to allow the O-ring to protrude from the fitting groove. (53) Propulsion motor : 200 kg (441 lbs.) SW880-06051 SW880-06051...
  • Page 169 VIBRATORY DRUM 36) Lift the bracket subassembly with a crane. Lift with crane. Lift with crane. Bracket subassembly : 250 kg (551 lbs.) SW880-06054 SW880-06054 37) Lower the bracket subassembly while keeping it level and install it on the spigot joint of the propulsion motor (53). (NOTICE) •...
  • Page 170 : 3,215 kg (7,088 lbs.) Weld bead Weld bead Chock Chock Chock Chock SW880-1-06003 SW880-1-06003 40) Remove the plugs (39-1) and (39-2). • Supply gear oil from the oil supply port and check that the Oil supply port Oil supply port...

  • Page 171: Brake

    BRAkE...

  • Page 173: Brake Pedal

    BRAKE 1. BRAkE PEDAL 0568-51803-0-11251-0 (1) Brake pedal (4) Nut : M10 P=1.25 (2) Foot brake switch (5) Return spring (3) Stopper bolt : M10×25 P=1.25 7-001...

  • Page 174: Brake System

    Parking brake solenoid valve when brake is ON. (without solenoid excited) Parking brake solenoid valve when brake is OFF. (with solenoid excited) Steering ・ charge pump The arrow ( ) symbol shows the direction of the hydraulic oil flow. SW880-1-07001 7-002...

  • Page 175: Operator Station

    OPERATOR STATION...

  • Page 177: Floorboard

    OPERATOR STATION 1. FLOORBOARD 1-1. Structure of Operator Station Fill grease DETAIL A SECTION B-B VIEw D-D SECTION C-C 0568-62806-0-11273-0 (1) Dashboard (10) Nut : M10 (2) Lever (11) Pedal (3) Pin (12) Bolt : M10×20 (4) Swing bearing (13) Rod end : M10 (left-hand thread) (5) Bolt : M10×50...

  • Page 178: Adjustment Of Swivel Lock Release Pedal

    OPERATOR STATION 1-2. Adjustment of Swivel Lock Release Pedal ① Loosen the nuts (14) and (16). ② Insert the pin (7) into the fixing hole to lock the pedal. ③ Using the rod (15), adjust the pedal height in the locked condition. Pedal height: 124 mm (4.9 in.) ★...

  • Page 179: Water Spray System

    WATER SPRAY SYSTEM...

  • Page 181: Water Spray Piping

    WATER SPRAY SYSTEM 1. WATER SPRAY PIPING Hose (Tee Pump 1 IN) Hose Hose (Tee Pump 2 IN) (3-way valve Filter IN) Nozzle Nozzle Filter DETAIL C 3-way valve VIEW A Water spray pump 2 Hose (Pump 2 OUT Pipe 2) Pipe 1 Pipe 2 Hose...

  • Page 183: Inspection And Adjustment

    INSPECTION AND ADJUSTMENT...

  • Page 185: 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 186: Measurement And Adjustment Of Propulsion Circuit Pressure

    ③ Set vibration frequency select switch to “2,500 vpm”. ④ Start the engine and set throttle switch to the “Full”. ⑤ Establish a condition in which machine propulsion load SW880-1-10001 SW880-1-10001 becomes maximum. (Pressure does not build up unless propulsion load is applied.)

  • Page 187: 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. 2-2-1. If pressures on both forward and reverse sides deviate from maximum circuit pressure range by same value ①...

  • Page 188: If Pressure On Either The Forward Or Reverse Side Deviates From

    INSPECTION AND ADJUSTMENT 2-2-2. If pressure on either the forward or reverse side deviates from maximum circuit pressure range ① Check nut (5) of high pressure relief valve (1-11) or (1-14) for evidence of having loosened. 1-11 1-11 • High pressure relief valve (1-11): Forward side •...

  • Page 189: Measurement And Adjustment Of Propulsion Charge Circuit Pressure

    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. 3-1. Measurement • Oil temperature during measurement: 50 °C (122 °F) ±...

  • Page 190: Adjustment

    INSPECTION AND ADJUSTMENT 3-2. Adjustment • If measurement results indicate 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 (1-15) for evidence of having loosened.

  • Page 191: Measurement Of Propulsion Servo Circuit Pressure

    • with parking brake applied (ON), measured pressures of (2) and (3) are same. • with parking brake released (OFF), measured pressures of (2) and (3) are different. SW880-1-10002 SW880-1-10002 Standard charge relief valve setting ★ : 2.5 MPa (362 psi) ±...

  • Page 192: Measurement Of Parking Brake Release Pressure

    INSPECTION AND ADJUSTMENT 5. MEASUREMENT OF PARkING BRAkE RELEASE PRESSURE • Since oil in charge circuit is supplied from steering circuit, confirm that steering operation is normal before measurement. 5-1. Measurement • Oil temperature during measurement: 50 °C (122 °F) ±...

  • Page 193: Measurement And Inspection Of Vibrator Circuit Pressure

    INSPECTION AND ADJUSTMENT 6. MEASUREMENT AND INSPECTION OF VIBRATOR CIRCUIT PRESSURE 6-1. Measurement C AUTION Take care not to operate the vibratory drum for a longer period of time than necessary with the machine stationary. Otherwise, the vibrator bearing could be seized.

  • Page 194: Inspection

    ⑧ If trapped dirt is present, disassemble and clean high pressure relief valve. ⑨ If a scratch is found on seat, replace high pressure relief valve. SW880-1-10008 SW880-1-10008 ⑩ After inspection, measure pressure again and check that pressure reaches maximum circuit pressure range.
  • Page 195 • Before adjusting pressure, energize solenoid valve SW880-1-10009 installed in vibrator valve block to have it function as a port relief valve. • To adjust pressure, loosen nut and turn adjustment screw (11).

  • Page 196: Measurement And Inspection Of Vibrator Charge Circuit Pressure

    INSPECTION AND ADJUSTMENT 7. MEASUREMENT AND INSPECTION OF VIBRATOR CHARGE CIRCUIT PRESSURE 7-1. Measurement • Oil temperature during measurement: 50 °C (122 °F) ± 5 ± 9 ① Remove plug from coupling of control pressure gauge port (2-10). Attach pressure with hose ⓢ and the connector ⓤ...

  • Page 197: Inspection

    INSPECTION AND ADJUSTMENT 7-2. Inspection • If measurement results indicate the pressure deviating from standard charge relief pressure setting range, make an adjustment in accordance with procedure described below. ① Remove charge relief valve (2-16). ② Check removed charge relief valve for trapped dirt and other abnormalities.

  • Page 198: Measurement And Inspection Of Steering Circuit Pressure

    Turn steering wheel to operate relief valve. Then, read pressure indicated by pressure gauge. Standard maximum circuit pressure ★ (orbitrol relief pressure + charge relief pressure) : 17.5 MPa (2,538 psi) ± 1.0 ± 145 SW880-1-10003 SW880-1-10003 PG002090 PG002090 10-014...

  • Page 199: Inspection

    INSPECTION AND ADJUSTMENT 8-2. Inspection • If measurement results indicate pressure deviating from standard maximum circuit pressure range, make an inspection in accordance with procedure described below. ① Remove relief valve (3) from orbitrol. ② Check removed relief valve for trapped dirt, scratches on its seat and other abnormalities.

  • Page 200: Measurement Of Hydraulic Pump Case Pressure

    ⑥ With propulsion load at maximum, measure pressure when speed change switch is in “ ” and “ ” and SW880-1-10004 SW880-1-10004 F-R lever is in “N”, “F”, and “R”, respectively. Allowable pump case pressure ★ : 0.4 MPa (58 psi) or less...

  • Page 201: Measurement Of Vibrator Pump Case Pressure

    ⑦ Measure pressure when vibration select switch is in ” and “ ” and vibration frequency select switch “ “2,500”, “3,000”, and “4,000”, respectively. SW880-1-10005 SW880-1-10005 ⑧ Press F-R lever vibration switch OFF as soon as measurement is finished. Allowable pump case pressure ★...

  • Page 202: Measurement Of Propulsion Motor Case Pressure

    ⑥ 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. SW880-1-10006 SW880-1-10006 Allowable motor case pressure ★ : 0.3 MPa (43.5 psi) or less...

  • Page 203: Measurement Of Vibrator Motor Case Pressure

    ⑦ Measure pressure when vibration select switch is in ” and “ ”and vibration frequency select switch “ “2,500”, “3,000”, and “4,000”, respectively. SW880-1-10007 SW880-1-10007 ⑧ Press F-R lever vibration switch OFF as soon as measurement is finished. Allowable motor case pressure ★...

  • Page 204: Adjustment Of F-R Lever Potentiometer

    ② Adjust with nut (5) so that F-R lever operating force reading becomes the following standard value when F-R lever is moved toward forward position. F-R lever operating force standard value ★ : 1.0 N (2.20 lbf) ± 0.2 ± 0.45 SW880-1-10010 SW880-1-10010 10-020...

  • Page 205: Adjustment Of Steel Ball Thrust

    F-R lever operating force standard value ★ : 18.0 N (4.0 lbf) ± 0.2 ± 0.45 In neutral In neutral When screw When screw rides out of detent rides out of detent SW880-1-10011 SW880-1-10011 10-021...

  • Page 206: Adjustment Of Potentiometer

    1 (6) is seated in notch of F-R lever (2), and operate F-R lever in both directions to its full stroke positions several times. SW880-1-10012 ① Set starter switch to ON. ② Operate F-R lever as follows and then take a measurement of voltage at potentiometer 1 when F-R lever is placed in “N”.

  • Page 207: Adjustment Of Potentiometer 1 Voltage When Forward Switch Operates

    • F-R lever must automatically return to neutral when F-R lever is released at a position slightly beyond SW880-1-10014 SW880-1-10014 forward switch operating point. If lever does not return automatically, make an adjustment by loosening disc spring tension adjusting nut (5) and tightening screw (7).

  • Page 208: Adjustment Of Potentiometer 1 Voltage When Reverse Switch Operates

    F-R lever is moved toward reverse position. • F-R lever must automatically return to neutral when SW880-1-10015 SW880-1-10015 F-R lever is released at a position slightly beyond reverse switch operating point. If lever does not return automatically, make an adjustment by loosening disc spring tension adjusting nut (5) and tightening screw (7).

  • Page 209: Troubleshooting

    TROUBLESHOOTING...

  • Page 211: 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 212: 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 213: 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 214: 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 215 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 216 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 217 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 218 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 219: 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 220 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 221: Fault Codes

    • “EGT. WARNING” Lamp - The “EGT. WARNING” lamp illuminates when the exhaust temperature becomes high. These messages require timely operator attention. ENGINE STOP WARNING WAIT TO START EGT.WARNING SW880-1-11001 11-011...

  • Page 222: 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. ENGINE STOP DIAG. SW880-1-11002 Example Fault Code Sequence Fault Code 214 : Each block represents 0.5 seconds = “WARNING”...

  • Page 223: 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 224 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 225 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 226 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 227 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 228 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 229 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 230 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 231 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 232: Error Codes

    • The traveling/working controller performs the system diagnostics function. when any system problem is detected, it displays the corresponding error code like as “E01” on the multiple display (Exact meter). EXACT METER SLOW SPEED FAST MPH( °F ) SW880-1-11009 11-022...

  • Page 233: Error Code List

    TROUBLESHOOTING 2-3-2. Error code list Error code Description Symptom Faulty potentiometer inside F-R lever. Engine stop. Faulty forward and reverse switch. Engine stop (only auto speed mode). Impact frequency lamp does not light. Faulty speed sensor. Automatic speed function does not operate. Vehicle speed is not displayed.
  • Page 234 187 LgY ENGINE STOP LAMP 178 G 1.0k SPEED CHANGE SWITCH 177 Y FUSE BOX-10 1.25BR THROTTLE SPEED CHANGE SWITCH 1.25BR STOP RELAY STARTER SWITCH RELAY SPEED CONNECTION STARTER 1.25BR 1.25BY SWITCH STARTER LOCKOUT RELAY TO COMBINATION METER SW880-1-11003 11-024...

  • Page 235: Engine

    TROUBLESHOOTING 2-4. Engine 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.11-006 to P.11-008). •...
  • Page 236 187 LgY ENGINE STOP LAMP 178 G 1.0k SPEED CHANGE SWITCH 177 Y FUSE BOX-10 1.25BR THROTTLE SPEED CHANGE SWITCH 1.25BR STOP RELAY STARTER SWITCH RELAY SPEED CONNECTION STARTER 1.25BR 1.25BY SWITCH STARTER LOCKOUT RELAY TO COMBINATION METER SW880-1-11003 11-026...

  • Page 237: Engine Will Not Start (Starter Motor Does Not Run) 2/17

    TROUBLESHOOTING 2-4-1. Engine will not start (Starter motor does not run) 2/17 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-4-1 Error code...
  • Page 238 187 LgY ENGINE STOP LAMP 178 G 1.0k SPEED CHANGE SWITCH 177 Y FUSE BOX-10 1.25BR THROTTLE SPEED CHANGE SWITCH 1.25BR STOP RELAY STARTER SWITCH RELAY SPEED CONNECTION STARTER 1.25BR 1.25BY SWITCH STARTER LOCKOUT RELAY TO COMBINATION METER SW880-1-11003 11-028...

  • Page 239: Engine Will Not Start (Starter Motor Does Not Run) 3/17

    TROUBLESHOOTING 2-4-1. Engine will not start (Starter motor does not run) 3/17 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-4-1 Error code...
  • Page 240 187 LgY ENGINE STOP LAMP 178 G 1.0k SPEED CHANGE SWITCH 177 Y FUSE BOX-10 1.25BR THROTTLE SPEED CHANGE SWITCH 1.25BR STOP RELAY STARTER SWITCH RELAY SPEED CONNECTION STARTER 1.25BR 1.25BY SWITCH STARTER LOCKOUT RELAY TO COMBINATION METER SW880-1-11003 11-030...

  • Page 241: Engine Will Not Start (Starter Motor Does Not Run) 4/17

    TROUBLESHOOTING 2-4-1. Engine will not start (Starter motor does not run) 4/17 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-4-1 Error code...
  • Page 242 187 LgY ENGINE STOP LAMP 178 G 1.0k SPEED CHANGE SWITCH 177 Y FUSE BOX-10 1.25BR THROTTLE SPEED CHANGE SWITCH 1.25BR STOP RELAY STARTER SWITCH RELAY SPEED CONNECTION STARTER 1.25BR 1.25BY SWITCH STARTER LOCKOUT RELAY TO COMBINATION METER SW880-1-11003 11-032...

  • Page 243: Engine Will Not Start (Starter Motor Does Not Run) 5/17

    TROUBLESHOOTING 2-4-1. Engine will not start (Starter motor does not run) 5/17 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-4-1 Error code...
  • Page 244 187 LgY ENGINE STOP LAMP 178 G 1.0k SPEED CHANGE SWITCH 177 Y FUSE BOX-10 1.25BR THROTTLE SPEED CHANGE SWITCH 1.25BR STOP RELAY STARTER SWITCH RELAY SPEED CONNECTION STARTER 1.25BR 1.25BY SWITCH STARTER LOCKOUT RELAY TO COMBINATION METER SW880-1-11003 11-034...

  • Page 245: Engine Will Not Start (Starter Motor Does Not Run) 6/17

    TROUBLESHOOTING 2-4-1. Engine will not start (Starter motor does not run) 6/17 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-4-1 Error code...
  • Page 246 187 LgY ENGINE STOP LAMP 178 G 1.0k SPEED CHANGE SWITCH 177 Y FUSE BOX-10 1.25BR THROTTLE SPEED CHANGE SWITCH 1.25BR STOP RELAY STARTER SWITCH RELAY SPEED CONNECTION STARTER 1.25BR 1.25BY SWITCH STARTER LOCKOUT RELAY TO COMBINATION METER SW880-1-11003 11-036...

  • Page 247: Engine Will Not Start (Starter Motor Does Not Run) 7/17

    TROUBLESHOOTING 2-4-1. Engine will not start (Starter motor does not run) 7/17 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-4-1 Error code...
  • Page 248 187 LgY ENGINE STOP LAMP 178 G 1.0k SPEED CHANGE SWITCH 177 Y FUSE BOX-10 1.25BR THROTTLE SPEED CHANGE SWITCH 1.25BR STOP RELAY STARTER SWITCH RELAY SPEED CONNECTION STARTER 1.25BR 1.25BY SWITCH STARTER LOCKOUT RELAY TO COMBINATION METER SW880-1-11003 11-038...

  • Page 249: Engine Will Not Start (Starter Motor Does Not Run) 8/17

    TROUBLESHOOTING 2-4-1. Engine will not start (Starter motor does not run) 8/17 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-4-1 Error code...
  • Page 250 187 LgY ENGINE STOP LAMP 178 G 1.0k SPEED CHANGE SWITCH 177 Y FUSE BOX-10 1.25BR THROTTLE SPEED CHANGE SWITCH 1.25BR STOP RELAY STARTER SWITCH RELAY SPEED CONNECTION STARTER 1.25BR 1.25BY SWITCH STARTER LOCKOUT RELAY TO COMBINATION METER SW880-1-11003 11-040...

  • Page 251: Engine Will Not Start (Starter Motor Does Not Run) 9/17

    TROUBLESHOOTING 2-4-1. Engine will not start (Starter motor does not run) 9/17 • Starter motor runs for only 2 seconds when starter switch is turned to START. • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-4-1 Error code Check point...
  • Page 252 187 LgY ENGINE STOP LAMP 178 G 1.0k SPEED CHANGE SWITCH 177 Y FUSE BOX-10 1.25BR THROTTLE SPEED CHANGE SWITCH 1.25BR STOP RELAY STARTER SWITCH RELAY SPEED CONNECTION STARTER 1.25BR 1.25BY SWITCH STARTER LOCKOUT RELAY TO COMBINATION METER SW880-1-11003 11-042...

  • Page 253: Engine Will Not Start (Starter Motor Does Not Run) 10/17

    TROUBLESHOOTING 2-4-1. Engine will not start (Starter motor does not run) 10/17 • Starter motor runs for only 2 seconds when starter switch is turned to START. • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-4-1 Error code Check point...
  • Page 254 187 LgY ENGINE STOP LAMP 178 G 1.0k SPEED CHANGE SWITCH 177 Y FUSE BOX-10 1.25BR THROTTLE SPEED CHANGE SWITCH 1.25BR STOP RELAY STARTER SWITCH RELAY SPEED CONNECTION STARTER 1.25BR 1.25BY SWITCH STARTER LOCKOUT RELAY TO COMBINATION METER SW880-1-11003 11-044...

  • Page 255: Engine Will Not Start (Starter Motor Does Not Run) 11/17

    TROUBLESHOOTING 2-4-1. Engine will not start (Starter motor does not run) 11/17 • Starter motor runs for only 2 seconds when starter switch is turned to START. • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-4-1 Error code Check point...
  • Page 256 187 LgY ENGINE STOP LAMP 178 G 1.0k SPEED CHANGE SWITCH 177 Y FUSE BOX-10 1.25BR THROTTLE SPEED CHANGE SWITCH 1.25BR STOP RELAY STARTER SWITCH RELAY SPEED CONNECTION STARTER 1.25BR 1.25BY SWITCH STARTER LOCKOUT RELAY TO COMBINATION METER SW880-1-11003 11-046...

  • Page 257: Engine Will Not Start (Starter Motor Does Not Run) 12/17

    TROUBLESHOOTING 2-4-1. Engine will not start (Starter motor does not run) 12/17 • Starter motor runs for only 2 seconds when starter switch is turned to START. • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-4-1 Error code Check point...
  • Page 258 187 LgY ENGINE STOP LAMP 178 G 1.0k SPEED CHANGE SWITCH 177 Y FUSE BOX-10 1.25BR THROTTLE SPEED CHANGE SWITCH 1.25BR STOP RELAY STARTER SWITCH RELAY SPEED CONNECTION STARTER 1.25BR 1.25BY SWITCH STARTER LOCKOUT RELAY TO COMBINATION METER SW880-1-11003 11-048...

  • Page 259: Engine Will Not Start (Starter Motor Does Not Run) 13/17

    TROUBLESHOOTING 2-4-1. Engine will not start (Starter motor does not run) 13/17 • Starter motor runs for only 2 seconds when starter switch is turned to START. • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-4-1 Error code Check point...
  • Page 260 187 LgY ENGINE STOP LAMP 178 G 1.0k SPEED CHANGE SWITCH 177 Y FUSE BOX-10 1.25BR THROTTLE SPEED CHANGE SWITCH 1.25BR STOP RELAY STARTER SWITCH RELAY SPEED CONNECTION STARTER 1.25BR 1.25BY SWITCH STARTER LOCKOUT RELAY TO COMBINATION METER SW880-1-11003 11-050...

  • Page 261: Engine Will Not Start (Starter Motor Does Not Run) 14/17

    TROUBLESHOOTING 2-4-1. Engine will not start (Starter motor does not run) 14/17 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 2) when display shows no error code Reference Fig.: 2-4-1 Check point...
  • Page 262 187 LgY ENGINE STOP LAMP 178 G 1.0k SPEED CHANGE SWITCH 177 Y FUSE BOX-10 1.25BR THROTTLE SPEED CHANGE SWITCH 1.25BR STOP RELAY STARTER SWITCH RELAY SPEED CONNECTION STARTER 1.25BR 1.25BY SWITCH STARTER LOCKOUT RELAY TO COMBINATION METER SW880-1-11003 11-052...

  • Page 263: Engine Will Not Start (Starter Motor Does Not Run) 15/17

    TROUBLESHOOTING 2-4-1. Engine will not start (Starter motor does not run) 15/17 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 2) when display shows no error code Reference Fig.: 2-4-1 Check point...
  • Page 264 187 LgY ENGINE STOP LAMP 178 G 1.0k SPEED CHANGE SWITCH 177 Y FUSE BOX-10 1.25BR THROTTLE SPEED CHANGE SWITCH 1.25BR STOP RELAY STARTER SWITCH RELAY SPEED CONNECTION STARTER 1.25BR 1.25BY SWITCH STARTER LOCKOUT RELAY TO COMBINATION METER SW880-1-11003 11-054...

  • Page 265: Engine Will Not Start (Starter Motor Does Not Run) 16/17

    TROUBLESHOOTING 2-4-1. Engine will not start (Starter motor does not run) 16/17 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 2) when display shows no error code Reference Fig.: 2-4-1 Check point...
  • Page 266 187 LgY ENGINE STOP LAMP 178 G 1.0k SPEED CHANGE SWITCH 177 Y FUSE BOX-10 1.25BR THROTTLE SPEED CHANGE SWITCH 1.25BR STOP RELAY STARTER SWITCH RELAY SPEED CONNECTION STARTER 1.25BR 1.25BY SWITCH STARTER LOCKOUT RELAY TO COMBINATION METER SW880-1-11003 11-056...

  • Page 267: Engine Will Not Start (Starter Motor Does Not Run) 17/17

    TROUBLESHOOTING 2-4-1. Engine will not start (Starter motor does not run) 17/17 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 2) when display shows no error code Reference Fig.: 2-4-1 Check point...
  • Page 268 TROUBLESHOOTING Fig.: 2-4-2 Drain Return Suction VIEW A SECTION B-B 0568-02804-0-11317-A (1) Hose (Fuel gear pump drain → Fuel tank return) (8) Fuel pre-filter (2) Fuel unit (9) Fuel tank (3) Hose (Fuel tank suction → Fuel pre-filter IN) (10) Plug (4) Hose (Fuel pre-filter OUT →...

  • Page 269: 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 270 187 LgY ENGINE STOP LAMP 178 G 1.0k SPEED CHANGE SWITCH 177 Y FUSE BOX-10 1.25BR THROTTLE SPEED CHANGE SWITCH 1.25BR STOP RELAY STARTER SWITCH RELAY SPEED CONNECTION STARTER 1.25BR 1.25BY SWITCH STARTER LOCKOUT RELAY TO COMBINATION METER SW880-1-11003 11-060...

  • Page 271: 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 + wire R and chassis ground. battery. Standard voltage : At least intermediate engine speed, 14 V or more •...
  • Page 272 187 LgY ENGINE STOP LAMP 178 G 1.0k SPEED CHANGE SWITCH 177 Y FUSE BOX-10 1.25BR THROTTLE SPEED CHANGE SWITCH 1.25BR STOP RELAY STARTER SWITCH RELAY SPEED CONNECTION STARTER 1.25BR 1.25BY SWITCH STARTER LOCKOUT RELAY TO COMBINATION METER SW880-1-11003 11-062...

  • Page 273: Starter Motor Runs Even When F-R Lever Is Not At "N" And

    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. Forward Switch • when starter switch is OFF and F-R lever is “F”, check Replace forward switch.
  • Page 274 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-064...

  • Page 275: 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.11-006 to P.11-008). •...
  • Page 276 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-066...

  • Page 277: Machine And Engine Suddenly Stops 2/11

    TROUBLESHOOTING 2-5-1. Machine and engine suddenly stops 2/11 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-5-1 Error code Check point...
  • Page 278 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-068...

  • Page 279: Machine And Engine Suddenly Stops 3/11

    TROUBLESHOOTING 2-5-1. Machine and engine suddenly stops 3/11 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-5-1 Error code Check point...
  • Page 280 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-070...

  • Page 281: Machine And Engine Suddenly Stops 4/11

    TROUBLESHOOTING 2-5-1. Machine and engine suddenly stops 4/11 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-5-1 Error code Check point...
  • Page 282 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-072...

  • Page 283: Machine And Engine Suddenly Stops 5/11

    TROUBLESHOOTING 2-5-1. Machine and engine suddenly stops 5/11 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-5-1 Error code Check point...
  • Page 284 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-074...

  • Page 285: Machine And Engine Suddenly Stops 6/11

    TROUBLESHOOTING 2-5-1. Machine and engine suddenly stops 6/11 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-5-1 Error code Check point...
  • Page 286 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-076...

  • Page 287: Machine And Engine Suddenly Stops 7/11

    TROUBLESHOOTING 2-5-1. Machine and engine suddenly stops 7/11 • Starter motor runs for only 2 seconds when starter switch is turned to START. • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-5-1 Error code Check point...
  • Page 288 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-078...

  • Page 289: Machine And Engine Suddenly Stops 8/11

    TROUBLESHOOTING 2-5-1. Machine and engine suddenly stops 8/11 • Starter motor runs for only 2 seconds when starter switch is turned to START. • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-5-1 Error code Check point...
  • Page 290 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-080...

  • Page 291: Machine And Engine Suddenly Stops 9/11

    TROUBLESHOOTING 2-5-1. Machine and engine suddenly stops 9/11 • Starter motor runs for only 2 seconds when starter switch is turned to START. • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-5-1 Error code Check point...
  • Page 292 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-082...

  • Page 293: Machine And Engine Suddenly Stops 10/11

    TROUBLESHOOTING 2-5-1. Machine and engine suddenly stops 10/11 • Starter motor runs for only 2 seconds when starter switch is turned to START. • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-5-1 Error code Check point...
  • Page 294 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-084...

  • Page 295: Machine And Engine Suddenly Stops 11/11

    TROUBLESHOOTING 2-5-1. Machine and engine suddenly stops 11/11 • Starter motor runs for only 2 seconds when starter switch is turned to START. • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-5-1 Error code Check point...
  • Page 296 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-086...

  • Page 297: Machine And Engine Suddenly Stops In Automatic Speed Mode 1/2

    TROUBLESHOOTING 2-5-2. Machine and engine suddenly stops in automatic speed mode 1/2 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. •...
  • Page 298 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-088...

  • Page 299: Machine And Engine Suddenly Stops In Automatic Speed Mode 2/2

    TROUBLESHOOTING 2-5-2. Machine and engine suddenly stops in automatic speed mode 2/2 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. •...
  • Page 300 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-090...

  • Page 301: Machine Moves Neither Forward Nor Backward 1/6

    TROUBLESHOOTING 2-5-3. Machine moves neither forward nor backward 1/6 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-5-1 Error code Check point...
  • Page 302 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-092...

  • Page 303: Machine Moves Neither Forward Nor Backward 2/6

    TROUBLESHOOTING 2-5-3. Machine moves neither forward nor backward 2/6 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-5-1 Error code Check point...
  • Page 304 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-094...

  • Page 305: Machine Moves Neither Forward Nor Backward 3/6

    TROUBLESHOOTING 2-5-3. Machine moves neither forward nor backward 3/6 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-5-1 Error code Check point...
  • Page 306 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-096...

  • Page 307: Machine Moves Neither Forward Nor Backward 4/6

    TROUBLESHOOTING 2-5-3. Machine moves neither forward nor backward 4/6 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-5-1 Error code Check point...
  • Page 308 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-098...

  • Page 309: Machine Moves Neither Forward Nor Backward 5/6

    TROUBLESHOOTING 2-5-3. Machine moves neither forward nor backward 5/6 • F-R lever must be in “N”. • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 2) when display shows no error code Reference Fig.: 2-5-1 Check point...
  • Page 310 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-100...

  • Page 311: Machine Moves Neither Forward Nor Backward 6/6

    TROUBLESHOOTING 2-5-3. Machine moves neither forward nor backward 6/6 • F-R lever must be in “N”. • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows any error code. 2) when display shows no error code Reference Fig.: 2-5-1 Check point...
  • Page 312 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-102...

  • Page 313: Machine Speed Cannot Be Changed

    TROUBLESHOOTING 2-5-4. Machine speed cannot be changed • 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. Speed Change Switch (1) when starter switch is ON, measure voltage between Replace speed change speed change switch terminal 1 inlet wire YW and switch.
  • Page 314 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-104...

  • Page 315: Auto Speed Function Does Not Work 1/9

    TROUBLESHOOTING 2-5-5. Auto speed function does not work 1/9 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Set speed change switch to “ ”. (Automatic speed function is disabled when speed change switch is “ ”.) •...
  • Page 316 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-106...

  • Page 317: Auto Speed Function Does Not Work 2/9

    TROUBLESHOOTING 2-5-5. Auto speed function does not work 2/9 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Set speed change switch to “ ”. (Automatic speed function is disabled when speed change switch is “ ”.) •...
  • Page 318 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-108...

  • Page 319: Auto Speed Function Does Not Work 3/9

    TROUBLESHOOTING 2-5-5. Auto speed function does not work 3/9 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Set speed change switch to “ ”. (Automatic speed function is disabled when speed change switch is “ ”.) •...
  • Page 320 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-110...

  • Page 321: Auto Speed Function Does Not Work 4/9

    TROUBLESHOOTING 2-5-5. Auto speed function does not work 4/9 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Set speed change switch to “ ”. (Automatic speed function is disabled when speed change switch is “ ”.) •...
  • Page 322 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-112...

  • Page 323: Auto Speed Function Does Not Work 5/9

    TROUBLESHOOTING 2-5-5. Auto speed function does not work 5/9 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Set speed change switch to “ ”. (Automatic speed function is disabled when speed change switch is “ ”.) •...
  • Page 324 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-114...

  • Page 325: Auto Speed Function Does Not Work 6/9

    TROUBLESHOOTING 2-5-5. Auto speed function does not work 6/9 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Set speed change switch to “ ”. (Automatic speed function is disabled when speed change switch is “ ”.) •...
  • Page 326 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-116...

  • Page 327: Auto Speed Function Does Not Work 7/9

    TROUBLESHOOTING 2-5-5. Auto speed function does not work 7/9 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Set speed change switch to “ ”. (Automatic speed function is disabled when speed change switch is “ ”.) •...
  • Page 328 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-118...

  • Page 329: Auto Speed Function Does Not Work 8/9

    TROUBLESHOOTING 2-5-5. Auto speed function does not work 8/9 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Set speed change switch to “ ”. (Automatic speed function is disabled when speed change switch is “ ”.) •...
  • Page 330 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-120...

  • Page 331: Auto Speed Function Does Not Work 9/9

    TROUBLESHOOTING 2-5-5. Auto speed function does not work 9/9 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Set speed change switch to “ ”. (Automatic speed function is disabled when speed change switch is “ ”.) •...
  • Page 332 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-122...

  • Page 333: Brake Cannot Be Released

    TROUBLESHOOTING 2-5-6. Brake cannot be released • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). • Check whether exact meter multiple display shows no error code. Reference Fig.: 2-5-1 Check point Check/Cause Action 1.
  • Page 334 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-124...

  • Page 335: Brake Does Not Work

    TROUBLESHOOTING 2-5-7. Brake does not work • Parking brake switch must be applied. • Foot brake switch must be OFF (Brake pedal is depressed) • Check whether exact meter multiple display shows no error code. Reference Fig.: 2-5-1 Check point Check/Cause Action 1.
  • Page 336 TO CIS SELECT SWITCH (OPTION) 185 RB 186 RY ENGINE ECM (CM2250) AV60,R J3 (60PIN) VIBRATION CHANGE SWITCH SPEED CHANGE SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION 1.25BR F-R LEVER AUTO SPEED STARTER SET SWITCH AV60,B SWITCH ENGINE STUD BOLT SW880-1-11004 11-126...

  • Page 337: Emergency Exit Propulsion Switch Does Not Work

    TROUBLESHOOTING 2-5-8. Emergency exit propulsion switch does not work • Disconnect SwP-6F PRO (P.5-006) connector from engine harness side and connect emergency switch connector SwP-6F EME (P.5-006). Reference Fig.: 2-5-1 Check point Check/Cause Action 1. Propulsion Pump • Disconnect harness for propulsion pump proportional Replace propulsion pump Proportional Solenoid a solenoid a (R) or b (F) and measure resistance of coils.
  • Page 338 STARTER SELECT SWITCH SWITCH STARTER SWITCH IPF SELECT SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION (NOTCH POSITION) VIBRATION MODE SELECT SWITCH VIBRATION CONNECTION MODE 1-2,4-6 VIBRATION CHANGE SWITCH 1-3,4-6 AUTO 1-3,4-5 VIBRATION MODE SELECT SWITCH F-R LEVER VIBRATION SWITCH SW880-1-11005 11-128...

  • Page 339: 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.11-006 to P.11-008). •...
  • Page 340 STARTER SELECT SWITCH SWITCH STARTER SWITCH IPF SELECT SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION (NOTCH POSITION) VIBRATION MODE SELECT SWITCH VIBRATION CONNECTION MODE 1-2,4-6 VIBRATION CHANGE SWITCH 1-3,4-6 AUTO 1-3,4-5 VIBRATION MODE SELECT SWITCH F-R LEVER VIBRATION SWITCH SW880-1-11005 11-130...

  • Page 341: No Vibration Occurs 2/3

    TROUBLESHOOTING 2-6-1. No vibration occurs 2/3 • F-R lever must be in “N”. • Parking brake switch must be released. • Set vibration mode select switch to “ ” (continuous mode). • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.: 2-6-1 Error code...
  • Page 342 STARTER SELECT SWITCH SWITCH STARTER SWITCH IPF SELECT SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION (NOTCH POSITION) VIBRATION MODE SELECT SWITCH VIBRATION CONNECTION MODE 1-2,4-6 VIBRATION CHANGE SWITCH 1-3,4-6 AUTO 1-3,4-5 VIBRATION MODE SELECT SWITCH F-R LEVER VIBRATION SWITCH SW880-1-11005 11-132...

  • Page 343: No Vibration Occurs 3/3

    TROUBLESHOOTING 2-6-1. No vibration occurs 3/3 • F-R lever must be in “N”. • Parking brake switch must be released. • Vibration mode select switch to“ ”. • Check whether exact meter multiple display shows any error code. 2) when display shows no error code Reference Fig.: 2-6-1 Check point Check/Cause...
  • Page 344 STARTER SELECT SWITCH SWITCH STARTER SWITCH IPF SELECT SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION (NOTCH POSITION) VIBRATION MODE SELECT SWITCH VIBRATION CONNECTION MODE 1-2,4-6 VIBRATION CHANGE SWITCH 1-3,4-6 AUTO 1-3,4-5 VIBRATION MODE SELECT SWITCH F-R LEVER VIBRATION SWITCH SW880-1-11005 11-134...

  • Page 345: Vibration Frequency Cannot Be Switched 1/3

    TROUBLESHOOTING 2-6-2. Vibration frequency cannot be switched 1/3 • Set vibration mode select switch to “ ” (continuous mode). • Vibration frequency select switch is fixed at 4000 vpm, vibration change switch is “ ” when frequency cannot be switched. •...
  • Page 346 STARTER SELECT SWITCH SWITCH STARTER SWITCH IPF SELECT SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION (NOTCH POSITION) VIBRATION MODE SELECT SWITCH VIBRATION CONNECTION MODE 1-2,4-6 VIBRATION CHANGE SWITCH 1-3,4-6 AUTO 1-3,4-5 VIBRATION MODE SELECT SWITCH F-R LEVER VIBRATION SWITCH SW880-1-11005 11-136...

  • Page 347: Vibration Frequency Cannot Be Switched 2/3

    TROUBLESHOOTING 2-6-2. Vibration frequency cannot be switched 2/3 • Set vibration mode select switch to “ ” (continuous mode). • Vibration frequency select switch is fixed at 4000 vpm, vibration change switch is “ ” when frequency cannot be switched. •...
  • Page 348 STARTER SELECT SWITCH SWITCH STARTER SWITCH IPF SELECT SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION (NOTCH POSITION) VIBRATION MODE SELECT SWITCH VIBRATION CONNECTION MODE 1-2,4-6 VIBRATION CHANGE SWITCH 1-3,4-6 AUTO 1-3,4-5 VIBRATION MODE SELECT SWITCH F-R LEVER VIBRATION SWITCH SW880-1-11005 11-138...

  • Page 349: Vibration Frequency Cannot Be Switched 3/3

    TROUBLESHOOTING 2-6-2. Vibration frequency cannot be switched 3/3 • Set vibration mode select switch to “ ” (continuous mode). • Vibration frequency select switch is fixed at 4000 vpm, vibration change switch is “ ” when frequency cannot be switched. •...
  • Page 350 STARTER SELECT SWITCH SWITCH STARTER SWITCH IPF SELECT SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION (NOTCH POSITION) VIBRATION MODE SELECT SWITCH VIBRATION CONNECTION MODE 1-2,4-6 VIBRATION CHANGE SWITCH 1-3,4-6 AUTO 1-3,4-5 VIBRATION MODE SELECT SWITCH F-R LEVER VIBRATION SWITCH SW880-1-11005 11-140...

  • Page 351: Continuous/Automatic Vibration Mode Cannot Be Switched 1/2

    TROUBLESHOOTING 2-6-3. Continuous/automatic vibration mode cannot be switched 1/2 Reference Fig. : 2-6-1 Check point Check/Cause Action 1. Vibration Mode Select (1) when starter switch is ON and vibration mode select Replace vibration mode Switch select switch. switch is “ ”, measure voltage between vibration mode select switch terminal 1, 4 inlet wires YW and chassis ground.
  • Page 352 STARTER SELECT SWITCH SWITCH STARTER SWITCH IPF SELECT SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION (NOTCH POSITION) VIBRATION MODE SELECT SWITCH VIBRATION CONNECTION MODE 1-2,4-6 VIBRATION CHANGE SWITCH 1-3,4-6 AUTO 1-3,4-5 VIBRATION MODE SELECT SWITCH F-R LEVER VIBRATION SWITCH SW880-1-11005 11-142...

  • Page 353: Continuous/Automatic Vibration Mode Cannot Be Switched 2/2

    TROUBLESHOOTING 2-6-3. Continuous/automatic vibration mode cannot be switched 2/2 Reference Fig. : 2-6-1 Check point Check/Cause Action 3. Traveling Controller (1) when starter switch is ON, measure voltage between Replace traveling traveling controller power supply terminal 2 inlet wire controller. WB and ground terminal 1 wire B.
  • Page 354 STARTER SELECT SWITCH SWITCH STARTER SWITCH IPF SELECT SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION (NOTCH POSITION) VIBRATION MODE SELECT SWITCH VIBRATION CONNECTION MODE 1-2,4-6 VIBRATION CHANGE SWITCH 1-3,4-6 AUTO 1-3,4-5 VIBRATION MODE SELECT SWITCH F-R LEVER VIBRATION SWITCH SW880-1-11005 11-144...

  • Page 355: Front And Rear Vibratory Drums Cannot Perform One-Drum Vibration

    TROUBLESHOOTING 2-6-4. Front and rear vibratory drums cannot perform one-drum vibration Reference Fig. : 2-6-1 Check point Check/Cause Action 1. Vibrator Solenoid (F) • Disconnect each harness of vibrator solenoid (F) or (R) (3 Replace vibrator solenoid or (R) (3 each for front each for front and rear) in front or rear drum and measure (F) or (R).
  • Page 356 STARTER SELECT SWITCH SWITCH STARTER SWITCH IPF SELECT SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION (NOTCH POSITION) VIBRATION MODE SELECT SWITCH VIBRATION CONNECTION MODE 1-2,4-6 VIBRATION CHANGE SWITCH 1-3,4-6 AUTO 1-3,4-5 VIBRATION MODE SELECT SWITCH F-R LEVER VIBRATION SWITCH SW880-1-11005 11-146...

  • Page 357: Exact Meter

    TROUBLESHOOTING 2-7. Exact Meter Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. (NOTICE) • If any abnormality is found in shielded twisted wires, be sure to replace them. 2-7-1. Exact meter indicator lamp does not illuminate while driving 1/9 •...
  • Page 358 STARTER SELECT SWITCH SWITCH STARTER SWITCH IPF SELECT SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION (NOTCH POSITION) VIBRATION MODE SELECT SWITCH VIBRATION CONNECTION MODE 1-2,4-6 VIBRATION CHANGE SWITCH 1-3,4-6 AUTO 1-3,4-5 VIBRATION MODE SELECT SWITCH F-R LEVER VIBRATION SWITCH SW880-1-11005 11-148...

  • Page 359: Exact Meter Indicator Lamp Does Not Illuminate While Driving 2/9

    TROUBLESHOOTING 2-7-1. Exact meter indicator lamp does not illuminate while driving 2/9 • Exact meter indicator lamp illuminates only while vibration is activated. • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.
  • Page 360 STARTER SELECT SWITCH SWITCH STARTER SWITCH IPF SELECT SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION (NOTCH POSITION) VIBRATION MODE SELECT SWITCH VIBRATION CONNECTION MODE 1-2,4-6 VIBRATION CHANGE SWITCH 1-3,4-6 AUTO 1-3,4-5 VIBRATION MODE SELECT SWITCH F-R LEVER VIBRATION SWITCH SW880-1-11005 11-150...

  • Page 361: Exact Meter Indicator Lamp Does Not Illuminate While Driving 3/9

    TROUBLESHOOTING 2-7-1. Exact meter indicator lamp does not illuminate while driving 3/9 • Exact meter indicator lamp illuminates only while vibration is activated. • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.
  • Page 362 STARTER SELECT SWITCH SWITCH STARTER SWITCH IPF SELECT SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION (NOTCH POSITION) VIBRATION MODE SELECT SWITCH VIBRATION CONNECTION MODE 1-2,4-6 VIBRATION CHANGE SWITCH 1-3,4-6 AUTO 1-3,4-5 VIBRATION MODE SELECT SWITCH F-R LEVER VIBRATION SWITCH SW880-1-11005 11-152...

  • Page 363: Exact Meter Indicator Lamp Does Not Illuminate While Driving 4/9

    TROUBLESHOOTING 2-7-1. Exact meter indicator lamp does not illuminate while driving 4/9 • Exact meter indicator lamp illuminates only while vibration is activated. • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.
  • Page 364 STARTER SELECT SWITCH SWITCH STARTER SWITCH IPF SELECT SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION (NOTCH POSITION) VIBRATION MODE SELECT SWITCH VIBRATION CONNECTION MODE 1-2,4-6 VIBRATION CHANGE SWITCH 1-3,4-6 AUTO 1-3,4-5 VIBRATION MODE SELECT SWITCH F-R LEVER VIBRATION SWITCH SW880-1-11005 11-154...

  • Page 365: Exact Meter Indicator Lamp Does Not Illuminate While Driving 5/9

    TROUBLESHOOTING 2-7-1. Exact meter indicator lamp does not illuminate while driving 5/9 • Exact meter indicator lamp illuminates only while vibration is activated. • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.
  • Page 366 STARTER SELECT SWITCH SWITCH STARTER SWITCH IPF SELECT SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION (NOTCH POSITION) VIBRATION MODE SELECT SWITCH VIBRATION CONNECTION MODE 1-2,4-6 VIBRATION CHANGE SWITCH 1-3,4-6 AUTO 1-3,4-5 VIBRATION MODE SELECT SWITCH F-R LEVER VIBRATION SWITCH SW880-1-11005 11-156...

  • Page 367: Exact Meter Indicator Lamp Does Not Illuminate While Driving 6/9

    TROUBLESHOOTING 2-7-1. Exact meter indicator lamp does not illuminate while driving 6/9 • Exact meter indicator lamp illuminates only while vibration is activated. • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.
  • Page 368 STARTER SELECT SWITCH SWITCH STARTER SWITCH IPF SELECT SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION (NOTCH POSITION) VIBRATION MODE SELECT SWITCH VIBRATION CONNECTION MODE 1-2,4-6 VIBRATION CHANGE SWITCH 1-3,4-6 AUTO 1-3,4-5 VIBRATION MODE SELECT SWITCH F-R LEVER VIBRATION SWITCH SW880-1-11005 11-158...

  • Page 369: Exact Meter Indicator Lamp Does Not Illuminate While Driving 7/9

    TROUBLESHOOTING 2-7-1. Exact meter indicator lamp does not illuminate while driving 7/9 • Exact meter indicator lamp illuminates only while vibration is activated. • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.
  • Page 370 STARTER SELECT SWITCH SWITCH STARTER SWITCH IPF SELECT SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION (NOTCH POSITION) VIBRATION MODE SELECT SWITCH VIBRATION CONNECTION MODE 1-2,4-6 VIBRATION CHANGE SWITCH 1-3,4-6 AUTO 1-3,4-5 VIBRATION MODE SELECT SWITCH F-R LEVER VIBRATION SWITCH SW880-1-11005 11-160...

  • Page 371: Exact Meter Indicator Lamp Does Not Illuminate While Driving 8/9

    TROUBLESHOOTING 2-7-1. Exact meter indicator lamp does not illuminate while driving 8/9 • Exact meter indicator lamp illuminates only while vibration is activated. • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig.
  • Page 372 STARTER SELECT SWITCH SWITCH STARTER SWITCH IPF SELECT SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION (NOTCH POSITION) VIBRATION MODE SELECT SWITCH VIBRATION CONNECTION MODE 1-2,4-6 VIBRATION CHANGE SWITCH 1-3,4-6 AUTO 1-3,4-5 VIBRATION MODE SELECT SWITCH F-R LEVER VIBRATION SWITCH SW880-1-11005 11-162...

  • Page 373: Exact Meter Indicator Lamp Does Not Illuminate While Driving 9/9

    TROUBLESHOOTING 2-7-1. Exact meter indicator lamp does not illuminate while driving 9/9 • Exact meter indicator lamp illuminates only while vibration is activated. • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 2) when display shows no error code Reference Fig.
  • Page 374 STARTER SELECT SWITCH SWITCH STARTER SWITCH IPF SELECT SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION (NOTCH POSITION) VIBRATION MODE SELECT SWITCH VIBRATION CONNECTION MODE 1-2,4-6 VIBRATION CHANGE SWITCH 1-3,4-6 AUTO 1-3,4-5 VIBRATION MODE SELECT SWITCH F-R LEVER VIBRATION SWITCH SW880-1-11005 11-164...

  • Page 375: No Vehicle Speed Indication On Display 1/3

    TROUBLESHOOTING 2-7-2. No vehicle speed indication on display 1/3 • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig. : 2-6-1 Error code Check point Check/Cause Action...
  • Page 376 STARTER SELECT SWITCH SWITCH STARTER SWITCH IPF SELECT SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION (NOTCH POSITION) VIBRATION MODE SELECT SWITCH VIBRATION CONNECTION MODE 1-2,4-6 VIBRATION CHANGE SWITCH 1-3,4-6 AUTO 1-3,4-5 VIBRATION MODE SELECT SWITCH F-R LEVER VIBRATION SWITCH SW880-1-11005 11-166...

  • Page 377: No Vehicle Speed Indication On Display 2/3

    TROUBLESHOOTING 2-7-2. No vehicle speed indication on display 2/3 • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 1) when display shows any error code Reference Fig. : 2-6-1 Error code Check point Check/Cause Action...
  • Page 378 STARTER SELECT SWITCH SWITCH STARTER SWITCH IPF SELECT SWITCH VIBRATION CHANGE SWITCH VIBRATION CONNECTION (NOTCH POSITION) VIBRATION MODE SELECT SWITCH VIBRATION CONNECTION MODE 1-2,4-6 VIBRATION CHANGE SWITCH 1-3,4-6 AUTO 1-3,4-5 VIBRATION MODE SELECT SWITCH F-R LEVER VIBRATION SWITCH SW880-1-11005 11-168...

  • Page 379: No Vehicle Speed Indication On Display 3/3

    TROUBLESHOOTING 2-7-2. No vehicle speed indication on display 3/3 • Set engine throttle switch to “FULL”. • Check whether exact meter multiple display shows any error code. 2) when display shows no error code Reference Fig. : 2-6-1 Check point Check/Cause Action 1.
  • Page 380 RELAY WORKING CONTROLLER (C2) 0.5WB 0.5GW 0.5WB PROPULSION PUMP NEUTRAL HOLDING RELAY FUSE F.L.65A BATTERY RELAY F-R LEVER WATER HORN SPRAY SWITCH RELAY F.L.65A STARTER SWITCH AV60,R 1.25BR 1.25BR STARTER FUSE BOX SWITCH AV60,B F.L.65A ENGINE STUD BOLT SW880-1-11006 11-170...

  • Page 381: Water Spray

    TROUBLESHOOTING 2-8. Water Spray Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. 2-8-1. Continuous water spray does not operate 1/4 • Water spray mode select switch must be “ ”. • Water spray timer switch must be “ ”.
  • Page 382 RELAY WORKING CONTROLLER (C2) 0.5WB 0.5GW 0.5WB PROPULSION PUMP NEUTRAL HOLDING RELAY FUSE F.L.65A BATTERY RELAY F-R LEVER WATER HORN SPRAY SWITCH RELAY F.L.65A STARTER SWITCH AV60,R 1.25BR 1.25BR STARTER FUSE BOX SWITCH AV60,B F.L.65A ENGINE STUD BOLT SW880-1-11006 11-172...

  • Page 383: Continuous Water Spray Does Not Operate 2/4

    TROUBLESHOOTING 2-8-1. Continuous water spray does not operate 2/4 • Water spray mode select switch must be “ ”. • Water spray timer switch must be “ ”. • Set water spray pump switch to simultaneous spray. Reference Fig. : 2-8-1 Check point Check/Cause Action...
  • Page 384 RELAY WORKING CONTROLLER (C2) 0.5WB 0.5GW 0.5WB PROPULSION PUMP NEUTRAL HOLDING RELAY FUSE F.L.65A BATTERY RELAY F-R LEVER WATER HORN SPRAY SWITCH RELAY F.L.65A STARTER SWITCH AV60,R 1.25BR 1.25BR STARTER FUSE BOX SWITCH AV60,B F.L.65A ENGINE STUD BOLT SW880-1-11006 11-174...

  • Page 385: Continuous Water Spray Does Not Operate 3/4

    TROUBLESHOOTING 2-8-1. Continuous water spray does not operate 3/4 • Water spray mode select switch must be “ ”. • Water spray timer switch must be “ ”. • Set water spray pump switch to simultaneous spray. Reference Fig. : 2-8-1 Check point Check/Cause Action...
  • Page 386 RELAY WORKING CONTROLLER (C2) 0.5WB 0.5GW 0.5WB PROPULSION PUMP NEUTRAL HOLDING RELAY FUSE F.L.65A BATTERY RELAY F-R LEVER WATER HORN SPRAY SWITCH RELAY F.L.65A STARTER SWITCH AV60,R 1.25BR 1.25BR STARTER FUSE BOX SWITCH AV60,B F.L.65A ENGINE STUD BOLT SW880-1-11006 11-176...

  • Page 387: Continuous Water Spray Does Not Operate 4/4

    TROUBLESHOOTING 2-8-1. Continuous water spray does not operate 4/4 • Water spray mode select switch must be “ ”. • Water spray timer switch must be “ ”. • Set water spray pump switch to simultaneous spray. Reference Fig. : 2-8-1 Check point Check/Cause Action...
  • Page 388 RELAY WORKING CONTROLLER (C2) 0.5WB 0.5GW 0.5WB PROPULSION PUMP NEUTRAL HOLDING RELAY FUSE F.L.65A BATTERY RELAY F-R LEVER WATER HORN SPRAY SWITCH RELAY F.L.65A STARTER SWITCH AV60,R 1.25BR 1.25BR STARTER FUSE BOX SWITCH AV60,B F.L.65A ENGINE STUD BOLT SW880-1-11006 11-178...
  • Page 389 TROUBLESHOOTING 2-8-2. Continuous water spray works, but intermittent water spray does not operate 1/2 • Water spray mode select switch must be “ ”. • Water spray timer switch must be “ I ”. • Set water spray pump switch to “PUMP 2”. Reference Fig.
  • Page 390 RELAY WORKING CONTROLLER (C2) 0.5WB 0.5GW 0.5WB PROPULSION PUMP NEUTRAL HOLDING RELAY FUSE F.L.65A BATTERY RELAY F-R LEVER WATER HORN SPRAY SWITCH RELAY F.L.65A STARTER SWITCH AV60,R 1.25BR 1.25BR STARTER FUSE BOX SWITCH AV60,B F.L.65A ENGINE STUD BOLT SW880-1-11006 11-180...
  • Page 391 TROUBLESHOOTING 2-8-2. Continuous water spray works, but intermittent water spray does not operate 2/2 • Water spray mode select switch must be “ ”. • Water spray timer switch must be “ I ”. • Set water spray pump switch to “PUMP 2”. Reference Fig.
  • Page 392 RELAY WORKING CONTROLLER (C2) 0.5WB 0.5GW 0.5WB PROPULSION PUMP NEUTRAL HOLDING RELAY FUSE F.L.65A BATTERY RELAY F-R LEVER WATER HORN SPRAY SWITCH RELAY F.L.65A STARTER SWITCH AV60,R 1.25BR 1.25BR STARTER FUSE BOX SWITCH AV60,B F.L.65A ENGINE STUD BOLT SW880-1-11006 11-182...
  • Page 393 TROUBLESHOOTING 2-8-3. Continuous water spray works, but automatic water spray does not operate • water spray mode select switch must be “AUTO”. • Water spray timer switch must be “ ”. • Set water spray pump switch to simultaneous spray. Reference Fig.

  • Page 394: Lighting

    STARTER SWITCH 7_16M 8_16M AV60,R ENGINE OIL 9_16M HYDRAURIC OIL PRESSURE SWITCH FILTER SWITCH1 EGT WARNING WARNING 10_16M RELAY LAMP RELAY LAMP 11_16M 12_16M AV60,B 13_16M HYDRAURIC OIL FILTER SWITCH2 14_16M ENGINE THERMO 15_16M STUD UNIT BOLT 16_16M SW880-1-11007 11-184...

  • Page 395: Head Lamp And Flood Lamp Do Not Light

    TROUBLESHOOTING 2-9. 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. 11-006 to P. 11-008). •...
  • Page 396 STARTER SWITCH 7_16M 8_16M AV60,R ENGINE OIL 9_16M HYDRAURIC OIL PRESSURE SWITCH FILTER SWITCH1 EGT WARNING WARNING 10_16M RELAY LAMP RELAY LAMP 11_16M 12_16M AV60,B 13_16M HYDRAURIC OIL FILTER SWITCH2 14_16M ENGINE THERMO 15_16M STUD UNIT BOLT 16_16M SW880-1-11007 11-186...

  • Page 397: Combination Meter Warning Lamp Or Indicator Lamp Is Abnormal

    TROUBLESHOOTING 2-9-2. Combination meter warning lamp or indicator lamp is abnormal Reference Fig. : 2-9-1 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 398 STARTER SWITCH 7_16M 8_16M AV60,R ENGINE OIL 9_16M HYDRAURIC OIL PRESSURE SWITCH FILTER SWITCH1 EGT WARNING WARNING 10_16M RELAY LAMP RELAY LAMP 11_16M 12_16M AV60,B 13_16M HYDRAURIC OIL FILTER SWITCH2 14_16M ENGINE THERMO 15_16M STUD UNIT BOLT 16_16M SW880-1-11007 11-188...

  • Page 399: Tachometer Reading Is Abnormal

    TROUBLESHOOTING 2-9-3. Tachometer reading is abnormal Reference Fig. : 2-9-1 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 400 STARTER SWITCH 7_16M 8_16M AV60,R ENGINE OIL 9_16M HYDRAURIC OIL PRESSURE SWITCH FILTER SWITCH1 EGT WARNING WARNING 10_16M RELAY LAMP RELAY LAMP 11_16M 12_16M AV60,B 13_16M HYDRAURIC OIL FILTER SWITCH2 14_16M ENGINE THERMO 15_16M STUD UNIT BOLT 16_16M SW880-1-11007 11-190...

  • Page 401: Temperature Meter Is Abnormal

    TROUBLESHOOTING 2-9-5. Temperature meter is abnormal Reference Fig. : 2-9-1 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 402 STARTER SWITCH 7_16M 8_16M AV60,R ENGINE OIL 9_16M HYDRAURIC OIL PRESSURE SWITCH FILTER SWITCH1 EGT WARNING WARNING 10_16M RELAY LAMP RELAY LAMP 11_16M 12_16M AV60,B 13_16M HYDRAURIC OIL FILTER SWITCH2 14_16M ENGINE THERMO 15_16M STUD UNIT BOLT 16_16M SW880-1-11007 11-192...

  • Page 403: Hydraulic Oil Filter Warning Lamp Remains On

    TROUBLESHOOTING 2-9-7. Hydraulic oil filter warning lamp remains ON Reference Fig. : 2-9-1 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 404 STARTER SWITCH 7_16M 8_16M AV60,R ENGINE OIL 9_16M HYDRAURIC OIL PRESSURE SWITCH FILTER SWITCH1 EGT WARNING WARNING 10_16M RELAY LAMP RELAY LAMP 11_16M 12_16M AV60,B 13_16M HYDRAURIC OIL FILTER SWITCH2 14_16M ENGINE THERMO 15_16M STUD UNIT BOLT 16_16M SW880-1-11007 11-194...

  • Page 405: Engine Oil Pressure Warning Lamp Remains On

    TROUBLESHOOTING 2-9-8. Engine oil pressure warning lamp remains ON • Check whether engine check lamps show no fault code. Reference Fig. : 2-9-1 Check point Check/Cause Action 1. Harness • Disconnect connectors between engine ECM, engine oil Repair or replace pressure switch relay and combination meter.
  • Page 406 STARTER SWITCH 7_16M 8_16M AV60,R ENGINE OIL 9_16M HYDRAURIC OIL PRESSURE SWITCH FILTER SWITCH1 EGT WARNING WARNING 10_16M RELAY LAMP RELAY LAMP 11_16M 12_16M AV60,B 13_16M HYDRAURIC OIL FILTER SWITCH2 14_16M ENGINE THERMO 15_16M STUD UNIT BOLT 16_16M SW880-1-11007 11-196...

  • Page 407: Charge Warning Lamp Remains On

    TROUBLESHOOTING 2-9-9. Charge warning lamp remains ON • Check with starting engine. Reference Fig. : 2-9-1 Check point Check/Cause Action 1. Harness • Disconnect connectors between alternator L terminal and Repair or replace lamp check relay terminal 2. harness. • Measure resistance between terminals and chassis ground.
  • Page 408 STARTER SWITCH 7_16M 8_16M AV60,R ENGINE OIL 9_16M HYDRAURIC OIL PRESSURE SWITCH FILTER SWITCH1 EGT WARNING WARNING 10_16M RELAY LAMP RELAY LAMP 11_16M 12_16M AV60,B 13_16M HYDRAURIC OIL FILTER SWITCH2 14_16M ENGINE THERMO 15_16M STUD UNIT BOLT 16_16M SW880-1-11007 11-198...

  • Page 409: Vibration Indicator Lamp Does Not Light

    TROUBLESHOOTING 2-9-10. Vibration indicator lamp does not light • Check that vibrator can be operated. Reference Fig. : 2-9-1 Check point Check/Cause Action 1. Harness • Measure resistance between working controller (C2) Repair or replace connector terminal 4 and combination meter connector harness.
  • Page 410 STARTER SWITCH 7_16M 8_16M AV60,R ENGINE OIL 9_16M HYDRAURIC OIL PRESSURE SWITCH FILTER SWITCH1 EGT WARNING WARNING 10_16M RELAY LAMP RELAY LAMP 11_16M 12_16M AV60,B 13_16M HYDRAURIC OIL FILTER SWITCH2 14_16M ENGINE THERMO 15_16M STUD UNIT BOLT 16_16M SW880-1-11007 11-200...

  • Page 411: Water Spray Indicator Lamp Does Not Light

    TROUBLESHOOTING 2-9-11. Water spray indicator lamp does not light • Check that water spray pump can be operated. Reference Fig. : 2-9-1 Check point Check/Cause Action 1. Harness • Measure resistance between water spray timer switch Repair or replace terminal 1 wire GB and combination meter connector harness.
  • Page 412 STARTER SWITCH 7_16M 8_16M AV60,R ENGINE OIL 9_16M HYDRAURIC OIL PRESSURE SWITCH FILTER SWITCH1 EGT WARNING WARNING 10_16M RELAY LAMP RELAY LAMP 11_16M 12_16M AV60,B 13_16M HYDRAURIC OIL FILTER SWITCH2 14_16M ENGINE THERMO 15_16M STUD UNIT BOLT 16_16M SW880-1-11007 11-202...

  • Page 413: Parking Brake Indicator Lamp Does Not Light

    TROUBLESHOOTING 2-9-12. Parking brake indicator lamp does not light Reference Fig. : 2-9-1 Check point Check/Cause Action 1. Harness • Measure resistance between parking brake switch Repair or replace terminal 4 wire L and combination meter connector harness. terminal wire No. 18 wire L. Standard resistance : 10 Ω...
  • Page 414 TROUBLESHOOTING Fig.: 2-10-1 F-R LEVER FORWARD REVERSE REVERSE SWITCH INTERLOCK RELAY BACKUP BUZZER HORN HORN RELAY HORN SWITCH FUSE BOX BATTERY RELAY AV60,R F.L.65A 1.25BR STARTER SWITCH AV60,R F.L.65A 1.25BR STARTER SWITCH AV60,B ENGINE STUD BOLT SW880-1-11008 11-204...

  • Page 415: Horn Does Not Sound

    TROUBLESHOOTING 2-9-13. Horn does not sound Reference Fig. : 2-10-1 Check point Check/Cause Action 1. Horn • Disconnect horn and directly connect battery positive Replace horn. terminal to horn terminal wire Lg side and negative terminal to horn terminal wire B side. •...

  • Page 416: 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 417: 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 418: 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 419: 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 4. 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 420: Propulsion System Is Overheating

    TROUBLESHOOTING 3-2-5. 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 421: 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 422: Only Front Or Rear Vibratory Drum Can Vibrate

    TROUBLESHOOTING 3-3-2. Only front or rear vibratory drum can vibrate (two-drum vibration cannot be performed) Check point Cause Check/Action 1. Vibrator Solenoid Vibrator pressure is bypassed because If the vibrator solenoid valve spool does Valve vibrator solenoid valve spool does not not switch, repair vibrator solenoid valve or (for Bypassing) switch.

  • Page 423: Amplitude Does Not Switch Between High And Low

    TROUBLESHOOTING 3-3-4. Amplitude does not switch between high and low Check point Cause Check/Action 1. Vibrator Pump Only high or low side proportional pressure Repair vibrator pump proportional solenoid Proportional reducing valve works. valve or replace them if necessary. Solenoid Valve 2.

  • Page 424: Abnormal Noise From Vibrator System

    TROUBLESHOOTING 3-3-7. Abnormal noise from vibrator system Check point Cause Check/Action 1. Vibrator Bearings Vibrator bearings supporting eccentric shaft Replace vibrator bearings. are damaged. 2. Hydraulic Hose Vibrator sound of hydraulic hose is Tighten bolts of loose hydraulic hose clamp Clamp generated because clamp securing to specified torque.

  • Page 425: 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 426: 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 428 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 © 2015 SAKAI HEAVY INDUSTRIES, LTD. All Rights Reserved. Printed in Japan 2015.7.50 ○ 0568-99009-0-31443-A...

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