Sakai CR271 Shop Manual
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Sakai CR271 Shop Manual

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CR271
SHOP MANUAL
3498-65634-0

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Summary of Contents for Sakai CR271

  • Page 1 CR271 SHOP MANUAL 3498-65634-0...
  • 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

    1-10. Maintenance   1-005 1-11. Transporting the Machine   1-007 2. SPECIFICATIONS 1. SPECIFICATION DATA 1-1. CR271   2-001 2. TABLE OF STANDARD VALUES 2-1. Engine   2-003 2-2. Propulsion   2-003 2-3. Hydraulic Systems  2-003 2-4.
  • Page 6 CR271 ○ 3. ENGINE AND CONTROLS 1. ENGINE 1-1. Engine Mount  3-001 2. CONTROL SYSTEM 2-1. Throttle Control   3-002 2-2. Forward-reverse Control  3-003 3. PUMP MOUNT 3-1. Pump Mount   3-004 3-1-1. Installation of pump   3-005 4.
  • Page 7 CR271 ○ 5. ELECTRICAL SYSTEM 1. PRECAUTIONS FOR wORk 1-1. wire Numbers, wire Sizes, wire Colors and Connectors Shown in Electrical Circuit Diagrams, wiring Harness Layout and wiring Harnesses   5-001 2. SYSTEM CIRCUIT DIAGRAM 2-1. Electrical Circuit Diagram  5-003 3.
  • Page 8 CR271 ○ 9. INSPECTION AND ADJUSTMENT 1. INSPECTION AND ADJUSTMENT 1-1. Safety Precautions for Inspection and Adjustment   9-001 1-2. Preparation for Inspection and Adjustment  9-001 1-3. Precautions for Inspection and Adjustment   9-001 1-4. Warm-up   9-001 1-5.
  • Page 9 CR271 ○ 2-2-1. Engine will not start (Starter motor does not run)  1 0-012 2-2-2. Engine will not start (But starter motor runs)  1 0-014 2-2-3. No charging   1 0-016 2-2-4. Starter motor runs even when F-R lever is not at “N” applied  1 0-016 2-3.

  • Page 11: Safety

    SAFETY...

  • Page 13: 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 14: 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 15: 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 16: 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 17: 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 18 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 19: 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 21: Specifications

    SPECIFICATIONS...

  • Page 24: Specification Data

    SPECIFICATIONS 1. SPECIFICATION DATA 1-1. CR271 1300 2000 0563-99006-0-10453-0 Model CR271 Operating weight 1,480 kg 3,265 lbs. Weight Front axle 650 kg 1,435 lbs. Rear axle 830 kg 1,830 lbs. Overall length 2,000 mm 79 in. Overall width 1,010 mm 40 in.
  • Page 25 SPECIFICATIONS HONDA GX630R Gasoline Engine Name (EPA Phase3) (China StageⅠ) Model Air-cooled, 4-cycle, 2-celinder, 90° V-type Bore x Stroke 78 mm x 72 mm (3.071 in. x 2.835 in.) Displacement 0.688 L (42 cu.in.) Rated speed 3,600 min (3,600 rpm) Rated output 12 kW (16.1 HP ) at 3,600 min (SAE J1349 JUN95)

  • Page 26: Table Of Standard Values

    SPECIFICATIONS 2. TABLE OF STANDARD VALUES 2-1. Engine Item Standard value Remarks HONDA GX630R Gasoline Engine Engine model (EPA Phase3) (China StageⅠ) Rated output 12/3,600 kW/min 16.1/3,600 HP/rpm ) Max. rpm under no load 3,850 ± 150 min Min. rpm under no load 1,400 ±...

  • Page 27: 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 5 mm 0.02 in. ) or less shaft direction 2-5. Capacities Item Standard value Remarks Engine oil pan 1.9 L...

  • Page 28: Fuel And Lubricants Specification

    SPECIFICATIONS 3. FUEL AND LUBRICANTS SPECIFICATION 3-1. Rating Ambient temp. and applicable viscosity rating Service Applicable Lubricant -30 to 0°C -20 to 40°C 10 to 40°C classification Standards Cold Moderate Tropical Engine oil API grade SF or SG SAE5W-30 SAE10W-30 SAE30 MIL-L-2104B Gear oil...

  • Page 29: 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 31 ENGINE AND CONTROLS...
  • Page 33 ENGINE AND CONTROLS 1. ENGINE 1-1. Engine Mount 0563-01802-0-10281-B (1) Engine (2) Key (3) Muffler (4) Bolt : M10×50 N•m (4) Bolt M10×50 : 49 N·m ( 36 lbf·ft ) 3-001...
  • Page 34 ENGINE AND CONTROLS 2. CONTROL SYSTEMS 2-1. Throttle Control 11 10 SECTION A-A IDLE FULL VIEW D VIEW C VIEW B (Choke) (Throttle) 0563-12804-0 -10466-A (1) Choke cable (8) Bush (Apply grease) (15) Stopper bolt (FULL) (2) Control cable (Throttle Cable) (9) Coned disc spring (16) Throttle lever (3) Nut...
  • Page 35 ENGINE AND CONTROLS 2-2. Forward-reverse Control DETAIL C SECTION B-B Apply grease DETAIL A 0563-12804-0 -10466-A (1) F-R lever (9) Plate (17) Steel ball (2) Control cable (F-R cable) (10) Safety switch (18) Set screw (3) Lock nut (11) Nut (19) Spring (Fill grease) (4) Stopper bolt (Forward) (12) Key...
  • Page 36 ENGINE AND CONTROLS 3. PUMP MOUNT 3-1. Pump Mount CR271-03001 (1) Set screw (8) Key (2) Set screw Coupling (3) Bolt (7-1) (4) Nut (7-2) Insert (5) Pump (7-3) N•m (4) Nut : 49 N·m ( 36 lbf·ft ) 3-004...
  • Page 37 1) and engine side hub (7-3). ★ Standard dimension a : 1.9 ± 0.7mm ( 0.07 ± 0.03 in.) • If measurement result deviates from standard dimension CR271-03002 range, loosen pump side set screw (1) in hub (7-1) and adjust the gap.
  • Page 39 HYDRAULIC SYSTEMS...
  • Page 42 HYDRAULIC SYSTEM 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 43 HYDRAULIC SYSTEM 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 44 HYDRAULIC SYSTEM 1-2. Hydraulic Circuit Diagram HONDA Engine GX630R 12 kW/3600 min Valve 14.4 block Proprlsion 10cc/rev pump (3/8″) (3/8″) 10.97 (1/2″) cc/rev (1″) Steering• vibrator• Valve charge pump (3/8″) Suction TD2 TD4 TD3 TD1 filter Hydraulic oil tank Hydraulic 17.2 17.2 oil filter...
  • Page 45 HYDRAULIC SYSTEM 2. PROPULSION HYDRAULIC SYSTEM 2-1. Propulsion Hydraulic Piping 2-1-1. Propulsion hydraulic piping (1) DETAIL C Hose (TVS VCS) SECTION D-D DETAIL B Hose Pump VBP) Hose TD2) Hose Hose (VCO Hose (TVS VCS) Hose Hydraulic oil tank (VBB TD4) VIEW A Hydraulic oil filter...
  • Page 46 HYDRAULIC SYSTEM 2-1-2. Propulsion hydraulic piping (2) Hose (FMB RMA) Hose Hose (FMD TD3) (RMD Hose Hose FMA) RMB) Propulsion motor (front) Propulsion motor (rear) Hose (RMD SECTION B-B Hose (FMD TD3) SECTION A-A VIEW D VIEW C 0563-36803-0-10462-0 The letters and figures (such as FMD and TD3) show each port and the arrow ( ) symbols show the hose connection and the direction of the flow of the oil.
  • Page 48 HYDRAULIC SYSTEM 2-2. Hydraulic Component Specifications 2-2-1. Hydraulic pump assembly (propulsion + vibrator + steering) 1-12 1-13 1-10 1-11 1-12 1-13 Pump circuit diagram CR271-04001 4-006...
  • Page 49 HYDRAULIC SYSTEM (1) Propulsion pump (1-1) Port A (Forward) [PA] : G3/8 (1-2) Port B (Reverse) [PB] : G3/8 (1-3) High pressure gauge port (Port A) 7/16-20UNF (1-4) High pressure gauge port (Port B) 7/16-20UNF (1-5) High pressure relief valve (Port A) (1-6) High pressure relief valve (Port B) (1-7) Charge supply port [PC]...
  • Page 50 HYDRAULIC SYSTEM 2-2-2. Propulsion hydraulic motor Flow of oil Counterclockwise rotation Clockwise rotation Motor circuit didgram CR271-04002 (1) Port B [FMB, RMB] : 7/8-14UNF (2) Port A [FMA, RMA] : 7/8-14UNF (3) Drain port [FMD, RMD] : 7/16-20UNF Specifications • Displacement...
  • Page 51 HYDRAULIC SYSTEM 2-2-3. Valve block Circuit diagram CR271-04003 (1) Port T : 3/4-16UNF (2) Port P [VBP] : 3/4-16UNF (3) Solenoid valve (4) Manifold block (5) Relief valve (6) Port B [VBB] : 3/4-16UNF (7) Port A [VBA] : 3/4-16UNF Specifications •...
  • Page 52 HYDRAULIC SYSTEM 2-2-4. Valve Circuit diagram CR271-04004 (1) Port IN [IN] : G1/2 (2) Port EF [EF] : G1/2 (3) Port PF [PF] : G3/8 Specifications • Maximum pressure : 17.2 MPa ( 2,494 psi • Rated flow 40 L/min ( 10.6 gal/min )
  • Page 53 HYDRAULIC SYSTEM 3. VIBRATOR HYDRAULIC SYSTEM 3-1. Vibrator Hydraulic Piping SECTION A-A Hose Hose (VMB TD5) (VBA VMA) Hose (VMD TD1) Vibrator motor The letters and figures (such as VMB and TD5) show each port and the arrow ( ) symbols show the hose connection and the direction of the flow of the oil.
  • Page 54 HYDRAULIC SYSTEM 3-2. Hydraulic Component Specification 3-2-1. Vibrator hydraulic motor VIEW A Flow of oil Counterclockwise rotation Clockwise rotation Motor circuit didgram CR271-04005 (1) Port A [VMA] : 7/8-14UNF (2) Drain port [VMD] : 9/16-18UNF (3) Port B [VMB] : 7/8-14UNF Specifications •...
  • Page 55 HYDRAULIC SYSTEM 4. STEERING SYSTEM 4-1. Steering Hydraulic Piping Power cylinder Hose Hose Hose Hose Steering wheel Orbitrol VIEW A 0563-32801-0-10183-D The letters and figures (such as L and CR) show each port and the arrow ( ) symbols show the hose connection and the direction of the flow of the oil. 4-013...
  • Page 56 HYDRAULIC SYSTEM 4-2. Hydraulic Component Specifications 4-2-1. Orbitrol VIEW A Circuit diagram CR271-04006 (1) Relief valve (2) Port L : G1/4 (3) Port R [R] : G1/4 (4) Port P : G1/4 (5) Port T : G1/4 Specifications • Displacement...
  • Page 57 HYDRAULIC SYSTEM 4-3. Frame (Center Pin) FRONT REAR 0563-61801-0-20175-C (1) Bearing unit (6) Bracket (11) Bolt : M12x35 (2) Adapter (7) Bolt : M12x35 (12) Bearing unit (3) Bolt : M10x30 (8) Bracket (13) Bolt : M12x45 (4) Washer (9) Bolt : M12x30 (14) Bolt : M4x30 (5) Bolt : M12x45 (10) Bracket...

  • Page 59: Electrical System

    ELECTRICAL SYSTEM...

  • Page 61: 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 24 1.25BR AVS wire size Fuel sensor Wire number STARTER...
  • Page 62 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 Orange stripe Red/ Red/ Red/ Red/ Red/ Green/ R Red White stripe Black stripe Yellow stripe...

  • Page 63: System Circuit Diagram

    ELECTRICAL SYSTEM 2. SYSTEM CIRCuIT DIAGRAM 2-1. Electrical Circuit Diagram (OFF) (ON) TERMINAL SYMBOL (START) 19 30 17 AC F-R LEVER VIBRATION VIBRATOR SOLENOID SWITCH SPARK STARTER ENGINE PLUG HORN HORN SWITCH IGNITION STOP BUTTON RELAY COIL RELAY FUSE 2 OIL LEVEL NO 5 SWITCH...

  • Page 64: Electrical Components

    ELECTRICAL SYSTEM 3. ELECTRICAL CoMPonEnTS 3-1. Electrical component Layout Horn Switch Starter switch Engine oil pressure pilot lamp VIEW A To engine diode Vibrator solenoid To engine fuel cut solenoid Fuel pump Starter motor B and S To engine alternator Engine oil F-R lever vibration pressure switch...

  • Page 66: Wiring Harnesses

    IL-SW Interlock switch 1.25R ㉞ ㉖ ㉝ Marking ⑫ Engine stop 1.25R 1.25B 1.25B STOP-RY 1.25R ㉜ relay 1.25B Marking B2B4 3R,60 ㉟ ⑯ ⑬ REG-UNT Harness of Fuse2 regulator (15A) (intermediate Marking harness) B2B4 1.25B,60 ㊳ REG-UNT2 CR271-05001 5-005...
  • Page 67 ELECTRICAL SYSTEM Line number of CONTACT NO. SIZW,COLOR CONNECTION electric wiring POINTS diagram ① Fuse-3(25A), Starter motor-B ② Fuse-3(25A), Joint-107 ③ 1.25B Engine oil pressure switch, Connecter-CN8PFL(to Harness (2)) ④ 1.25R HORN-RY , Horn ⑤ 1.25R IL-RY , Starter motor-S ⑥ -1 1.25B -Vibrator solenoid, Joint-105 ⑥ -2 1.25B -Vibrator solenoid, Joint-105 ⑦ 1.25R VIB-SOL -Vibrator solenoid, Joint-102 ⑧ 1.25B -Fuel pump, Joint-105 ⑨...

  • Page 68: Harness (1)

    Hour meter HOUR ㉑ 1.25B,100 ACR6 Marking CB104 1.25R,160 ㉒ VIB-SW1-1 F-R lever Vibration switch Marking CB104 1.25R,160 ㉓ VIB-SW1-2 Marking CB104 1.25R,410 ㉔ VIB-SW2-2 VIB-SW2-1 Marking CA104 1.25R,410 VIB-SW2-1 ㉒ VIB-SW2-2 Marking CB104 1.25R,410 ㉕ No. connection VIB-SW2-3 CR271-0502 5-007...
  • Page 69 ELECTRICAL SYSTEM Line number of CONTACT NO. SIZW,COLOR CONNECTION electric wiring POINTS diagram ③ 1.25B OIL-ALM -Engine oil pressure pilot lamp, Connecter-CN8PFL(to Harness (1)) ⑭ ST-SW-30 , Connecter-CN8PFL(to Harness (1)) ⑮ ST-SW-17 , Connecter-CN8PFL(to Harness (1)) 1.25R ⑯ 1.25R ST-SW-AC , Connecter-CN8PFL(to Harness (1)) ⑰ 1.25R OIL-ALM -Engine oil pressure pilot lamp, Joint-101 ⑱ 1.25B HORN-SW -Horn switch, Connecter-CN8PFL(to Harness (1)) ⑲ 1.25B HORN-SW -Horn switch, Joint-100 ⑳ 1.25R HOUR -Hour meter, Joint-101 1.25B HOUR...

  • Page 71: Drums

    DRUMS...

  • Page 73: Precautions For Disassembly And Reassembly

    DRUMS 1. PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY • When removing, installing, disassembling or reassembling the unit, observe the general precautions described below. 1) Precautions for removal work • Coolant that contains antifreeze should be treated as a chemical, and must not be drained carelessly on the ground. • To prevent dust from getting into disconnected hoses and tubes, cover them with a plug or similar means. • When draining oil, use a receptacle with sufficient capacity to receive it. • Before proceeding with the work, look for matchmarks that show the installation location. For reassembly, place matchmarks in the required locations to prevent errors. Then remove. • When disconnecting wiring connectors, hold the connector components so that unreasonable force is not applied to the wires. • Label wires and hoses to ensure correct installation location. • Confirm the number and thickness of shims prior to storage. • When lifting parts, use lifting equipment of sufficient capacity. • When separating parts by using pull bolts, tighten the bolts alternately. • Before removing a unit, clean its surrounding area. Then after removal, cover it to prevent dust and other substances from getting in. • Before removing piping for hydraulic oil or coolant, or removing related parts, satisfactorily release internal pressure. 2) Precautions for installation work • Tighten bolts and nuts (sleeve nuts) to the specified torque (screw tightening torque table). • When installing hoses, do not twist them or allow them to interfere with other parts.
  • Page 74 DRUMS 3) Precautions when work is completed • If coolant has been drained, securely retighten the drain cock and fill with coolant (mixing in long- life coolant) to the specified level. Start the engine and allow the coolant to circulate through the piping. Then add coolant again to the specified level. • If hydraulic equipment has been removed and reinstalled, fill with hydraulic oil to the specified level. Start the engine and allow the oil to circulate through the piping. Then add oil again to the specified level. 6-002...

  • Page 75: Removal And Installation Of Drums

    2. REMOvAL AND INSTALLATION OF DRUMS 2-1. Removal of Drums 2-1-1. Front drum 1) Joint front frame and rear frame with lock pin. CR271-06001 The hydraulic oil in the machine is hot and compressed immediately after the machine is stopped. Disconnecting the hydraulic hoses in this condition can cause burns. Wait for the hydraulic oil to cool down before starting the work.
  • Page 76 DRUMS 4) Flip up scraper blade. • L oosen both side bracket fastening bolts. Scraper blade CR271-06004 5) Lift frame with a crane. Front axle : 650 kg (1,435 lbs.) • R emove bolts. • R emove side plate. CR271-06005 6) Flip up scraper blade. Scraper blade CR271-06006 6-004...
  • Page 77 DRUMS 7) Remove drum assembly together with bracket from frame. CR271-06007 6-005...

  • Page 78: Rear Drum

    DRUMS 2-1-2. Rear drum 1) Remove bolts (1). • R emove cover (2). CR271-06009 2) Remove clevis (3). CR271-06010 3) Remove parking brake cable (4). CR271-06011 6-006...
  • Page 79 DRUMS 4) See step 5) and subsequent steps under “2-1-1. Front drum”. Rear axle : 680 kg (1,500 lbs.) 6-007...

  • Page 80: Installation Of Drums

    DRUMS 2-2. Installation of Drums 1) Install drum in reverse order in which it was removed. • T ightening torque for bolts where particular care is required when installing drum. Bolt M16×50: 2 65 N·m (196 lbf·ft) (Side bracket fastening bolts) 2) Upon installing vibratory drum, pay particular attention to items mentioned below. • F ill hydraulic oil tank to specified level to make for any oil leakage. • Start engine and circulate oil through piping. Then check oil level again, ensuring that the oil is at specified level.

  • Page 81: Drum Assembly

    DRUMS 3. DRUM ASSEMBLY 3-1. Front Drum 33,34 12,13 17,18 0563-43801-0 -10176-C (1) Drum (19) Bolt : M12x50 (2) Disc (20) Flange (3) Ball bearing (21) Bolt : M12x35 (4) Vibrator bearing (22) Hub (5) Eccentric shaft (23) Boss (6) Vibrator bearing (24) Bolt : M12x35 (7) Castle nut : 1″-20UNF (25) Cover (8) Split pin...

  • Page 82: Rear Drum

    DRUMS 3-2. Rear Drum 10,11 30,31 26,27 15,16 0563-27803-0 -10289-0 (1) Drum (18) Side plate (2) Sunk key (19) Disc plate (3) Castle nut : 1″-20UNF (20) Flange (4) Split pin (21) Shaft (5) Brake ASSY (22) Key (6) Bracket (23) Flange (7) Bolt : M10x25 (24) Side plate (8) Spacer (25) Damper (9) Washer...

  • Page 83: Disassembly And Reassembly Of Drums

    • L ead line numbers shown in the illustrations for the following drum disassembly and reassembly procedures are constant with part numbers of drum assembly shown on page 6-008, 6-009. 4-1-1. Front drum 1) Remove nuts (14), (32). • R emove bracket (15), (31). (15), (31) Bracket : 25 kg (55 lbs.) CR271-06012 • When standing the vibratory drum, use wooden blocks of sufficient strength to Vibratory drum securely support the drum. ASSY • Carry out the work in an unstrained posture...
  • Page 84 DRUMS 4) Remove coupling (29). CR271-06015 5) Remove bolts (24). CR271-06016 R emove eight bolts (24). • Disc SUB ASSY CR271-06017 6-012...
  • Page 85 DRUMS 6) Remove disc SUB ASSY. Disc SUB ASSY Disc SUB ASSY : 40 kg (88 lbs.) CR271-06018 7) Remove eccentric shaft (5). (5) Eccentric shaft : 10 kg (22 lbs.) CR271-06019 Be careful because reversing the vibratory d r u m i n v o l v e s R i s k . C o n f i r m t h a t t h e...
  • Page 86 DRUMS 9) Remove bolts (19). CR271-06021 R emove four bolts (19). • Propulsion motor SUB ASSY CR271-06022 R emove two bolts (19). • Propulsion motor SUB ASSY CR271-06023 6-014...
  • Page 87 DRUMS 10) Remove propulsion motor SUB ASSY. Propulsion motor SUB ASSY : 40 kg (88 lbs.) CR271-06024 11) Remove bolts (21). CR271-06025 12) Remove hub (22). Durm (22) Hub : 10 kg (22 lbs.) CR271-06026 6-015...
  • Page 88 DRUMS 13) Disassembly of disc SUB ASSY. • R emove bolt (26). • R emove cover (25). Wooden block Wooden block CR271-06027 14) Remove retaining ring (30). CR271-06028 15) Put a piece of steel plate on end of boss (23). Puller • S et a puller on disc (2). Plate • R emove disc SUB ASSY with bearing (3) from boss (23). Disc SUB ASSY : 25 kg (55 lbs.) CR271-06029 6-016...
  • Page 89 DRUMS 16) Disassembly of propulsion motor SUB ASSY. (Remove propulsion motor) • R emove split pin (8). • R emove castle nut (7). • R emove flange (20). (20) Flange : 5 kg (11 lbs.) CR271-06030 17) Remove bolt (17), nut (18). CR271-06031 18) Remove propulsion motor (16). (16) Propulsion motor : 15 kg (33 lbs.) Disc SUB ASSY CR271-06032 6-017...

  • Page 90: Rear Drum

    4-1-2. Rear drum 1) Remove nuts (14), (28). • R emove bracket (6), (33). (6) Bracket : 20 kg (44 lbs.) (33) Bracket : 30 kg (66 lbs.) CR271-06033 • When standing the vibratory drum, use wooden blocks of sufficient strength to securely support the drum. • Carry out the work in an unstrained posture using a work stool or the like.
  • Page 91 DRUMS R emove six bolts (13). • CR271-06036 4) Remove disc brake SUB ASSY. Disc brake SUB ASSY Disc brake SUB ASSY : 50 kg (110 lbs.) CR271-06037 Be careful because reversing the drum involves Risk. Confirm that the surrounding area is safe, Drum SUB ASSY and work in a natural, unstained posture. 5) Reverse drum SUB ASSY. Drum SUB ASSY : 260 kg (573 lbs.) CR271-06038 6-019...
  • Page 92 DRUMS 6) Remove bolts (29). CR271-06039 R emove four bolts (29). • Propulsion motor SUB ASSY CR271-06040 7) Remove propulsion motor SUB ASSY. Propulsion motor SUB ASSY : 35 kg (77 lbs.) CR271-06041 6-020...
  • Page 93 DRUMS 8) Remove split pin (4). • R emove castle nut (3). • R emove flange (23). (23) Flange : 10 kg (22 lbs.) CR271-06042 9) Remove bolt (30), nut (31). CR271-06043 10) Remove propulsion motor (32). (32) Propulsion motor : 15 kg (33 lbs.) Side plate SUB ASSY CR271-06044 6-021...
  • Page 94 DRUMS 11) Remove bolt (7). CR271-06045 R emove three bolts (7). • CR271-06046 12) Remove split pin (11). • R emove castle nut (10). • R emove washer (9). CR271-06047 6-022...
  • Page 95 DRUMS 13) Remove side plate SUB ASSY. Side plate SUB ASSY : 20 kg (44 lbs.) CR271-06048 6-023...

  • Page 96: Reassembly Of Drums

    • Carry out the work in an unstrained posture using a work stool or the like. 1) Stand drum (1) with its propulsion motor side facing Drum : 225 kg (496 lbs.) CR271-06049 NOTE : Propulsion motor side dimension “a” : 320m (12.5 in. ). 2) Apply a coat of gear oil to hub (22) at where bearing will be press-fitted.
  • Page 97 DRUMS 4) Secure hub SUB ASSY with eight bolts (21) and Hub SUB ASSY washers. (21) Bolt : 108 N·m (80 lbf·ft) CR271-06052 5) Install propulsion motor (16) to disc SUB ASSY. (16) Propulsion motor : 15 kg (33 lbs.) Disc SUB ASSY CR271-06053 6) Secure propulsion motor (16) with fore bolts (17) nut (18) and washers. (18) Nut : 108 N·m (80 lbf·ft) CR271-06054 6-025...
  • Page 98 DRUMS 7) Install sunk key (9). • I nstall flange (20). Flange : 5 kg (11 lbs.) CR271-06055 8) Secure flange (20) with castle nut (7). (7) Nut : 200 N·m (147.5 lbf·ft) CR271-06056 I nstall split pin (8). • CR271-06057 6-026...
  • Page 99 DRUMS 9) Lower propulsion motor SUB ASSY on mounting surface of hub. Propulsion motor SUB ASSY : 40 kg (88 lbs.) CR271-06058 10) Secure propulsion motor SUB ASSY with bolts (19) and washers. CR271-06059 Secure propulsion motor SUB ASSY with four •...
  • Page 100 (19) Bolt : 108 N·m (80 lbf·ft) CR271-06061 Be careful because reversing the vibratory d r u m i n v o l v e s R i s k . C o n f i r m t h a t t h e...
  • Page 101 DRUMS 13) A pply a coat of gear oil to boss (23) at where bearing will be press-fitted. • D rive in vibrator bearing (4). CR271-06064 14) A pply a coat of gear oil to disc SUB ASSY at where Disc SUB ASSY bearing will be press-fitted. • D rive in bearing (3). CR271-06065 15) Reverse disc SUB ASSY. Disc SUB ASSY Drum SUB ASSY : 25 kg (55 lbs.) • A pply a coat of gear oil to disc SUB ASSY at where bearing will be press-fitted.
  • Page 102 DRUMS 16) A pply a coat of gear oil to boss (23) at where Disc SUB ASSY bearing will be press-fitted. • L ower disc SUB ASSY to boss SUB ASSY. Disc SUB ASSY : 30 kg (66 lbs.) CR271-06067 17) Install retaining ring (30). NOTE : Make sure that the retaining ring is fitted completely in its groove. CR271-06068 18) Install cover hub (25). CR271-06069 6-030...
  • Page 103 DRUMS 19) Secure cover hub (25) to disc SUB ASSY with four bolts (26) and spring washers. (26) Bolt : 59 N·m (44 lbf·ft) CR271-06070 20) Lower disc SUB ASSY on mounting surface of Disc SUB ASSY vibratory drum slowly.
  • Page 104 DRUMS S ecure disc SUB ASSY with eight bolts (24) and • Disc SUB ASSY washers. (24) Bolt : 108 N·m (80 lbf·ft) CR271-06017 22) Drive spring pin into coupling (29). Spring pin CR271-06072 23) A pply molybdenum-based grease to splined portion of coupling (29). • F it coupling (29) to splined portion on eccentric shaft end. CR271-06073 6-032...
  • Page 105 DRUMS 24) Lower vibrator motor (28) on mounting surface of cover. Vibrator motor : 5 kg (11 lbs.) CR271-06074 25) Secure vibrator motor (28) to cover with two bolts (27), spring washers and washers. (27) Bolt : 62 N·m (46 lbf·ft) CR271-06075 26) Secure bracket (15), (31) with nuts (14), (32), spring washers and washers. (15), (31) Bracket : 25 kg (55 lbs.) (14), (32) Nut : 157 N·m (116 lbf·ft) CR271-06012 6-033...

  • Page 106: Rear Drum

    • Carry out the work in an unstrained posture using a work stool or the like. 1) Stand drum (1) with its propulsion motor side facing Drum : 225 kg (496 lbs.) NOTE : Propulsion motor side dimension “b” : CR271-06076 298 mm (11.7 in. ). 2) Install propulsion motor (32) to side plate SUB ASSY. Propulsion motor : 15 kg (33 lbs.)
  • Page 107 DRUMS 4) Install sunk key (2). • I nstall flange (23). (23) Flange : 10 kg (22 lbs.) CR271-06079 5) Secure flange (23) with castle nut (3) and washer. (3) Castle Nut : 200 N·m (147.5 lbf·ft) CR271-06080 I nstall split pin (4). • CR271-06081 6-035...
  • Page 108 DRUMS 6) Lower propulsion motor SUB ASSY on mounting surface of drum. Propulsion motor SUB ASSY : 35 kg (77 lbs.) CR271-06082 7) Secure propulsion motor SUB ASSY with bolts (29) and washers. CR271-06039 Secure propulsion motor SUB ASSY with six •...
  • Page 109 R i s k . C o n f i r m t h a t t h e Drum SUB ASSY surrounding area is safe, and work in a natural, unstained posture. 8) Reverse drum SUB ASSY. Drum SUB ASSY : 260 kg (573 lbs.) CR271-06083 9) Apply a coat of gear oil to side plate (18) at where bearing will be press-fitted. • D rive in bearing (12). NOTE : Take care not to damage the bearing when installing it.
  • Page 110 DRUMS 11) Install spacer (8). Side plate SUB ASSY CR271-06086 12) Fill the grease. • A pply a coat of gear oil to side plate SUB ASSY at where bearing will be press-fitted. • D rive in bearing (12). Grease CR271-06087 13) Install washer (9). CR271-06088 6-038...
  • Page 111 DRUMS 14) Secure washer with castle nut (10) and washers. (10) Castle nut : 106 N·m (78 lbf·ft) Washer CR271-06089 I nstall split pin (11). • CR271-06090 15) Install disc plate (19). • Secure disc plate (19) with bolts (7) and washers CR271-06045 6-039...
  • Page 112 DRUMS S ecure disc plate (19) with three bolts (7) and • washers. (7) Bolt : 49 N·m (36 lbf·ft) CR271-06091 16) Install control cable. Control cable CR271-06092 17) Lower disc brake SUB ASSY on mounting surface Disc brake SUB ASSY of drum. Disc brake SUB ASSY : 50 kg (110 lbs.) CR271-06093 6-040...
  • Page 113 DRUMS S ecure side plate SUB ASSY with bolts (13) and • washers. CR271-06094 S ecure side plate SUB ASSY with six bolts (13) • and washers. (13) Bolt : 108 N·m (80 lbf·ft) CR271-06035 18) Secure bracket (6), (33) with nuts (14), (28), spring washers and washers. (6) Bracket : 30 kg (66 lbs.) (33) Bracket : 20 kg (44 lbs.) (14), (28) Nut : 157 N·m (116 lbf·ft) CR271-06033 6-041...

  • Page 115: Parking Brake

    PARKING BRAKE...

  • Page 117: Brake

    PARKING BRAKE 1. PARKING BRAKE 1-1. Brake 7, 8 11, 12, 13 CR271-07001 (1) Cover (8) Split pin (2) Bolt : M8x20 (9) Control cable (3) Parking brake (10) Brake ASSY (4) Bolt : M8x20 (11) Pin (5) Parking brake base ASSY...

  • Page 119: Water Spray System

    WATER SPRAY SYSTEM...

  • Page 122: Water Spray System

    WATER SPRAY SYSTEM 1. WATER SPRAY SYSTEM 1-1. Water spray Water spray tank 0563-75801-0-10190-F 8-001...
  • Page 123 SECTION A-A SECTION B-B Cock (R) Water spray tank Cock (F) Water spray diagram CR271-08001 (1) Cap (11) Cock (R) (2) Pipe (F) (12) Cock (F) (3) Hose (Cock (F) → Pipe (F)) (13) Wing knob (4) Hose (Tee → Cock (F))
  • Page 125 INSPECTION AND ADJUSTMENT...
  • Page 127 INSPECTION AND ADJUSTMENT 1. INSPECTION AND ADJUSTMENT 1-1. Safety Precautions for Inspection and Adjustment WARNING Unexpected machine movement may cause a serious accident. When inspecting the machine while the engine is running, always follow the instructions below. • Park the machine on level, flat ground. • Apply the parking brake. • Set chocks in front and behind each drum or tire.
  • Page 128 (0 to 3,625 psi) ② S tart the engine and set throttle lever to “FUll”. ③ E stablish a condition in which machine propulsion load becomes maximum. (Pressure does not build up unless propulsion load is applied.) CR271-09001 ④ W ith propulsion load at maximum, slowly move F-R lever to the side to be measured. • Then, read pressure indicated by pressure gauge. ⑤ After measuring, promptly return F-R lever to “N”. ★ Maximum circuit pressure (high pressure relief valve setting) : 17.2...
  • Page 129 ③ I f trapped dirt is present, disassemble and clean high pressure relief valve. ④ I f pressure still deviates from maximum circuit pressure range after valve is disassembled and cleaned, replace high pressure relief valve. ⑤ A fter inspection, measure pressure again and check that CR271-09002 pressure reaches maximum circuit pressure range. Plug : 78 N·m (57.5 lbf·ft) N•m (NOTICE) • Carefully disassemble and reassemble after taking steps to prevent foreign material from getting in.
  • Page 130 ① R emove plug from propulsion pump charge pressure gauge port (1-8). Attach pressure gauge with adapter ⓨ . • Adapter for ⓨ : 7/16-20UNF • Pressure gauge : 0 to 5 MPa (0 to 725 psi) ② A pply brake by parking brake lever. ③ S tart the engine and set throttle lever to “FUll”. • Then, read pressure indicated by pressure gauge. ★ Standard charge relief valve setting : 0.5 MPa (72.5 psi) CR271-09003 PG001011 • The number “1-8” appearing in above illustrations is consistent with lead line numbers shown in illustration of propulsion pump in “2-2. Hydraulic Component Specifications” (page 4-006). 9-004...
  • Page 131 ⑤ A fter inspection, measure pressure again and check that pressure reaches standard charge relief valve setting range. Plug : 78 N·m (57.5 lbf·ft) N•m (NOTICE) CR271-09004 • Carefully disassemble and reassemble after taking steps to prevent foreign material from getting in. 9-005...
  • Page 132 • Pressure gauge : 0 to 10 MPa (0 to 1,450 psi) ② C onfirm that F-R lever is in “N” properly. ③ S tart the engine and set throttle lever to “FUll”. ④ T urn steering wheel to operate relief valve. • Then, read pressure indicated by pressure gauge. ★ Standard maximum circuit pressure (Orbitroll relief pressure + charge relief pressure) : 8.5 MPa (1,233 psi) ± 1.0 ± 145 CR271-09005 PG002002 9-006...
  • Page 133 : Pressure rise Adjustment plug turned counterclockwise : Pressure drop Pressure change rate : 1.8 MPa/turn (261 psi/turn) ③ I f there is no evidence of having loosened, remove relief valve. ④ C heck removed relief valve for trapped dirt and scratches on its seat. CR271-09006 ⑤ I f trapped dirt is present, disassemble and clean relief valve. ⑥ I f a scratch is found on seat, replace relief valve. ⑦ A fter adjustment, measure pressure again and check that pressure reaches standard maximum circuit pressure range. (NOTICE) • Carefully disassemble and reassemble after taking steps to prevent foreign material from getting in.
  • Page 134 ③ E stablish a condition in which machine propulsion load becomes maximum. (Pressure does not build up unless propulsion load is applied.) ④ W ith propulsion load at maximum, measure pressure when F-R lever is in “N”, “F”, and “R”, respectively. ★ Pump case pressure : 0.1 MPa (14.5 psi) CR271-09008 PG002003 9-008...
  • Page 135 ③ E stablish a condition in which machine propulsion load becomes maximum. (Pressure does not build up unless propulsion load is applied.) ④ W ith propulsion load at maximum, measure pressure when F-R lever is in “N”, “F”, and “R”, respectively. ★ Motor case pressure : 14 MPa (2,030 psi) CR271-09009 PG002002 9-009...
  • Page 136 °C (122 °F) ± 5 ± 9 ① Set throttle lever (1) to “IDlE”. ② Attach control cable (2) to throttle lever (1). IDLE CR271-09010 ③ A ttach control cable (2) to control lever (5) of control ASSY on the engine side. ④ S tart the engine. ⑤ l oosen lock nut (3). ⑥ U sing stopper bolt (IDlE) (4), adjust so that standard minimum no-load rotational speed is achieved. ★ Standard minimum no-load rotational speed : 1,400 ±...
  • Page 137 INSPECTION AND ADJUSTMENT ⑧ Set throttle lever (1) to “FUll”. ⑨ loosen lock nut (7). FULL CR271-09012 ⑩ U sing stopper bolt (FUll) (6), adjust so that control lever (8) contacts stopper (9). ⑪ C onfirm that the engine speed is within standard range. ★ Standard minimum no-load rotational speed : 3,850 ± 150 ⑫ U sing lock nut (7), firmly secure stopper bolt (6). (NOTICE) • If maximum no-load rotational speed is not in standard range even when control lever (8) is against stopper (9), adjust control linkage, or repair or replace them.
  • Page 138 F-R lever does not move smoothly, make an adjustment in accordance with procedure described below. • “N” positions of F-R lever (1) are positioned by notches. ① Set F-R lever (1) “N”. ② Attach control cable (2) to F-R lever. ★ Specified dimension a : 170 mm (6.7 in.) CR271-09014 ③ A ttach control cable (2) to propulsion pump control lever (3). ★ Specified dimension b : 170 mm (6.7 in.) CR271-09015 9-012...
  • Page 139 ⑤ S hift F-R lever to “F” direction until propulsion pump control lever (3) moves specified dimension “fc” in forward direction. ⑥ Contact stopper bolt (5) to F-R lever. ⑦ Using lock nut (4), firmly secure stopper bolt (5). ★ Specified dimension fc : 14 mm (0.55 in.) CR271-09016 ⑧ loosen lock nut (7). ⑨ S hift F-R lever to “R” direction until propulsion pump control lever (3) moves specified dimension “rc” in reverse direction. ⑩ Contact stopper bolt (6) to F-R lever ⑪ Using lock nut (7), firmly secure stopper bolt (6).
  • Page 141 TROUBLESHOOTING...
  • Page 143 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. • Set chocks in front and behind each drum or tire. • Make sure that service personnel are given the appropriate information at the appropriate time.
  • Page 144 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 145 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 146 TROUBLESHOOTING 2-1-2. Inspection procedures using a tester Some of the various inspection procedures are presented here for reference, using a sample circuit below. Equipment A Main power source Ground of Signal from Power to of equipment B equipment A equipment A equipment A Battery Equipment B...
  • Page 147 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 148 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 149 TROUBLESHOOTING Measurement using a test harness Test harness Equipment A Equipment B Measurement on a lead cable Measurement from the backside of connector Test probe Wire Connector Needle Lead cable GW750-2-10002 Measurement method For measurement of voltage, connect the tester probes in parallel to the portion to be measured. Because the voltage can be measured only when the connector is connected in position, contact the tester probes to the terminals without disconnecting the connector.
  • Page 150 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 151 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 152 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 154 TROUBLESHOOTING Fig.: 2-2-1 (OFF) TERMINAL (ON) SYMBOL (START) 19 30 17 AC F-R LEVER VIBRATION VIBRATOR SOLENOID SWITCH SPARK STARTER ENGINE PLUG HORN HORN SWITCH IGNITION STOP BUTTON RELAY COIL RELAY FUSE 2 OIL LEVEL NO 5 SWITCH INTERLOCK HORN SWITCH AV3 R HOUR...
  • Page 155 TROUBLESHOOTING 2-2. Engine Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. 2-2-1. Engine will not start (Starter motor does not run) • F-R lever must be “N”. Reference Fig.: 2-2-1 Check point Check/Cause Action 1.
  • Page 156 TROUBLESHOOTING Fig.: 2-2-1 (OFF) TERMINAL (ON) SYMBOL (START) 19 30 17 AC F-R LEVER VIBRATION VIBRATOR SOLENOID SWITCH SPARK STARTER ENGINE PLUG HORN HORN SWITCH IGNITION STOP BUTTON RELAY COIL RELAY FUSE 2 OIL LEVEL NO 5 SWITCH INTERLOCK HORN SWITCH AV3 R HOUR...
  • Page 157 TROUBLESHOOTING 2-2-2. Engine will not start (But starter motor runs) • In case of engine will not start while starter motor runs, generally trouble is caused by that fuel is not supplied, supply amount of fuel is extremely low, or selection of fuel is not appropriate. •...
  • Page 158 TROUBLESHOOTING Fig.: 2-2-1 (OFF) TERMINAL (ON) SYMBOL (START) 19 30 17 AC F-R LEVER VIBRATION VIBRATOR SOLENOID SWITCH SPARK STARTER ENGINE PLUG HORN HORN SWITCH IGNITION STOP BUTTON RELAY COIL RELAY FUSE 2 OIL LEVEL NO 5 SWITCH INTERLOCK HORN SWITCH AV3 R HOUR...
  • Page 159 TROUBLESHOOTING 2-2-3. No charging Reference Fig.: 2-2-1 Check point Check/Cause Action 1. Regulator/Rectifier • After starting engine, measure voltage between battery Replace regulator/ terminals. rectifier or battery. Standard voltage : At least intermediate engine speed, 13.5 ～ 14.5 V. • If voltage is higher or lower than standard, regulator/ rectifier is faulty.
  • Page 160 TROUBLESHOOTING Fig.: 2-2-1 (OFF) TERMINAL (ON) SYMBOL (START) 19 30 17 AC F-R LEVER VIBRATION VIBRATOR SOLENOID SWITCH SPARK STARTER ENGINE PLUG HORN HORN SWITCH IGNITION STOP BUTTON RELAY COIL RELAY FUSE 2 OIL LEVEL NO 5 SWITCH INTERLOCK HORN SWITCH AV3 R HOUR...
  • Page 161 TROUBLESHOOTING 2-3. Propulsion Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. 2-3-1. Hour meter is abnormal Reference Fig.: 2-2-1 Check point Check/Cause Action 1. Hour meter (1) When starter switch is ON, measure voltage between Replace hour meter.
  • Page 162 TROUBLESHOOTING Fig.: 2-2-1 (OFF) TERMINAL (ON) SYMBOL (START) 19 30 17 AC F-R LEVER VIBRATION VIBRATOR SOLENOID SWITCH SPARK STARTER ENGINE PLUG HORN HORN SWITCH IGNITION STOP BUTTON RELAY COIL RELAY FUSE 2 OIL LEVEL NO 5 SWITCH INTERLOCK HORN SWITCH AV3 R HOUR...
  • Page 163 TROUBLESHOOTING 2-4. Vibration Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. • Throttle lever must be “FULL”. 2-4-1. No vibration occurs Reference Fig.: 2-2-1 Check point Check/Cause Action 1. Vibrator Solenoid • Disconnect harness and measure resistance of coil. Replace vibrator Standard resistance : 4.7 Ω...
  • Page 164 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 165 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 166 TROUBLESHOOTING 3-2-2. Machine moves in one direction only (forward or backward) Check point Cause Check/Action 1. F-R Lever Linkage F-R lever linkage is faulty. Check and adjust F-R lever linkage or replace it if necessary. 2. High Pressure Low circuit pressure due to incorrect high •...
  • Page 167 TROUBLESHOOTING 3-2-4. Machine does not stop completely with F-R lever in “N” Check point Cause Check/Action 1. F-R lever Linkage F-R lever linkage is faulty. Check and adjust F-R lever linkage or replace it if necessary. 2. Swash Plate Faulty pump swash plate setting. Repair propulsion pump or replace it if necessary.
  • Page 168 TROUBLESHOOTING 3-3. 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 169 TROUBLESHOOTING 3-3-3. Steering wheel backlash or play is large Check point Cause Check/Action 1. Orbitrol Spline of orbitrol is worn. Replace orbitrol. 2. Steering Wheel Serration (spline) of wheel is worn. Replace wheel. 3-3-4. Steering system is overheating Check point Cause Check/Action 1.
  • Page 170 SAKAI HEAVY INDUSTRIES, LTD. Head office: Seiwa Bldg., 4-8, Shibadaimon 1-chome, Minato-ku, Tokyo, Japan Telephone: +81-3-3434-3401 Global Service Division: 2500 Takayanagi, Kuki-shi, Saitama, Japan Telephone: +81-480-52-1111 Copyright © 2013 SAKAI HEAVY INDUSTRIES, LTD. All Rights Reserved. Printed in Japan 2013.11.00 ○ 0404-99053-0-32048-0...

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