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Sakai SV510-III Shop Manual

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SV510 -
SHOP MANUAL
3498-6412A-0

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  • Page 1 SV510 - SHOP MANUAL 3498-6412A-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

    SV510- ○ 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 SV510- ○ 2. CONTROL SYSTEM 2-1. Forward-reverse Control  3-003 3. PUMP MOUNT 3-1. Pump Mount   3-004 3-1-1. Installation of pump   3-005 4. HYDRAULIC SYSTEMS 1. SYSTEM CIRCUIT DIAGRAM 1-1. Graphic Symbols for Hydraulic Circuits  4-001 1-2.
  • Page 7 SV510- ○ 6. VIBRATORY DRUM • REAR AXLE 1. PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY   6-001 2. VIBRATORY DRUM 2-1. Removal and Installation of Vibratory Drum   6-003 2-1-1. Removal of vibratory drum   6-003 2-1-2. Installation of vibratory drum  6-006 2-2.
  • Page 8 SV510- ○ 2. MEASUREMENT AND ADJUSTMENT OF PROPULSION CIRCUIT PRESSURE 2-1. Measurement  8-002 2-2. Adjustment   8-003 3. MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT PRESSURE 3-1. Measurement  8-004 3-2. Adjustment   8-005 4. MEASUREMENT OF MACHINE HIGH/LOW SPEED CHANGE CIRCUIT PRESSURE 4-1.
  • Page 9 SV510- ○ 1-2. Important Information for Troubleshooting  9-001 1-3. Before Starting  9-002 1-4. Wire Color Code and Number   9-002 2. ELECTRICAL SYSTEM TROUBLESHOOTING 2-1. When Performing Electrical System Fault Diagnosis   9-003 2-1-1. Precautions to take during electrical circuit fault diagnosis   9-003 2-1-2.
  • Page 10 SV510- ○ 2-7-5. Temperature meter is abnormal  9-057 2-7-6. Fuel meter is abnormal  9-057 2-7-7. Hydraulic oil filter warning lamp remains ON  9-057 2-7-8. Oil pressure warning lamp remains ON  9-059 2-7-9. Vibration indicator lamp does not light   9-061 2-7-10.

  • 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

    SAFETY • Park behind a safe barrier, use proper flags, and warning devices, especially when parking in areas of heavy traffic. 1-10. Maintenance • In any performing any work concerning the operation, adjustment or modification of the machine or it’s safety devices or any work related to maintenance, inspection or repair, always follow the start-up and shut-down procedures in the Operator’s Manual and the Maintenance Manual.
  • Page 18 Always clean up any spilled fuel. • Ensure safe operation, optimum performance of the machine and its warranty by using only genuine SAKAI replacement parts. • Use only the specified fluids and lubricants. Substitute only products known to be equivalent from reputable manufacturers.

  • Page 19: Transporting The Machine

    SAFETY • Observe all product safety regulations when handling fuel, oils, grease, engine coolant and other chemical substances. Be careful especially when these items are hot as there is a risk of burning or scalding. • Operate internal combustion engines and fuel operated heating systems only in adequately ventilated premises.

  • Page 21: Specifications

    SPECIFICATIONS...

  • Page 24: Specification Data

    SPECIFICATIONS 1. SPECIFICATION DATA 1-1. SV510D- 2130 1100 2970 1670 1560 2300 5740 0412-99030-0-10448-0 Model SV510D-Ⅲ Operating weight 10,670 kg 23,525 lbs. ) Weight Front axle 5,760 kg 12,700 lbs. ) Rear axle 4,910 kg 10,825 lbs. ) Overall length 5,740 mm 226 in.
  • Page 25 SPECIFICATIONS CUMMINS QSB4.5 Tier 3 Diesel Engine Name with turbocharger Water-cooled, 4-cycle, 4-cylinder, in-line, Model direct-injection, with turbocharger Number of cylinders - Bore × Stroke 4-107 mm × 124 mm (4-4.213 in. × 4.882 in.) Displacement 4.5 L ( 274.6 cu.in Rated speed 2,300 min ( 2,300 rpm...

  • Page 26: Sv510T-Ⅲ

    SPECIFICATIONS 1-2. SV510T- 2130 1115 2970 1670 1560 2300 5755 0412-99031-0-10449-0 Model SV510T-Ⅲ Operating weight 11,030 kg 24,320 lbs. ) Weight Front axle 6,110 kg 13,470 lbs. ) Rear axle 4,920 kg 10,850 lbs. ) Overall length 5,755 mm 227 in. Overall width 2,300 mm 91 in.
  • Page 27 SPECIFICATIONS CUMMINS QSB4.5 Tier 3 Diesel Engine Name with turbocharger Water-cooled, 4-cycle, 4-cylinder, in-line, Model direct-injection, with turbocharger Number of cylinders - Bore × Stroke 4-107 mm × 124 mm (4-4.213 in. × 4.882 in.) Displacement 4.5 L ( 274.6 cu.in Rated speed 2,300 min ( 2,300 rpm...

  • Page 28: Sv510Tf-Ⅲ

    SPECIFICATIONS 1-3. SV510TF- 2130 1100 2970 1680 1560 2300 5750 0412-99032-0-10461-0 Model SV510TF-Ⅲ Operating weight 13,270 kg 29,255 lbs. ) Weight Front axle 8,380 kg 18,475 lbs. ) Rear axle 4,890 kg 10,780 lbs. ) Overall length 5,750 mm 226 in. Overall width 2,300 mm 91 in.
  • Page 29 SPECIFICATIONS CUMMINS QSB4.5 Tier 3 Diesel Engine Name with turbocharger Water-cooled, 4-cycle, 4-cylinder, in-line, Model direct-injection, with turbocharger Number of cylinders - Bore × Stroke 4-107 mm × 124 mm (4-4.213 in. × 4.882 in.) Displacement 4.5 L ( 274.6 cu.in Rated speed 2,300 min ( 2,300 rpm...

  • Page 30: Table Of Standard Values

    SPECIFICATIONS 2. TABLE OF STANDARD VALUES 2-1. Engine Item Standard value Remarks CUMMINS QSB4.5 Tier 3 Diesel Engine Engine model with turbocharger 110/2,300 kW/ min 148/2,300 HP/rpm Rated output 2,300 Max. rpm under no load ± 30 Min. rpm under no load ±...

  • Page 31: 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 169 mm (6.7 in.)

  • Page 32: Fuel And Lubricants Specification

    SPECIFICATIONS 3. FUEL AND LUBRICANTS SPECIFICATION 3-1. Rating Ambient temp. and applicable viscosity rating Service Applicable -15 to 30°C 0 to 40°C 15 to 55°C Lubricant classification Standards (5 to 86°F) (32 to 104°F) (59 to 131°F) Cold Moderate Tropical Engine oil API grade CH-4 SAE10W-30...

  • Page 33: 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 35: Engine And Controls

    ENGINE AND CONTROLS...

  • Page 37: Engine

    ENGINE AND CONTROLS 1. ENGINE 1-1. Engine Mount VIEW A DETAIL B DETAIL C 0412-01804-0-10471-0 (1) Bolt : M10×100 (7) Bolt : M16×100 (13) Bolt : M10×20 (2) Engine (8) Nut : M16 (14) Damper (3) Bracket (9) Bolt : M10×20 (15) Nut : M16 (4) Bracket...

  • Page 39: Engine Exterior

    ENGINE AND CONTROLS 1-2. Engine Exterior Water pump Air inlet Coolant outlet Turbocharger wastegate actuator Exhaust manifold Belt tensioner Engine speed sensor Coolant temperature (camshaft) sensor Air compressor coolant connection Oil fill cap Coolant inlet Tone wheel Fuel rail pressure sensor Engine speed sensor (crankshaft) Starter mounting...

  • Page 41: Control System

    ENGINE AND CONTROLS 2. CONTROL SYSTEM 2-1. Forward-reverse Control Fill grease DETAIL A VIEW C SECTION B-B 0412-12801-0-10007-A (1) F-R lever (7) Steel ball (2) Backup buzzer switch (8) Nut : M16 (3) F-R lever switch (9) Bolt : M16×30 (4) Control cable (10) Spring (5) Pump lever...

  • Page 42: Pump Mount

    ENGINE AND CONTROLS 3. PUMP MOUNT 3-1. Pump Mount SECTION A-A 0412-36814-0-20312-0 (1) Bolt : M10×30 (6) Housing (2) Bolt : M10×38 (7) Bolt : M14×45 (3) Retaining ring (8) Pump (4) Hub (9) Bolt : M12×35 (5) Flange N•m (1) Bolt M10×30 : 59 N·m ( 44 lbf·ft )

  • Page 43: Installation Of Pump

    ENGINE AND CONTROLS 3-1-1. Installation of pump • When the pump assembly 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 (8) and hub (4) splines. ②...

  • Page 45: Hydraulic Systems

    HYDRAULIC SYSTEMS...

  • Page 48: System Circuit Diagram

    HYDRAULIC SYSTEMS 1. SYSTEM CIRCUIT DIAGRAM 1-1. Graphic Symbols for Hydraulic Circuits Basic Symbols Pump, Motors and Cylinders DESCRIPTION SYMBOL DESCRIPTION SYMBOL Lines: Hydraulic pumps: Fixed displacement Main working Unidirectional Pilot control Bidirectional Drain or bleed Variable displacement Lines, joining Unidirectional Not connected Bidirectional...
  • Page 49 HYDRAULIC SYSTEMS Valves Methods of Operation DESCRIPTION SYMBOL DESCRIPTION SYMBOL Spring Check valve Manual shut off (On-Off) Manual Pressure compensated Pressure relief Reversing motor Flow control, adjustable Pilot pressure: Internal supply Valve symbols: The basic valve symbol Remote supply one or more squares with lines representing Solenoid: flow paths and flow con-...

  • Page 51: Hydraulic Circuit Diagram

    HYDRAULIC SYSTEMS 1-2. Hydraulic Circuit Diagram Steering cylinder (Left) Φ75XΦ35-380 (1/2") (3/8") 400 cc/rev (3/8") Orbitrol Steering cylinder (Right) Hydraulic oil filter 1 Φ75XΦ35-380 (1/4") (1/2") (1/4") (1/2") Parking brake solenoid valve (1/4") Bypass valve (3/8") (3/4") Propulsion Vibrator pump pump Drum (3/4")

  • Page 53: Propulsion Hydraulic System

    HYDRAULIC SYSTEMS 2. PROPULSION HYDRAULIC SYSTEM Propulsion motor (Rear) 2-1. Propulsion Hydraulic Piping 2-1-1. Propulsion hydraulic piping (front type 1) Hose (RB1 Hose (RA1 Gear box Hose (FMT Hydraulic oil tank) SECTION A-A Hose (RA1 Hose (RB1 Propulsion motor (Front) Hose Hydraulic oil tank Hose...

  • Page 55: Propulsion Hydraulic Piping (Front Type 2)

    HYDRAULIC SYSTEMS 2-1-2. Propulsion hydraulic piping (front type 2) Propulsion motor (Rear) Hose (RB1 Hose (RA1 Hose (FMT Hydraulic oil tank) Gear box SECTION A-A Hose (RB1 Hose (RA1 Hose (FMT Hydraulic oil tank) Propulsion motor (Front) Hose Hydraulic oil tank (FMT Hydraulic oil tank) SECTION B-B Hose...

  • Page 57: Propulsion Hydraulic Piping (Rear)

    HYDRAULIC SYSTEMS 2-1-3. Propulsion hydraulic piping (rear) Hose Hydraulic oil tank (PA1 RB2) Hose (RB3 Hose Hose (RMT PT1) (PB1 RA2) SECTION A-A Hose (PT2 Hose Hose (RA3 Hydraulic oil tank) SECTION B-B Oil cooler Propulsion pump Bypass valve Hose (RMT PT1) Hose...

  • Page 60: Hydraulic Component Specifications

    HYDRAULIC SYSTEMS 2-2. Hydraulic Component Specifications 2-2-1. Hydraulic pump assembly (propulsion + vibrator + steering) 1-10 1-12 2-10 2-11 2-12 1-13 2-13 1-11 VIEW A 1-3 1-2 1-13 1-11 2-10 2-7 2-1 1-8 1-6 2.34 MPa 1.89 MPa 45.9/35 75.0 cc/rev cc/rev 25 MPa...
  • Page 61 HYDRAULIC SYSTEMS (1) Propulsion pump (1-1) Multifunction valve (Port A1) (1-2) Charge supply port [PC] : G1/2 (1-3) Charge pressure gauge port : 9/16-18UNF (1-4) Multifunction valve (Port B1) (1-5) Port B1 (Forward) [PB1] : SAE 1” (1-6) Servo pressure gauge port : 9/16-18UNF [PT1] : 1 1/16-12UN (1-7) Drain port...

  • Page 62: Gear Box

    HYDRAULIC SYSTEMS 2-2-2. Gear box SV510- -04004 (1) Gear box Specifications • Reduction ratio : 1/63.49 • Weight 168 kg ( 370 lbs. ) 4-009...
  • Page 63 HYDRAULIC SYSTEMS 1) Structure of gear box 1-10 1-11 1-12 1-13 1-18 1-14 1-15 1-16 1-17 SV510- -04005 (1) Gear box (1-1) Input shaft/coupling subassembly (1-10) Bolt (1-2) Hub/spindle subassembly (1-11) Intermediate carrier subassembly (1-3) Dowel pin (1-12) Sun gear (1-4) Output planetary subassembly (1-13) Input carrier subassembly (1-5) External retaining ring (1-14) Sun gear...

  • Page 64: Propulsion Hydraulic Motor (Front)

    HYDRAULIC SYSTEMS 2-2-3. Propulsion hydraulic motor (front) (back of 10) SV510- -04002 13 8 2.45 MPa 11 L/min 16.0/80.7 cc/rev Motor circuit diagram SV510- -04003 (1) Servo pressure gauge port : 9/16-18UNF (8) Servo pressure min. angle gauge port : 9/16-18UNF (2) Control pressure gauge port : 9/16-18UNF (9) Port A (Reverse) [FA] : SAE 1”...

  • Page 65: Propulsion Hydraulic Motor (Rear)

    HYDRAULIC SYSTEMS 2-2-4. Propulsion hydraulic motor (rear) (back of 9) SV510- -04006 7 10 2.45MPa 11L/min 32.0/80.7 cc/rev Motor circuit diagram SV510- -04007 (1) Servo pressure gauge port : 9/16-18UNF (7) Servo pressure min. angle gauge port : 9/16-18UNF (2) Drain port [RMT] : 1 1/16-12UN (8) Port A (Forward) [RA] : SAE 1”...

  • Page 67: Vibrator Hydraulic System

    HYDRAULIC SYSTEMS 3. VIBRATOR HYDRAULIC SYSTEM Hose 3-1. Vibrator Hydraulic Piping (PB2 VMB) Hose (VMT Hydraulic oil tank) Hydraulic oil tank Hose Hose (VT2 PT2) (PA2 VMA) SECTION A-A Hose Hose (PA2 VMA) (VMT Hydraulic oil tank) Hose (PB2 VMB) SECTION B-B Hose (PB2...

  • Page 69: Hydraulic Component Specifications

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

  • Page 71: Steering System

    HYDRAULIC SYSTEMS 4. STEERING SYSTEM 4-1. Steering Hydraulic Piping Hose RC1) Hose Hydraulic oil tank Hose Hose Hose (LC1   RC2) (RC1 LC2) LC1) Hose    RC1) Hose Steering cylinder (R) (PP P) Hose LS1) SECTION A-A Hose Hose (PP P) (Hydraulic oil tank Steering cylinder (L) Hose...

  • Page 73: Steering Wheel

    HYDRAULIC SYSTEMS 4-2. Steering Wheel VIEW A-A 0404-32804-021754-Ａ (1) Column shaft (6) Bolt : M10×30 (2) Nut : M12 P=1.25 (7) Bracket (3) Steering wheel (8) Bolt : M8×12 (4) Nut : M10 (9) Orbitrol (5) Damper N•m (2) Nut M12 P=1.25 : 35 N·m ( 26 lbf·ft ) (4) Nut M10 49 N·m ( 36 lbf·ft )

  • Page 74: Hydraulic Component Specifications

    HYDRAULIC SYSTEMS 4-3. Hydraulic Component Specifications 4-3-1. Orbitrol Hydraulic circuit diagram SV510- -04010 (1) Port L : 3/4-16UNF (2) Port R : 3/4-16UNF (3) Port T : 3/4-16UNF (4) Port P : 3/4-16UNF Specifications • Displacement 400 cm /rev ( 24.4 cu.in./rev ) •...

  • Page 75: Frame (Center Pin)

    HYDRAULIC SYSTEMS 4-4. Frame (Center Pin) 0402-61802-0-10059-G (1) Bolt : M16×60 (5) Swing bearing (9) Roller bearing (2) Bolt : M16×80 (6) Yoke (10) Bracket (upper) (3) Nut : M20 (7) Bolt : M16×45 (11) Bracket (lower) (4) Bolt : M20×110 (8) Cover (12) O-ring N•m...

  • Page 77: Electrical System

    ELECTRICAL SYSTEM...

  • Page 79: System Circuit Diagram

    ELECTRICAL SYSTEM 1. SYSTEM CIRCUIT DIAGRAM 1-1. Electrical Circuit Diagram FOOT BRAKE 2 GB 2 GB SWITCH STOP 42 RY BACKUP BUZZER REVERSE FORWARD 37 BrW 36 LgR PARKING 38 GR NC NOCOM BRAKE HORN SOLENOID PARKING BRAKE 36 LgR SWITCH BACKUP BUZZER...

  • Page 81: Electrical Components

    ELECTRICAL SYSTEM 2. ELECTRICAL COMPONENTS 2-1. Electrical Component Layout (1) Horn switch Alternator Starter relay Starter motor Vibrator solenoid (a) Traction control box Backup buzzer Vibrator solenoid (b) Fuel unit SECTION A-A Battery relay Parking brake solenoid Battery Thermo unit Hydraulic oil filter switch 1 Hydraulic oil filter switch 2 Front motor rotation sensor...

  • Page 83: Electrical Component Layout (2)

    ELECTRICAL SYSTEM 2-2. Electrical Component Layout (2) Warning lamp Engine stop lamp Combination meter Speed change switch Vibration amplitude selector switch Parking brake switch Throttle switch ENGINE   STOP Starter switch WARNING IDLE FULL WAIT TO START ENGINE SPEED ENGINE CHECK Vibration mode change switch VIEW A VIEW B...

  • Page 85: Electrical Component Specifications

    ELECTRICAL SYSTEM 3. ELECTRICAL COMPONENT SPECIFICATIONS 3-1. Fuse Box (BW) Interlock relay Starter relay (RW) F-R lever switch Backup buzzer switch Foot brake switch (RY) Throttle switch Horn relay (YW) Combination meter Engine ECM Speed change switch Traction control box Alternator (RY) Combination meter...

  • Page 87: Vibratory Drum • Rear Axle

    VIBRATORY DRUM • REAR AXLE...

  • Page 89: Precautions For Disassembly And Reassembly

    VIBRATORY DRUM • REAR AXLE 1. PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY • When removing, installing, disassembling or reassembling the unit, observe the general precautions described below. 1) Precautions for removal work • Coolant that contains antifreeze should be treated as a chemical, and must not be drained carelessly on the ground.
  • Page 90 VIBRATORY DRUM • REAR AXLE 3) Precautions when work is completed • If coolant has been drained, securely retighten the drain cock and fill with coolant (mixing in long- life coolant) to the specified level. Start the engine and allow the coolant to circulate through the piping.

  • Page 91: Vibratory Drum

    VIBRATORY DRUM • REAR AXLE 2. VIBRATORY DRUM 2-1. Removal and Installation of Vibratory Drum 2-1-1. Removal of vibratory drum 1) Joint front frame and rear frame with steering lock bar (1). W A RN IN G When lifting the machine body, use an appropriate hoist of sufficient strength.
  • Page 92 VIBRATORY DRUM • REAR AXLE 4) Lift cross member (4) with a crane and hold it. Lift with crane. Lift with crane. • Remove two bolts (3) (left and right sides). • Lift cross member (4) and remove it from frame. Cross member SV510D-  : 460 kg (1,014 lbs.) SV510T-  : 470 kg (1,036 lbs.)
  • Page 93 VIBRATORY DRUM • REAR AXLE 6) Remove eight bolts (2) (left and right sides). Lift with crane. Lift with crane. • Lift off vibratory drum (11) from frame. Vibratory drum assembly SV510D-  : 4,470 kg ( 9,855 lbs.) SV510T-  : 4,810 kg (10,604 lbs.) SV510TF-  : 7,180 kg (15,829 lbs.) Support stand...

  • Page 94: Installation Of Vibratory Drum

    VIBRATORY DRUM • REAR AXLE 2-1-2. Installation of vibratory drum 1) Install vibratory drum in the reverse order in which it was removed. • Tightening torque for bolts where particular care is required when installing vibratory drum. (3) Bolts M20×110 : 539 N·m (398 lbf·ft) N•m (Cross member) (2) Bolts M20×90 : 539 N·m (398 lbf·ft)

  • Page 95: Vibratory Drum Assembly

    VIBRATORY DRUM • REAR AXLE 2-2. Vibratory Drum Assembly (1) Drum (2) Disc (3) Bolt : M10×20 (4) Vibrator bearing (5) Eccentric shaft (6) Shaft (7) Bolt : M12×40 (8) Sleeve (9) Spring pin (10) Bolt : M20×60 (11) Plug (12) Housing (13) Oil seal (14) Roller bearing...

  • Page 97: Disassembly And Reassembly Of Vibratory Drum

    VIBRATORY DRUM • REAR AXLE 2-3. Disassembly and Reassembly of Vibratory Drum • Lead line numbers shown in the illustrations for the following vibratory drum disassembly and reassembly procedures 11-1 11-1 are constant with part numbers of vibratory drum assembly shown on page 6-007.
  • Page 98 VIBRATORY DRUM • REAR AXLE W A RNIN G Lifting bolt Lifting bolt When installing lifting bolts, secure them with nuts. 4) Install lifting bolts and nuts (M20) to holders (20) and (34). SV510- -06013 SV510- -06013 5) Remove sixteen bolts (17). SV510- -06014 SV510- -06014 6) Lift holders (20), (34), dampers (19) and disc (15) together...
  • Page 99 VIBRATORY DRUM • REAR AXLE 7) Pull out sleeve (8). • Remove sixteen bolts (10). SV510- -06015 SV510- -06015 Lift axle shaft (35) using two pulling bolts (M20×60). Pulling bolt Pulling bolt SV510- -06021 SV510- -06021 W A RN IN G When attaching lifting bolts, screw in the threads fully Lifting bolt Lifting bolt before using.
  • Page 100 VIBRATORY DRUM • REAR AXLE 10) Slowly lift axle shaft subassembly (35) with a crane and remove it. Wooden hammer Wooden hammer Wooden bar Wooden bar (NOTICE) • In order not to lift eccentric shaft (5) together with axle shaft subassembly (35), tap on the eccentric shaft end with a wooden hammer via a wooden bar during lifting.
  • Page 101 VIBRATORY DRUM • REAR AXLE 13) Lift eccentric shaft subassembly (5) with a crane and remove it. Movable weight Movable weight (NOTICE) • When lifting the eccentric shaft, put the movable weights at their outmost position. (5) Eccentric shaft subassembly : 260 kg (573 lbs.) SV510- -06020 SV510- -06020 W A RN IN G...
  • Page 102 VIBRATORY DRUM • REAR AXLE 16) Install lifting bolts and nuts (M20) to holders (42) and (51). Lifting bolt Lifting bolt SV510- -06024 SV510- -06024 17) Remove twenty bolts (45). SV510- -06025 SV510- -06025 18) Lift holders (42), (51), dampers (41) and disc (2) together with a crane and remove them.
  • Page 103 VIBRATORY DRUM • REAR AXLE 19) Install lifting bolts (M20, P=1.5) to gearbox (48). Lifting bolt Lifting bolt • Remove sixteen bolts (44). SV510- -06027 SV510- -06027 20) Lift gearbox subassembly (48) with a crane and remove it. Total weight of parts to be lifted : 220 kg (485 lbs.) SV510- -06028 SV510- -06028 21) Remove sixteen bolts (39).
  • Page 104 VIBRATORY DRUM • REAR AXLE 22) Lift axle shaft (43) using two pulling bolts (M20×60). Pulling bolts Pulling bolts SV510- -06031 SV510- -06031 23) Install lifting bolts (M20) on axle shaft (43). Lifting bolts Lifting bolts SV510- -06098 SV510- -06098 24) Lift axle shaft (43) with a crane and remove it. (43) Axle shaft : 235 kg (518 lbs.) SV510- -06030 SV510- -06030...
  • Page 105 VIBRATORY DRUM • REAR AXLE 25) Put removed axle shaft (43) on wooden blocks. SV510- -06038 SV510- -06038 26) The right illustration shows axle shaft subassembly (35) removed from vibratory drum. SV510- -06032 SV510- -06032 27) Remove six bolts (32). • Remove cover (24). (24) Cover : 10 kg (22 lbs.) SV510- -06033 SV510- -06033...
  • Page 106 VIBRATORY DRUM • REAR AXLE 28) Remove eight bolts (25). • Remove cover (29). • Remove shim (33). SV510- -06034 SV510- -06034 29) Put a piece of wooden board on the end of axle shaft (35) and set a puller on housing (12). Puller Puller •...
  • Page 107 VIBRATORY DRUM • REAR AXLE 31) Lift housing subassembly (12) with a crane and separate it from axle shaft (35). (12) Housing subassembly : 45 kg (99 lbs.) SV510- -06037 SV510- -06037 32) The right illustration shows axle shaft (43) removed from vibratory drum.
  • Page 108 VIBRATORY DRUM • REAR AXLE 34) Insert a round steel bar through bolt holes and alternately strike each side on outer race of vibrator bearing (4). Round steel bar Round steel bar • Remove vibrator bearing (4) from axle shaft (43). Strike on Strike on outer ring.

  • Page 109: Reassembly Of Vibratory Drum

    VIBRATORY DRUM • REAR AXLE 2-3-2. Reassembly of vibratory drum • Before reassembling, clean disassembled parts well and check that there is no abnormality. • When removed bolts threaded with thread sealant, replace new bolts. W A RN IN G When standing the vibratory drum, use wooden blocks of sufficient strength to securely support the drum.
  • Page 110 VIBRATORY DRUM • REAR AXLE 4) Lift axle shaft (43) with a crane and reverse it. (43) Axle shaft : 235 kg (518 lbs.) • Install two bolts (3) and seal washers. SV510- -06043 SV510- -06043 W A RNIN G Lifting bolt Lifting bolt When attaching lifting bolts, screw in the threads fully before using.
  • Page 111 VIBRATORY DRUM • REAR AXLE 7) Secure axle shaft (43) to vibratory drum (1) with sixteen bolts (39) and washers. (39) Bolts M20×60 : 539 N·m (398 lbf·ft) N•m SV510- -06047 SV510- -06047 8) Secure ring (49) to gearbox (48) with twenty bolts (38) and spring washers.
  • Page 112 VIBRATORY DRUM • REAR AXLE 10) Lift gearbox subassembly (48) with a crane and lower it on the mounting surface of axle shaft (43). SV510- -06050 SV510- -06050 11) Secure gearbox subassembly (48) with sixteen bolts (44) and washers. (44) Bolts M20×70 : 539 N·m (398 lbf·ft) N•m SV510- -06051 SV510- -06051...
  • Page 113 VIBRATORY DRUM • REAR AXLE 13) Lift disc subassembly (2) with a crane and lower it on mounting surface of gearbox (48). (2) Disc subassembly : 230 kg (507 lbs.) SV510- -06053 SV510- -06053 14) Secure disc subassembly (2) with twenty bolts (45) and spring washers.
  • Page 114 VIBRATORY DRUM • REAR AXLE W A RNIN G Be careful because reversing the vibratory drum involves risk. Confirm that the surrounding area is safe, and work in a natural, unstrained posture. 16) Lift vibratory drum subassembly (1) with a crane and reverse it.
  • Page 115 VIBRATORY DRUM • REAR AXLE 19) Apply a coat of gear oil to eccentric shaft subassembly (5) at where bearing will be installed. Movable weight Movable weight • Lift eccentric shaft subassembly (5) with a crane and install it on vibratory drum slowly. (5) Eccentric shaft subassembly : 260 kg (573 lbs.) (NOTICE) •...
  • Page 116 VIBRATORY DRUM • REAR AXLE 21-2) Apply a thin coat of gear oil to axle shaft (35) on its surface where vibrator bearing (37) will be press-fitted. • Drive in vibrator bearing (37). (NOTICE) • Take care not to damage the bearing when installing Wooden block Wooden block SV510- -06058...
  • Page 117 VIBRATORY DRUM • REAR AXLE 21-5) Apply a thin coat of gear oil to roller bearing (14) outer race on its surface to be press-fitted. • Drive outer race of roller bearing (14) into housing (12). • Install oil seal (13). •...
  • Page 118 VIBRATORY DRUM • REAR AXLE 21-8) Apply sufficient amount of lithium-based grease to rollers of roller bearing (14) inner race. • Drive in roller bearing (14) inner race until rollers come in contact with outer race. SV510- -06064 SV510- -06064 21-9) Preload adjustment of roller bearing ①...
  • Page 119 VIBRATORY DRUM • REAR AXLE ② Remove four bolts (25). • Remove cover (29). • Remove shim (33). SV510- -06067 SV510- -06067 ③  W ithout inserting shim, install cover (29). • Install washers to four bolts (25) and tighten. • Using a thickness gauge, measure the gap at dimension There must be no gap There must be no gap “A”.
  • Page 120 VIBRATORY DRUM • REAR AXLE ⑤ Install oil seal (31) on cover (24). • Apply a thin coat of grease to lip of oil seal (31). • Apply liquid packing to mounting surface. SV510- -06070 SV510- -06070 ⑥ S ecure cover (24) to housing subassembly (12) with six bolts (32) and spring washers.
  • Page 121 VIBRATORY DRUM • REAR AXLE 22) Install lifting bolts (M20) to axle shaft subassembly (35). Lifting bolt Lifting bolt SV510- -06077 SV510- -06077 23) Apply grease to entire periphery of O-ring (36). • Install O-ring (36) on axle shaft subassembly (35). SV510- -06078 SV510- -06078 24) Lift axle shaft subassembly (35) with a crane and lower it Pipe...
  • Page 122 VIBRATORY DRUM • REAR AXLE 25) Secure axle shaft subassembly (35) to drum with sixteen bolts (10). (10) Bolts M20×60 : 539 N·m (398 lbf·ft) N•m SV510- -06080 SV510- -06080 26) Install a lifting bolt (M8) on shaft end of eccentric shaft (5). Lifting bolt Lifting bolt SV510- -06081...
  • Page 123 VIBRATORY DRUM • REAR AXLE 28) Install lifting bolts and nuts (M20) on a subassembly of Lifting bolt Lifting bolt holders (20), (34), dampers (19) and disc (15) as shown on the right. SV510- -06083 SV510- -06083 29) Lift disc subassembly (15) with a crane and lower it on mounting surface of housing (12).
  • Page 124 VIBRATORY DRUM • REAR AXLE 31) Drive two spring pins (9) into sleeve (8). SV510- -06086 SV510- -06086 32) Apply molybdenum-based grease to splined portion of sleeve (8). • Fit sleeve (8) to splined shaft on eccentric shaft end. SV510- -06087 SV510- -06087 33) Apply grease to O-ring (27). •...
  • Page 125 VIBRATORY DRUM • REAR AXLE 34) Secure vibrator motor (26) to cover (24) with two new thread sealant bolts (28) and washers. (26) Vibrator motor : 20 kg (44 lbs.) (28) Bolts M14×40 : 170 N·m (80 lbf·ft) N•m • Wind seal tape around the threaded portion of breather (23).

  • Page 127: Rear Axle

    VIBRATORY DRUM • REAR AXLE 3. REAR AXLE 3-1. Rear Axle Assembly 3-1-1. Rear axle assembly (type 1) (1) Tire (2) Nut : M22 P=1.5 (3) Hub reduction gear (4) Bolt (brake release) (5) Plug (brake drain) (6) Plug (brake filler and level gauge) (7) Plug (gearbox filler and level gauge) (8) Plug (gearbox drain) (9) Brake...

  • Page 129: Rear Axle Assembly (Type 2)

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

  • Page 131: Rear Axle Lubrication

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

  • Page 132: Rear Axle Structure

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

  • Page 133: Differential

    VIBRATORY DRUM • REAR AXLE 3-3-2. Differential SV510- -06101 (1) Bolt (7) Bevel gear set (13) Shim (2) Ring nut (8) Nospin differential (14) Seal (3) Taper roller bearing (9) Spacer (15) Spacer (4) Bolt (10) Bolt (16) Shim (5) Spring washer (11) Ring nut (6) Differential carrier (12) Taper roller bearing...

  • Page 134: Hub Reduction Gear

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

  • Page 135: Brake (Type 1)

    VIBRATORY DRUM • REAR AXLE 3-3-4. Brake (type 1) SV510- -06096 (1) Spring (8) Cover (15) O-ring (2) O-ring (9) O-ring (16) Lock plate (3) Piston (10) Disc (17) Bolt (4) O-ring (11) Cylinder bolt (18) Plate (5) Bolt (12) Brake disc (19) Lock washer (6) Seal washer (13) Ring...

  • Page 136: Brake (Type 2)

    VIBRATORY DRUM • REAR AXLE 3-3-5. Brake (type 2) SV700-06094 (1) Spring (7) Brake disc (2) O-ring (8) Plug (3) Piston (9) Bolt (4) O-ring (10) Nut (5) Ring (11) Lock washer (6) Dowel (12) Plug 6-044...

  • Page 137: Gearbox

    VIBRATORY DRUM • REAR AXLE 3-3-6. Gearbox SV510- -06097 (1) Vent (7) Cover (13) Gear (2) Housing (8) Cylinder bolt (14) Plug (3) Ball bearing (9) O-ring (15) Spring washer (4) Circlip (10) Intermediate cover (16) Bolt (5) Spacer (11) Cylinder bolt (17) Magnet plug (6) Gear (12) Bolt...

  • Page 139: Brake

    BRAKE...

  • Page 141: Brake Pedal

    BRAKE 1. BRAKE PEDAL SECTION A-A 0411-51801-0-10045-B (1) Bearing unit (9) Rod (17) Rod (2) Shaft (10) Nut : M10 (Left-hand thread) (18) Stopper bolt : M10×40 (3) Brake pedal (11) Ball joint (Left-hand thread) (19) Nut : M10 (4) Clevis (12) Rod (20) Return spring (5) Nut...

  • Page 143: Brake Hydraulic Piping

    BRAKE 2. BRAKE HYDRAULIC PIPING Hydraulic oil tank Brake (right) Hose Hose (BT→Hydraulic oil tank) (RBL←→RBR) Parking brake solenoid valve Hose Brake (LO1→BP) (left) Hydraulic oil filter 1 Hose (BA←→RBL) The letters and figures (such as BA and RBL) show each port and the arrow ( ) symbols show the hose connection and the direction of the flow of the oil.

  • Page 145: Brake System

    BRAKE 3. BRAKE SYSTEM Fuse Foot brake switch (Condition in which brake pedal pressed) combination meter Parking brake switch (Brake OFF condition) Brake (Brake ON condition) Parking brake solenoid valve when brake is ON. (without solenoid excited) Steering･charge pump Parking brake solenoid valve when brake is OFF.

  • Page 146: Hydraulic Component Specifications

    BRAKE 4. HYDRAULIC COMPONENT SPECIFICATIONS 4-1. Brake Solenoid Valve Hydraulic circuit diagram (＋) (−) Connection diagram J-40026 (1) Solenoid (2) O-ring (1B P14) (3) Spool (J) (4) Body (5) Spring (6) Port P [BP] : G1/4 (7) Port A [BA] : G1/4 (8) Port T [BT] : G1/4 Specifications...

  • Page 147: Inspection And Adjustment

    INSPECTION AND ADJUSTMENT...

  • Page 149: 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 150: Measurement And Adjustment Of Propulsion Circuit Pressure

    INSPECTION AND ADJUSTMENT 2. MEASUREMENT AND ADJUSTMENT OF PROPULSION CIRCUIT PRESSURE 2-1. Measurement W A RNIN G Confirm that the parking brake works properly before measurement. • Oil temperature during measurement : 50 °C (122 °F) ± 5 ± 41 ①...

  • Page 151: Adjustment

    INSPECTION AND ADJUSTMENT 2-2. Adjustment • If measurement results indicate the pressure deviating from maximum circuit pressure range, make an adjustment in accordance with procedure described below. ①  C heck nut (2) of multifunction valve (1-1) or (1-4) for evidence of having loosened.

  • Page 152: 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 153: Adjustment

    INSPECTION AND ADJUSTMENT 3-2. Adjustment • If measurement results indicate the pressure deviating from standard charge relief pressure setting range, make an adjustment in accordance with procedure described below. ①  C heck nut (2) of charge relief valve (1-9) for evidence of having loosened.

  • Page 154: Measurement Of Machine High/Low Speed Change Circuit

    INSPECTION AND ADJUSTMENT 4. MEASUREMENT OF MACHINE HIGH/LOW SPEED CHANGE CIRCUIT PRESSURE 4-1. Measurement • Oil temperature during measurement : 50 °C (122 °F) ± 5 ± 41 ① Remove plugs from propulsion motor’s gauge ports (1), (2), (3) and (4). Attach pressure gauge with the adapter ⓗ . •...

  • Page 155: 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 156: Measurement And Inspection Of Vibrator Circuit Pressure

    INSPECTION AND ADJUSTMENT 6. MEASUREMENT AND INSPECTION OF VIBRATOR CIRCUIT PRESSURE 6-1. Measurement CAU T IO N 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 157: Inspection

    INSPECTION AND ADJUSTMENT 6-2. Inspection • If measurement results indicate the pressure deviating from maximum circuit pressure range, make an adjustment in accordance with procedure described below. ①  R emove high pressure relief valve (2-4) or (2-12) responsible for vibrator whose circuit pressure is abnormal. •...

  • Page 158: Measurement And Inspection Of Vibrator Charge Circuit

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

  • Page 159: Measurement

    INSPECTION AND ADJUSTMENT 7-1. Measurement • Oil temperature during measurement : 50 °C (122 °F) ± 5 ± 41 ① Remove plug from charge pressure gauge port (1-3). Attach pressure gauge with adapter ⓗ . • Adapter ⓗ : 9/1 6-18UNF •...

  • Page 160: 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. 2-11 2-11 • Since charge relief valve is a fixed type, adjustment of the pressure setting is not possible.

  • Page 161: Measurement And Inspection Of Steering Circuit Pressure

    INSPECTION AND ADJUSTMENT 8. MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE 8-1. Measurement W A RN IN G Make sure that there is no person around the articulated portion of the machine before operating the steering wheel. • Oil temperature during measurement : 50 °C (122 °F) ±...

  • Page 162: Inspection

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

  • Page 163: Measurement Of Hydraulic Pump Case Pressure

    INSPECTION AND ADJUSTMENT 9. MEASUREMENT OF HYDRAULIC PUMP CASE PRESSURE 9-1. Measurement of Propulsion Pump Case Pressure • Oil temperature during measurement : 50 °C (122 °F) ± 5 ± 41 ① Remove plug from drain port (1-12). Attach pressure gauge with adapter ⓩ...

  • Page 164: Measurement Of Vibrator Pump Case Pressure

    INSPECTION AND ADJUSTMENT 9-2. Measurement of Vibrator Pump Case Pressure CAU T IO N 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 165: Measurement Of Propulsion Motor Case Pressure

    INSPECTION AND ADJUSTMENT 10. MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE 10-1. Measurement • Oil temperature during measurement : 50 °C (122 °F) ± 5 ± 41 ① Remove plug from drain port (1) and (2). Attach pressure gauge and adapter ⓩ . •...

  • Page 166: Measurement Of Vibrator Motor Case Pressure

    INSPECTION AND ADJUSTMENT 11. MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE 11-1. Measurement CAU T IO N 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 167: Adjustment Of F-R Lever Linkage

    INSPECTION AND ADJUSTMENT 12. ADJUSTMENT OF F-R LEVER LINKAGE 12-1. Adjustment • If F-R lever linkage was replaced, make an adjustment in accordance with procedure described below. • Neutral position of F-R lever (1) and maximum stroke on forward-reverse side are positioned by notches. ①...

  • Page 168: Brake Adjustment

    INSPECTION AND ADJUSTMENT 13. BRAKE ADJUSTMENT 13-1. Manually Releasing the Brake 1)  L oosen nut (24) of bolt (25). • Loosen nut on the opposite side. 24 25 24 25 SV510- -08027 SV510- -08027 2) Tighten bolt (25), and press it into disc (16). •...

  • Page 169: Adjustment After Manual Release Of Brake

    INSPECTION AND ADJUSTMENT 13-2. Adjustment after Manual Release of Brake ① Remove bolt (25), nut (24), and seal washer (26). ②  R eplace seal washer (26) with a new one. ③ Apply grease to bolt (25) threads. ④  A s shown on the right, install bolt (25), nut (24), and seal washer (26).

  • Page 170: Brake Clearance Adjustment (Type 1 Only)

    INSPECTION AND ADJUSTMENT 13-3. Brake Clearance Adjustment (Type 1 only) • Remove bolt (2) and lock plate (3). • Rotate adjustment pinion (4) counterclockwise to eliminate all existing clearance between braking discs. Rotate up to a torque of 8 to 10 N·m (5.9 to 7.4 lbf·ft) N•m SV510- -08026 SV510- -08026...

  • Page 171: Troubleshooting

    TROUBLESHOOTING...

  • Page 173: 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 174: 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 175: 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 176: 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 177 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 178 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 179 TROUBLESHOOTING Measurement using a test harness Test harness Equipment A Equipment B Measurement from the backside of connector Measurement on a lead cable Test probe Wire Connector Needle Lead cable GW750-2-10002 Measurement method For measurement of voltage, connect the tester probes in parallel to the portion to be measured. Because the voltage can be measured only when the connector is connected in position, contact the tester probes to the terminals without disconnecting the connector.
  • Page 180 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 181: 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 182 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 183: Fault Codes

    TROUBLESHOOTING 2-2. Fault Codes 2-2-1. Description of fault codes The electronic engine control system can display and record certain detectable fault conditions. These failures are displayed as fault codes, which make troubleshooting easier. The fault codes are retained in the ECM. There are two types of diagnostic codes: •...

  • Page 184: Reading Procedures Of Fault Codes

    TROUBLESHOOTING 2-2-2. Reading procedures of fault codes • Fault codes can be accessed in at least two different ways; using the electronic service tool, or fault code flash out. • To check for active engine electronic fuel system and engine protection system fault codes, turn the starter switch OFF and move the diagnostic switch to the ON position.

  • Page 185: Fault Code List

    TROUBLESHOOTING 2-2-3. Fault code list Fault code Reason Effect (Lamp) Engine magnetic crankshaft speed/position lost Fueling to the injectors is disabled and the (Red) both of two signals engine cannot be started. • Data erratic, intermittent, or incorrect. The ECM has detected that the primary engine speed sensor and the backup engine speed sensor signals are reversed.
  • Page 186 TROUBLESHOOTING Fault code Reason Effect (Lamp) Intake manifold 1 temperature sensor circuit Possible white smoke. Fan will stay ON if (Orange) • Voltage below normal or shorted to low controlled by ECM. No engine protection for source. Low signal voltage detected at intake intake manifold air temperature.
  • Page 187 TROUBLESHOOTING Fault code Reason Effect (Lamp) Engine position sensor main supply (Orange) • Out of range high. — • Error. Engine Fuel Temperature Calibration dependent progressive power (Orange) • Data valid but above normal operation range. and speed derate and engine shutdown with •...
  • Page 188 TROUBLESHOOTING Fault code Reason Effect (Lamp) Injector solenoid driver cylinder 3 circuit Engine can misfire or possibly run rough. (Orange) • Current below normal or open circuit. High resistance or no current detected at number 3 injector driver or return pin. Injector solenoid driver cylinder 6 circuit Engine can misfire or possibly run rough.
  • Page 189 TROUBLESHOOTING Fault code Reason Effect (Lamp) Coolant level reading incorrect. No action taken by the ECM. (Orange) Oil temperature in-range error. No action taken by the ECM. (Orange) SAE J1939 datalink None on performance. J1939 devices possibly (None) • Data erratic, intermittent, or incorrect. do not operate.
  • Page 190 TROUBLESHOOTING Fault code Reason Effect (Lamp) Injector metering rail 1 pressure Possibly hard to start, low power or engine (Orange) • Data valid but below normal operation range. smoke. • Moderately severe level. The ECM has detected that fuel pressure is lower than commanded pressure.
  • Page 191 TROUBLESHOOTING Fault code Reason Effect (Lamp) 1845 Water in fuel indicator sensor circuit No action taken by the ECM. (Maintenance) • Voltage above normal or shorted to high source. 1846 Water in fuel indicator sensor circuit No action taken by the ECM. (Maintenance) •...
  • Page 192 TROUBLESHOOTING Fault code Reason Effect (Lamp) 2311 Electronic fuel injection control valve circuit Possible low power. (Orange) • Condition exists. Fuel pump actuator circuit resistance too high or too low. 2321 Engine crankshaft speed/position sensor Engine may exhibit misfire as control switches (None) •...

  • Page 193: Error Codes

    TROUBLESHOOTING 2-3. Error Codes 2-3-1. Description of error codes • The traction control system is comprised of traction control box, motor rotation sensors and motor proportional solenoids. The traction control box receives signals from motor rotation sensors. When the sensor signal indicates that the drum or drive wheels are spinning, the traction control box sends an output signal to the motor proportional solenoid of the spinning drum or drive wheels to reduce the flow to the motor.
  • Page 194 TROUBLESHOOTING Fig.: 2-4-1 REVERSE FORWARD THROTTLE F-R LEVER SWITCH SWITCH 30 RY 97 RW 92 WL 91 LW 26 1.25Lg 25 1.25BW 13 W INTERLOCK 94 BW RELAY 97 RW THROTTLE RELAY FUSE BOX ENGINE ECM. 67 3W 3(+)BATTERY BATTERY(-)2 66 3B 4(+)BATTERY BATTERY(-)1...

  • Page 195: 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 following using tester” (P.9-006 to P.9-008). •...
  • Page 196 TROUBLESHOOTING Fig.: 2-4-1 REVERSE FORWARD THROTTLE F-R LEVER SWITCH SWITCH 30 RY 97 RW 92 WL 91 LW 26 1.25Lg 25 1.25BW 13 W INTERLOCK 94 BW RELAY 97 RW THROTTLE RELAY FUSE BOX ENGINE ECM. 67 3W 3(+)BATTERY BATTERY(-)2 66 3B 4(+)BATTERY BATTERY(-)1...

  • Page 197: Engine Will Not Start (Starter Motor Does Not Run) 2/2

    TROUBLESHOOTING 2-4-1. Engine will not start (Starter motor does not run) 2/2 • F-R lever must be in neutral position. Reference Fig.: 2-4-1 Check point Check/Cause Action 5. Starter Relay (1) When starter switch is START, measure voltage Replace starter relay. between starter relay terminal 1 inlet wire RW and chassis ground.
  • Page 198 TROUBLESHOOTING Fig.: 2-4-2 * The actual equipment may differ from that shown above. SV510- -09005 Fuel schematic From fuel tank Fuel pre-filter (not mounted on engine) ECM cooling plate To fuel supply pump To fuel filter Fuel filter head Fuel filter To high pressure pump High pressure pump 10 To fuel rail...

  • Page 199: 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 200 TROUBLESHOOTING Fig.: 2-4-1 REVERSE FORWARD THROTTLE F-R LEVER SWITCH SWITCH 30 RY 97 RW 92 WL 91 LW 26 1.25Lg 25 1.25BW 13 W INTERLOCK 94 BW RELAY 97 RW THROTTLE RELAY FUSE BOX ENGINE ECM. 67 3W 3(+)BATTERY BATTERY(-)2 66 3B 4(+)BATTERY BATTERY(-)1...

  • Page 201: 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. terminal BATTERY wire R and chassis ground. Replace regulator. Standard voltage: At least intermediate engine speed, Replace battery. 14 V or more •...
  • Page 202 TROUBLESHOOTING Fig.: 2-4-1 REVERSE FORWARD THROTTLE F-R LEVER SWITCH SWITCH 30 RY 97 RW 92 WL 91 LW 26 1.25Lg 25 1.25BW 13 W INTERLOCK 94 BW RELAY 97 RW THROTTLE RELAY FUSE BOX ENGINE ECM. 67 3W 3(+)BATTERY BATTERY(-)2 66 3B 4(+)BATTERY BATTERY(-)1...

  • Page 203: Starter Motor Runs Even When F-R Lever Is Not At Neutral Position

    TROUBLESHOOTING 2-4-5. Starter motor runs even when F-R lever is not at neutral position Reference Fig.: 2-4-1 Check point Check/Cause Action 1. F-R Lever Switch • When starter switch is OFF and F-R lever is in forward Replace F-R lever or reverse position, check continuity between F-R lever switch.
  • Page 204 TROUBLESHOOTING Fig.: 2-5-1 REVERSE FORWARD BACKUP BUZZER SWITCH F-R LEVER SWITCH 37 BrW 36 LgR 12 R 36 LgR PARKING 38 GR BRAKE FOOT BRAKE SOLENOID SWITCH PARKING BRAKE SWITCH COMBINATION INTERLOCK METER RELAY C2-P12 C1-P1 REAR MOTOR PROPORTIONAL 40 G C2-P11 C1-P2 SOLENOID...

  • Page 205: Propulsion

    TROUBLESHOOTING 2-5. Propulsion Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. • When measuring voltage and current without disconnecting connectors, refer to “Measuring voltage and current flowing using tester” (P.9-006 to P.9-008). •...
  • Page 206 TROUBLESHOOTING Fig.: 2-5-1 REVERSE FORWARD BACKUP BUZZER SWITCH F-R LEVER SWITCH 37 BrW 36 LgR 12 R 36 LgR PARKING 38 GR BRAKE FOOT BRAKE SOLENOID SWITCH PARKING BRAKE SWITCH COMBINATION INTERLOCK METER RELAY C2-P12 C1-P1 REAR MOTOR PROPORTIONAL 40 G C2-P11 C1-P2 SOLENOID...

  • Page 207: Machine Speed Cannot Be Changed

    TROUBLESHOOTING 2-5-2. Machine speed cannot be changed • Check whether traction control box LED shows no error code. 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 4 inlet wire G and chassis switch.
  • Page 208 TROUBLESHOOTING Fig.: 2-5-1 REVERSE FORWARD BACKUP BUZZER SWITCH F-R LEVER SWITCH 37 BrW 36 LgR 12 R 36 LgR PARKING 38 GR BRAKE FOOT BRAKE SOLENOID SWITCH PARKING BRAKE SWITCH COMBINATION INTERLOCK METER RELAY C2-P12 C1-P1 REAR MOTOR PROPORTIONAL 40 G C2-P11 C1-P2 SOLENOID...

  • Page 209: Traction Control Does Not Work 1/3

    TROUBLESHOOTING 2-5-3. Traction control does not work 1/3 • Check whether traction control box LED shows any error code. 1) When LED shows any error code Reference Fig.: 2-5-1 Error code Check point Check/Cause Action 1 to 9 1. Connector •...
  • Page 210 TROUBLESHOOTING Fig.: 2-5-1 REVERSE FORWARD BACKUP BUZZER SWITCH F-R LEVER SWITCH 37 BrW 36 LgR 12 R 36 LgR PARKING 38 GR BRAKE FOOT BRAKE SOLENOID SWITCH PARKING BRAKE SWITCH COMBINATION INTERLOCK METER RELAY C2-P12 C1-P1 REAR MOTOR PROPORTIONAL 40 G C2-P11 C1-P2 SOLENOID...

  • Page 211: Traction Control Does Not Work 2/3

    TROUBLESHOOTING 2-5-3. Traction control does not work 2/3 • Check whether traction control box LED shows any error code. 1) When LED shows any error code Reference Fig.: 2-5-1 Error code Check point Check/Cause Action 21 to 25 1. Connector •...
  • Page 212 TROUBLESHOOTING Fig.: 2-5-1 REVERSE FORWARD BACKUP BUZZER SWITCH F-R LEVER SWITCH 37 BrW 36 LgR 12 R 36 LgR PARKING 38 GR BRAKE FOOT BRAKE SOLENOID SWITCH PARKING BRAKE SWITCH COMBINATION INTERLOCK METER RELAY C2-P12 C1-P1 REAR MOTOR PROPORTIONAL 40 G C2-P11 C1-P2 SOLENOID...

  • Page 213: Traction Control Does Not Work 3/3

    TROUBLESHOOTING 2-5-3. Traction control does not work 3/3 • Check whether traction control box LED shows any error code. 2) When LED shows no error code Reference Fig.: 2-5-1 Check point Check/Cause Action 1. Harness (1) Measure resistance between traction control box Repair or replace terminal C1-P2 wire G and fuse box terminal 6 wire G.
  • Page 214 TROUBLESHOOTING Fig.: 2-5-2 REVERSE FORWARD F-R LEVER SWITCH 37 BrW 36 LgR 12 R 36 LgR PARKING 38 GR BRAKE FOOT BRAKE SOLENOID SWITCH PARKING BRAKE SWITCH COMBINATION INTERLOCK METER RELAY FUSE BOX SV510- -09012 9-042...

  • Page 215: Brake Does Not Work

    TROUBLESHOOTING 2-5-4. Brake does not work • Parking brake switch must be applied. • Foot brake switch must be OFF (Brake pedal is depressed). Reference Fig.: 2-5-2 Check point Check/Cause Action 1. Parking Brake Solenoid • Disconnect harness and measure resistance of coil. Replace parking brake Standard resistance : 12.3 Ω...
  • Page 216 TROUBLESHOOTING Fig.: 2-6-1 DIODE UNIT THROTTLE SWITCH 30 RY 81 RG 97 RW 97 RW 11 Y 92 WL F-R LEVER VIBRATION MODE 91 LW VIBRATION CHANGE SWITCH SWITCH HIGH 9 YR ENGINE ECM THROTTLE 10 YB RELAY VIBRATION AMPLITUDE SELECTOR VIBRATOR SWITCH...

  • Page 217: Vibration

    TROUBLESHOOTING 2-6. Vibration Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. • Throttle switch must be “FULL” position. 2-6-1. No vibration occurs • Vibration mode change switch must be “CONT” position (continuous mode). •...
  • Page 218 TROUBLESHOOTING Fig.: 2-6-2 DIODE UNIT THROTTLE SWITCH 30 RY 81 RG 97 RW 97 RW 11 Y 92 WL F-R LEVER VIBRATION MODE 91 LW VIBRATION CHANGE SWITCH SWITCH HIGH 9 YR ENGINE ECM THROTTLE 10 YB RELAY VIBRATION AMPLITUDE SELECTOR VIBRATOR SWITCH...

  • Page 219: Amplitude Does Not Change (Remains Either Low Or High)

    TROUBLESHOOTING 2-6-2. Amplitude does not change (Remains either Low or High) • Vibration mode change switch must be “CONT” position (continuous mode). • Vibration amplitude selector switch must be OFF. Reference Fig. : 2-6-2 Check point Check/Cause Action 1. Vibrator Solenoid •...
  • Page 220 TROUBLESHOOTING Fig.: 2-6-3 DIODE UNIT THROTTLE SWITCH 30 RY 81 RG 97 RW 97 RW 11 Y 92 WL F-R LEVER VIBRATION MODE 91 LW VIBRATION CHANGE SWITCH SWITCH HIGH 9 YR ENGINE ECM THROTTLE 10 YB RELAY VIBRATION AMPLITUDE SELECTOR VIBRATOR SWITCH...

  • Page 221: Vibration Mode Cannot Be Switched

    TROUBLESHOOTING 2-6-3. Vibration mode cannot be switched (F-R lever vibration switch does not work) • Vibration mode change switch to “ ” position (manual mode). • Vibration amplitude selector switch must not be OFF. Reference Fig. : 2-6-3 Check point Check/Cause Action 1.
  • Page 222 TROUBLESHOOTING Fig.: 2-7-1 ENGINE ECM. 3(+)BATTERY BATTERY(-)2 COMBINATION METER 4(+)BATTERY BATTERY(-)1 43 STOP LAMP. COMBI. 44 WARNING LAMP. METER LAMPS 8 YL 50 WAIT TO START LAMP. 39 KEY SW. SIGNAL OIL PRESSURE 42 ECM RETURN RELAY 49 SW.OUTPUT 34 SW. RETURN 2 DIAGNOSTIC SW.

  • Page 223: Lighting

    TROUBLESHOOTING 2-7. Lighting Check following item before troubleshooting. • No blown fuse and power is applied up to fuses. • When measuring voltage and current without disconnecting connectors, refer to “measuring voltage and current following using tester” (P.9-006 to P.9-008). •...
  • Page 224 TROUBLESHOOTING Fig.: 2-7-1 ENGINE ECM. 3(+)BATTERY BATTERY(-)2 COMBINATION METER 4(+)BATTERY BATTERY(-)1 43 STOP LAMP. COMBI. 44 WARNING LAMP. METER LAMPS 8 YL 50 WAIT TO START LAMP. 39 KEY SW. SIGNAL OIL PRESSURE 42 ECM RETURN RELAY 49 SW.OUTPUT 34 SW. RETURN 2 DIAGNOSTIC SW.

  • Page 225: Combination Meter Warning Lamp Or Indicator Lamp Is Abnormal

    TROUBLESHOOTING 2-7-2. Combination meter warning lamp or indicator lamp is abnormal Reference Fig. : 2-7-1 Check point Check/Cause Action 1. Each Bulb • Check that none of lamp bulbs is burned out or has a Replace each bulb. contact failure (charge warning lamp, oil pressure warning lamp, hydraulic oil filter warining lamp and parking brake indicator lamp).
  • Page 226 TROUBLESHOOTING Fig.: 2-7-1 ENGINE ECM. 3(+)BATTERY BATTERY(-)2 COMBINATION METER 4(+)BATTERY BATTERY(-)1 43 STOP LAMP. COMBI. 44 WARNING LAMP. METER LAMPS 8 YL 50 WAIT TO START LAMP. 39 KEY SW. SIGNAL OIL PRESSURE 42 ECM RETURN RELAY 49 SW.OUTPUT 34 SW. RETURN 2 DIAGNOSTIC SW.

  • Page 227: Tachometer Reading Is Abnormal

    TROUBLESHOOTING 2-7-3. Tachometer reading is abnormal Reference Fig. : 2-7-1 Check point Check/Cause Action 1. Tachometer Sensor • Start engine and fix engine speed at 1,000 rpm. Measure Replace tachometer pulse between tachometer sensor terminal outlet wire BrR sensor. and ground terminal wire LgY. Standard pulse : 126,023/min.
  • Page 228 TROUBLESHOOTING Fig.: 2-7-1 ENGINE ECM. 3(+)BATTERY BATTERY(-)2 COMBINATION METER 4(+)BATTERY BATTERY(-)1 43 STOP LAMP. COMBI. 44 WARNING LAMP. METER LAMPS 8 YL 50 WAIT TO START LAMP. 39 KEY SW. SIGNAL OIL PRESSURE 42 ECM RETURN RELAY 49 SW.OUTPUT 34 SW. RETURN 2 DIAGNOSTIC SW.

  • Page 229: Temperature Meter Is Abnormal

    TROUBLESHOOTING 2-7-5. Temperature meter is abnormal Reference Fig. : 2-7-1 Check point Check/Cause Action 1. Thermo Unit • Disconnect harness and measure resistance of thermo Replace thermo unit. unit. Standard resistance: 153.9 Ω [(at unit temperature of 50°C (122°F)] 24.9 Ω [(at unit temperature of 103°C (217°F)] •...
  • Page 230 TROUBLESHOOTING Fig.: 2-7-1 ENGINE ECM. 3(+)BATTERY BATTERY(-)2 COMBINATION METER 4(+)BATTERY BATTERY(-)1 43 STOP LAMP. COMBI. 44 WARNING LAMP. METER LAMPS 8 YL 50 WAIT TO START LAMP. 39 KEY SW. SIGNAL OIL PRESSURE 42 ECM RETURN RELAY 49 SW.OUTPUT 34 SW. RETURN 2 DIAGNOSTIC SW.

  • Page 231: Oil Pressure Warning Lamp Remains On

    TROUBLESHOOTING 2-7-8. Oil pressure warning lamp remains ON • Check whether engine check lamps show no fault code. Reference Fig. : 2-7-1 Check point Check/Cause Action 1. Oil Pressure Relay (1) When starter switch is ON, measure voltage between Replace oil pressure oil pressure relay terminal 1 outlet wire GB and chassis relay.
  • Page 232 TROUBLESHOOTING Fig.: 2-7-1 ENGINE ECM. 3(+)BATTERY BATTERY(-)2 COMBINATION METER 4(+)BATTERY BATTERY(-)1 43 STOP LAMP. COMBI. 44 WARNING LAMP. METER LAMPS 8 YL 50 WAIT TO START LAMP. 39 KEY SW. SIGNAL OIL PRESSURE 42 ECM RETURN RELAY 49 SW.OUTPUT 34 SW. RETURN 2 DIAGNOSTIC SW.

  • Page 233: Vibration Indicator Lamp Does Not Light

    TROUBLESHOOTING 2-7-9. Vibration indicator lamp does not light • Check that vibrator can be activated. Reference Fig. : 2-7-1 Check point Check/Cause Action 1. Bulb • Check if bulb has burned out or is poorly contacted. Replace bulb. • Bulb is faulty or poorly connected. 2.
  • Page 234 TROUBLESHOOTING Fig.: 2-7-1 ENGINE ECM. 3(+)BATTERY BATTERY(-)2 COMBINATION METER 4(+)BATTERY BATTERY(-)1 43 STOP LAMP. COMBI. 44 WARNING LAMP. METER LAMPS 8 YL 50 WAIT TO START LAMP. 39 KEY SW. SIGNAL OIL PRESSURE 42 ECM RETURN RELAY 49 SW.OUTPUT 34 SW. RETURN 2 DIAGNOSTIC SW.

  • Page 235: Parking Brake Indicator Lamp Does Not Light

    TROUBLESHOOTING 2-7-10. Parking brake indicator lamp does not light Reference Fig. : 2-7-1 Check point Check/Cause Action 1. Bulb • Check if bulb has burned out or is poorly contacted. Replace bulb. • Bulb is faulty or poorly connected. 2. Parking Brake Switch •...
  • Page 236 TROUBLESHOOTING Fig. : 2-7-2 REVERSE FORWARD 2 GB BACKUP BUZZER SWITCH BACKUP BUZZER 2 GB HORN 34 LgW 30 RY 33 Lg 30 RY HORN SWITCH HORN RELAY FUSE BOX SV510- -09009 9-064...

  • Page 237: Horn Does Not Sound

    TROUBLESHOOTING 2-7-11. Horn does not sound Reference Fig. : 2-7-2 Check point Check/Cause Action 1. Horn • Disconnect horn and directly connect battery positive Replace horn. terminal to horn terminal wire LgW side and negative terminal to horn terminal wire B side. •...

  • Page 238: 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 239: 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 240: 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. Brake Solenoid Brake remains applied because spool of Repair brake solenoid valve or replace it if Valve brake solenoid valve does not shift. necessary. 10. Brake Inlet Brake cannot be released because brake •...

  • Page 241: 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 6. Propulsion Pump Discharge flow rate is insufficient due to • Measure discharge flow rate of propulsion efficiency degradation of propulsion pump. pump with flow meter. •...

  • Page 242: Propulsion System Is Overheating

    TROUBLESHOOTING 3-2-6. Propulsion system is overheating Check point Cause Check/Action 1. Oil Level of Oil level in hydraulic oil tank is low. Fill tank until correct oil level is obtained. Hydraulic Oil Tank 2. Oil Cooler Cooling efficiency is reduced due to clogged Clean oil cooler fins.

  • Page 243: 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 244: Vibrator Frequency Is Too Low

    TROUBLESHOOTING 3-3-2. Vibrator frequency is too low Check point Cause Check/Action 1. Oil Level of Oil level in hydraulic oil tank is low. Fill tank until correct oil level is obtained. Hydraulic Oil Tank 2. Charge Circuit Stroke of vibrator pump swash plate is small •...

  • Page 245: Vibrator System Is Overheating

    TROUBLESHOOTING 3-3-5. Vibrator 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 246: 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 247: 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 248 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 © 2011 SAKAI HEAVY INDUSTRIES, LTD. All Rights Reserved. Printed in Japan 2011.09.50 ○ 0412-99023-0-30315-D...

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