Sakai SV201-1 Shop Manual
  1. Manuals
  2. Brands
  3. Sakai Manuals
  4. Construction Equipment
  5. SV201-1
  6. Shop manual

Sakai SV201-1 Shop Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
SV201
- 1
SHOP MANUAL
3498-64064-0

Advertisement

Table of Contents
loading

Related Manuals for Sakai SV201-1

Summary of Contents for Sakai SV201-1

  • Page 1 SV201 SHOP MANUAL 3498-64064-0...
  • 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

    SV201 ○ 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 SV201 ○ 3. ENGINE AND CONTROLS 1. ENGINE 1-1. Engine Mount  3-001 1-2. Engine Exterior   3-002 2. CONTROL SYSTEM 2-1. Throttle Control   3-003 2-2. Forward-reverse Control  3-004 3. PUMP MOUNT 3-1. Pump Mount   3-005 3-1-1.
  • Page 7 SV201 ○ 4-3-2. Orbitrol (SV201TB )   4-020 4-4. Frame (Center Pin)  4-021 5. BLADE SYSTEM 5-1. Blade Hydraulic Piping   4-022 5-2. Hydraulic Component Specifications  4-023 5-2-1. Stack valve   4-023 5. ELECTRICAL SYSTEM 1.
  • Page 8 SV201 ○ 7. BRAKE 1. BRAKE PEDAL  7-001 2. BRAKE HYDRAULIC PIPING   7-002 3. BRAKE SYSTEM   7-003 4. HYDRAULIC COMPONENT SPECIFICATIONS 4-1. Brake Solenoid Valve  7-004 8. INSPECTION AND ADJUSTMENT 1. INSPECTION AND ADJUSTMENT 1-1.
  • Page 9 SV201 ○ 11. ADJUSTMENT OF F-R LEVER LINKAGE 11-1. Adjustment  8-016 12. BRAKE ADJUSTMENT 12-1. Manually Releasing the Brake 8-018 12-2. Adjustment after Manual Release of Brake  8-019 9. TROUBLESHOOTING 1. TROUBLESHOOTING 1-1. Safety Precautions for Troubleshooting  9-001 1-2.
  • Page 10 SV201 ○ 2-5. Lighting   9-032 2-5-1. Illumination of combination meter does not turn on  9-032 2-5-2. Combination meter warning lamp or indicator lamp is abnormal  9-034 2-5-3. Tachometer reading is abnormal  9-036 2-5-4. Hour meter is abnormal   9-036 2-5-5.
  • Page 11 SV201 ○ 3-5. Blade (SV201TB )   9-059 3-5-1. Blade up/down operation not possible   9-059 3-5-2. Blade movement is slow or force is small  9-059 3-5-3. Blade floating operation not possible  9-060 3-5-4. Blade hydraulic system is overheating  9-060 3-5-5.

  • Page 13: Safety

    SAFETY...

  • Page 15: General Safety

    SAFETY 1. GENERAL SAFETY 1-1. Understanding the Safety Symbols and Words The words DANGER, WARNING, and CAUTION are used with the safety-alert symbol. DANGER identifies the most serious hazard. When the symbols DANGER, WARNING and CAUTION are displayed, become alert. Your safety or those around you may be involved. NOTICE is used to provide important information that is not hazard related.

  • Page 16: Qualifications Of Operators And Maintenance Personnel

    SAFETY • The machine is designed specifically for the compaction of asphalt or soil road construction materials. Use of the machine for other purposes such as towing other equipment is considered contrary to the designated use. The manufacturer cannot be responsible or held liable for any damage resulting from such use.

  • Page 17: Pre Start Inspection

    SAFETY • Observe all safety instructions and warnings attached to the machine. • Make sure all safety instructions and warnings on the machine are complete and perfectly legible. • Stop the machine immediately in the event of any malfunction. Report any malfunction immediately to the supervisor or other person of authority.

  • Page 18: Starting

    SAFETY 1-7. Starting • Start the machine only from the driver’s seat and always wear the seat belt. • Watch that the warning lights and indicators during start-up and shutdown are working in accordance with operating instructions. • Watch that no one is in danger before starting and when moving the machine. •...

  • Page 19: Maintenance

    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 20 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 21: 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 23: Specifications

    SPECIFICATIONS...

  • Page 26: Specification Data

    SPECIFICATIONS 1. SPECIFICATION DATA 1-1. SV201D 1370 2330 1080 1085 1530 4210 0406-99817-0-10901-A Model SV201D Operating weight 4,350 kg 9,590 lbs. Weight Front axle 2,150 kg 4,740 lbs. Rear axle 2,200 kg 4,850 lbs. Overall length 4,210 mm 166 in. Overall width 1,530 mm 60 in.
  • Page 27 SPECIFICATIONS KUBOTA V3307-DI-T-E3B Name Diesel Engine with turbocharger Water-cooled, 4-cycle, 4-cylinder in-line, vertical mounted, Model overhead valve, direct-injection type Bore × Stroke 94 mm × 120 mm ( 3.701 in. × 4.724 in.) Displacement 3.331 L ( 203.3 cu.in Rated speed 2,200 min ( 2,200 rpm 54.6 kW...

  • Page 28: Sv201T -1

    SPECIFICATIONS 1-2. SV201T 1370 2330 1080 1085 1530 4210 0406-99818-0-10902-A Model SV201T Operating weight 4,450 kg 9,810 lbs. Weight Front axle 2,250 kg 4,960 lbs. Rear axle 2,200 kg 4,850 lbs. Overall length 4,210 mm 166 in. Overall width 1,530 mm 60 in.
  • Page 29 SPECIFICATIONS KUBOTA V3307-DI-T-E3B Name Diesel Engine with turbocharger Water-cooled, 4-cycle, 4-cylinder in-line, vertical mounted, Model overhead valve, direct-injection type Bore × Stroke 94 mm × 120 mm ( 3.701 in. × 4.724 in.) Displacement 3.331 L ( 203.3 cu.in Rated speed 2,200 min ( 2,200 rpm 54.6 kW...

  • Page 30: Sv201Tf -1

    SPECIFICATIONS 1-3. SV201TF 1370 2330 1080 1085 1530 4210 0406-99820-0-10904-A Model SV201TF Operating weight 5,200 kg 11,465 lbs. Weight Front axle 3,000 kg 6,615 lbs. Rear axle 2,200 kg 4,850 lbs. Overall length 4,210 mm 166 in. Overall width 1,530 mm 60 in.
  • Page 31 SPECIFICATIONS KUBOTA V3307-DI-T-E3B Name Diesel Engine with turbocharger Water-cooled, 4-cycle, 4-cylinder in-line, vertical mounted, Model overhead valve, direct-injection type Bore × Stroke 94 mm × 120 mm ( 3.701 in. × 4.724 in.) Displacement 3.331 L ( 203.3 cu.in Rated speed 2,200 min ( 2,200 rpm 54.6 kW...

  • Page 32: Sv201Tb -1

    SPECIFICATIONS 1-4. SV201TB 1370 1530 1360 2330 1080 1085 1580 4770 0406-99819-0-10903-A Model SV201TB Operating weight 4,750 kg 10,470 lbs. Weight Front axle 2,600 kg 5,730 lbs. Rear axle 2,150 kg 4,740 lbs. Overall length 4,770 mm 188 in. Overall width 1,580 mm 62 in.
  • Page 33 SPECIFICATIONS KUBOTA V3307-DI-T-E3B Name Diesel Engine with turbocharger Water-cooled, 4-cycle, 4-cylinder in-line, vertical mounted, Model overhead valve, direct-injection type Bore × Stroke 94 mm × 120 mm ( 3.701 in. × 4.724 in.) Displacement 3.331 L ( 203.3 cu.in Rated speed 2,200 min ( 2,200 rpm 54.6 kW...

  • Page 34: Table Of Standard Values

    SPECIFICATIONS 2. TABLE OF STANDARD VALUES 2-1. Engine Item Standard value Remarks KUBOTA V3307-DI-T-E3B-RRSH2 Engine model Diesel Engine with turbocharger Rated output 54.6/2,200 kW/ min 73.2/2,200 HP/rpm ) Max. rpm under no load 2,400 ± 50 Min. rpm under no load 1,000 ±...

  • Page 35: 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 178 mm (7.0 in.)

  • Page 36: 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 CF SAE10W-30...

  • Page 37: Tightening Torque Chart

    SPECIFICATIONS 4. TIGHTENING TORQUE CHART N·m (lbf·ft) Strength Classification Nominal Pitch Dia. 10.9 12.9 (3.6) (4.4) (5.8) (5.8) (5.8) (7.2) (9.6) (9.6) 1.25 (13) (17) (23) (23) (29) (36) (44) (44) 1.75 (51) (58) (80) (80) (72) (94) (123) (123) (116) (145) (195)

  • Page 39: Engine And Controls

    ENGINE AND CONTROLS...

  • Page 42: Engine

    ENGINE AND CONTROLS 1. ENGINE 1-1. Engine Mount DETAIL B DETAIL C VIEW A 0406-01802-0-10824-B (1) Bracket (6) Nut : M12 P=1.25 (11) Plate (2) Bracket (7) Damper (12) Damper (3) Engine (8) Nut : M12 P=1.25 (13) Nut : M16 (4) Bracket (9) Bolt : M14×35...

  • Page 43: Engine Exterior

    ENGINE AND CONTROLS 1-2. Engine Exterior The actual equipment may differ from that shown above. SW652-1-03001 (1) Injection pump (8) Engine oil filter (15) Oil filler cap (2) Engine stop solenoid (9) Oil pressure switch (16) Speed control lever (3) EGR valve (10) Oil drain plug (17) Fuel filter (4) Cooling fan...

  • Page 44: Control System

    ENGINE AND CONTROLS 2. CONTROL SYSTEM 2-1. Throttle Control IDLE FULL DETAIL C DETAIL A SECTION B-B 0406-12803-0-10896-B (1) Throttle lever (7) Washer (Apply grease*) (2) Control cable (8) Shaft (3) Lock nut : M10 (9) Rod end (Apply grease*) (4) Stopper bolt (FULL) : M10×35 (10) Bush (Apply grease*) (5) Stopper bolt (IDLE) : M10×35...

  • Page 45: Forward-Reverse Control

    ENGINE AND CONTROLS 2-2. Forward-reverse Control 13 14 15 16 Fill grease Apply grease* 20 19 DETAIL A SECTION B-B 0406-12801-0-10030-G (1) Rod end (11) F-R lever switch (2) Bracket (12) Backup buzzer switch (3) Shaft (13) Bolt : M16×30 (4) F-R lever (14) Nut : M16...

  • Page 46: Pump Mount

    ENGINE AND CONTROLS 3. PUMP MOUNT 3-1. Pump Mount 0406-36810-0-20885-0 (1) Bolt : M10×25 P=1.25 (8) Housing (2) Propulsion pump (9) Bolt : M10×25 P=1.25 (3) Bolt : M12×45 (10) Sunk key (4) O-ring (11) Washer (5) Steering·vibrator pump (12) Nut : 3/4-16UNF (6) Bolt : 3/8-30UNC...

  • Page 47: Installation Of Pump

    ④ Secure housing (8) to engine flywheel with twelve bolts (9). (9) Bolt M10×25 P=1.25 : 69 N·m (51 lbf·ft) N•m SV201-1-03001 SV201-1-03001 ⑤ Apply grease to hub (13) and flange (14) splines. ⑥ Set spacer (7) on housing (8).

  • Page 49: Hydraulic Systems

    HYDRAULIC SYSTEMS...

  • Page 52: 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 53 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 55: Hydraulic Circuit Diagram

    HYDRAULIC SYSTEMS 1-2. Hydraulic Circuit Diagram 1-2-1. Hydraulic circuit diagram (SV201D (3/8) (3/8) 11.8 MPa cc/rev (3/8) (3/8) 70X 35-380 Steering cylinder Orbitrol (1/4) Valve Vibrator motor (1/2) 17.2 MPa Parking brake Rear axle solenoid valve assembly 23.3 cc/rev Propulsion motor (Rear) (3/4) i=6.00...

  • Page 57: Hydraulic Circuit Diagram

    HYDRAULIC SYSTEMS 1-2-2. Hydraulic circuit diagram (SV201T (3/8) (3/8) 11.8 MPa cc/rev (3/8) (3/8) 70X 35-380 Steering cylinder Orbitrol (1/4) Valve Vibrator motor (1/2) 17.2 MPa Parking brake Rear axle solenoid valve assembly 23.3 cc/rev Propulsion motor (Rear) (3/4) i=6.00 (1/2) 7300kg/1800vpm 3.0 MPa...
  • Page 59 HYDRAULIC SYSTEMS 1-2-3. Hydraulic circuit diagram (SV201TB Stack valve (3/8) (3/8) cc/rev 80X 45-310 11.8 MPa Blade cylinder (3/8) (3/8) (3/8) 70X 35-380 Steering cylinder (3/8) 11.8 MPa Valve (1/4) Vibrator motor Orbitrol (3/8) (1/2) 17.2 MPa Parking brake Rear axle solenoid valve assembly 23.3...

  • Page 61: Propulsion Hydraulic System

    HYDRAULIC SYSTEMS 2. PROPULSION HYDRAULIC SYSTEM 2-1. Propulsion Hydraulic Piping Hose 2-1-1. Propulsion hydraulic piping (Front) (TEE Hose Propulsion motor (Rear) CD1) Hose Hose Hose (TEE Propulsion motor (Front) SECTION A-A The letters and figures (such as FA and FB) show each port and the arrow ( ) symbols show the hose connection and the direction of the flow of the oil.

  • Page 63: Propulsion Hydraulic Piping (Rear)

    HYDRAULIC SYSTEMS 2-1-2. Propulsion hydraulic piping (Rear) Hose Hydraulic oil tank Hose (CD1 RA1) (CA1 Hose Hose Hose Propulsion pump CA2) Hose VP1) Hose (Hydraulic oil tank VIEW A-A Hose Hose Bypass valve (RA2 BV2) Hose Hose Hose (VB1 Hydraulic oil filter Hose (VA1 VIEW B-B...

  • Page 66: Hydraulic Component Specifications

    2-2. Hydraulic Component Specifications 2-2-1. Hydraulic pump assembly (propulsion + vibrator • steering) 1-10 1-11 1-14 1-13 1-12 VIEW A 1-3 1-7 2-3 2-2 28 MPa 28 MPa Vibrator  steering pump circuit diagram 2.4 MPa 1-14 1-11 Propulsion pump circuit diagram SV201-1-04001 4-008...
  • Page 67 HYDRAULIC SYSTEMS (1) Propulsion pump (1-1) Port B (Reverse) [PB] : 1 1/16-12UN (1-2) High pressure gauge port (For port B) 9/16-18UNF (1-3) Servo pressure gauge port 9/16-18UNF (1-4) Drain port [PD] : 1 5/16-12UN (1-5) High pressure gauge port (For port A) 9/16-18UNF (1-6) Port A (Forward)

  • Page 68: Propulsion Hydraulic Motor (Front)

    HYDRAULIC SYSTEMS 2-2-2. Propulsion hydraulic motor (Front) Motor circuit diagram SV201-1-04002 (1) Port A [FA] : G3/4 (7) Drain port : G3/4 (2) Port B [FB] : G3/4 (8) Motor [FC] : G1/4 (3) Hi-Lo change port (9) Reduction gear...

  • Page 69: Propulsion Hydraulic Motor (Rear)

    HYDRAULIC SYSTEMS 2-2-3. Propulsion hydraulic motor (Rear) VIEW A Motor ciruit diagram SV201-1-04003 (1) System pressure port : 1 1/16-12UN (6) 2 speed control port (Min) : 9/16-18UNF (2) 2 speed control port (Max) [X2] : 9/16-18UNF (7) Port B...

  • Page 70: Valve

    HYDRAULIC SYSTEMS 2-2-4. Valve Hydraulic circuit diagram SV201-1-04004 (1) Port A [VA1] : G3/4 (9) O-ring (2) Port B [VB1] : G3/4 (10) O-ring (3) Body (11) O-ring (4) Spool (12) Sub spool (5) Spool plug (13) Port P [VP1] : G1...

  • Page 71: Vibrator Hydraulic System

    HYDRAULIC SYSTEMS 3. VIBRATOR HYDRAULIC SYSTEM 3-1. Vibrator Hydraulic Piping Vibrator motor Hose Hydraulic oil tank Hose (CD2 Oil cooler SECTION A-A Hose (Hydraulic oil tank Hose (CP1 VT5) Hose Hose (VA3 CP2) (VT4 SECTION B-B Hose (MP1 CP1) Hose Hose (CP2 MP2)

  • Page 73: Hydraulic Component Specifications

    HYDRAULIC SYSTEMS 3-2. Hydraulic Component Specifications 3-2-1. Vibrator hydraulic motor Hydraulic circuit diagram Flow of oil 2 Clockwise rotation 1 Counterclockwise rotation SV201-1-04005 (1) Port P2 [MP2] : G1/2 [MP1] : G1/2 (2) Port P1 (3) Drain port [MD] : G1/2 Specifications •...

  • Page 74: Valve

    HYDRAULIC SYSTEMS 3-2-2. Valve Hydraulic circuit diagram SV201-1-04006 (1) Port B [VB3] : G3/4 (4) Port A [VA3] : G3/4 (2) Solenoid valve (5) Port T [VT3] : G3/4 (3) Body (6) Port P : G3/4 Specifications • Maximum flow 70 L/min ( 18 gal./min )

  • Page 75: Steering System

    HYDRAULIC SYSTEMS 4. STEERING SYSTEM 4-1. Steering Hydraulic Piping 4-1-1. Steering hydraulic piping (SV201D , TF Hydraulic oil tank Hose Hose Vibrator  steering pump Hose Hose Orbitrol Hose SECTION A-A Steering cylinder Hose SECTION B-B Hose Hose SECTION C-C Hose The letters and figures (such as R and SR) show each port and the arrow ( ) symbols show the hose connection and the direction of the flow of the oil.

  • Page 77: Steering Hydraulic Piping

    HYDRAULIC SYSTEMS 4-1-2. Steering hydraulic piping (SV201TB Hydraulic oil tank Hose Hose Vibrator  steering pump Hose Hose Orbitrol Hose SECTION A-A Steering cylinder Hose SECTION B-B Hose Hose SECTION C-C Hose The letters and figures (such as R and SR) show each port and the arrow ( ) symbols show the hose connection and the direction of the flow of the oil.

  • Page 79: 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 : M 8×12 (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 80: Hydraulic Component Specifications

    HYDRAULIC SYSTEMS 4-3. Hydraulic Component Specifications 4-3-1. Orbitrol (SV201D , TF Hydraulic circuit diagram SW800-04018 (1) Port L : G3/8 (4) Port T : G3/8 (2) Port R : G3/8 (5) Relief valve (3) Port P : G3/8 Specifications • Displacement 184 cm /rev (...

  • Page 81: Orbitrol

    HYDRAULIC SYSTEMS 4-3-2. Orbitrol (SV201TB Hydraulic circuit diagram SV201-1-04009 (1) Relief valve (4) Port P : G1/2 (2) Port L : G3/8 (5) Port EF [EF] : G1/2 (3) Port R : G3/8 (6) Port T : G3/8 Specifications •...

  • Page 82: Frame (Center Pin)

    HYDRAULIC SYSTEMS 4-4. Frame (Center Pin) 0406-61801-0-10011-0 (1) Bolt : M16×60 (4) Swing bearing (7) Bracket (upper) (2) Bolt : M16×60 (5) Yoke (8) Cover (3) Bolt : M20×70 (6) Ball bearing (9) Bracket (lower) N•m Bolt M16×60 : 265 N·m ( 195 lbf·ft ) Bolt M16×60 : 265 N·m ( 195 lbf·ft ) Bolt M20×70 : 539 N·m ( 398 lbf·ft ) 4-021...

  • Page 83: Blade System

    HYDRAULIC SYSTEMS 5. BLADE SYSTEM 5-1. Blade Hydraulic Piping Hose (AD2 Blade Blade cylinder Hose (AD1 VIEW A Hose Hose Orbitrol Hose AD2) AD1) Down Neutral Floating Blade control lever Stack valve Hose SECTION B-B AD1) Hose AD2) Hose AD2) Hose AD1) SECTION C-C...

  • Page 85: Hydraulic Component Specifications

    HYDRAULIC SYSTEMS 5-2. Hydraulic Component Specifications 5-2-1. Stack valve Hydraulic circuit diagram SV201-1-04010 (1) Relief valve (4) Pressure gauge port : Rc 1/4 (2) Port T [ST] : G3/4 (5) Port B [SB] : G1/2 (3) Port P [SP] : G3/4...

  • Page 87: Electrical System

    ELECTRICAL SYSTEM...

  • Page 89: System Circuit Diagram

    ELECTRICAL SYSTEM 1. SYSTEM CIRCUIT DIAGRAM 1-1. Electrical Circuit Diagram (OPTION) (OPTION) FLOOD LAMP (R) (55W) TURN SIGNAL LAMP (R) (20W) HEAD LAMP (R) (55W) FLOOD LAMP (L) (55W) LIGHTING Br 11 SWITCH 2BrW F-R LEVER VIBRATOR SOLENOID VIBRATION SWITCH TURN SIGNAL SWITCH HEAD LAMP (L)

  • Page 91: Electrical Components

    ELECTRICAL SYSTEM 2. ELECTRICAL COMPONENTS 2-1. Electrical Component Layout (1) Glow plug Tachometer sensor Engine stop solenoid Fuel pump Alternator Starter motor Engine oil pressure switch Horn VIEW A Battery relay Hydraulic oil filter switch Parking brake solenoid Battery Vibrator solenoid Thermo unit Fuel unit Backup buzzer...

  • Page 93: Electrical Component Layout (2)

    ELECTRICAL SYSTEM 2-2. Electrical Component Layout (2) Combination meter Parking brake switch Horn relay Glow lamp timer Parking interlock relay Interlock relay Safety relay Starter switch Vibrator lamp relay Vibrator relay Glow relay Starter relay Fuse box Vibration mode select switch SECTION B-B VIEW A VIEW C-C...

  • Page 95: Electrical Component Specifications

    F-R lever switch Starter relay Battery relay (RG) Combination meter Lighting switch (option) Flasher unit (option) SV201-1-05001 Harness color codes : Red RY : Red/Yellow stripe : Light green RG : Red/Green stripe BW : Black/White stripe RL : Red/Blue stripe...

  • Page 96: Combination Meter

    Preheating indicator Hydraulic oil filter of connecting surfaces on the warning Lamp check connector side. Coolant temp. SEL.1 Coolant temp. SEL.2 Wire number System configuration diagram Wire color Note: The circuit in the dashed box is not mounted. SV201-1-05002 5-005...

  • Page 97: Vibratory Drum • Rear Axle

    VIBRATORY DRUM • REAR AXLE...

  • Page 99: 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 100 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 101: Vibratory Drum

    W AR N ING When lifting the machine body, use an appropriate hoist of sufficient strength. Confirm that the surrounding area SV201-1-06001 SV201-1-06001 is safe, and work in a natural, unstrained posture. Also, to firmly secure the machine body, use a support Lift with crane.
  • Page 102 : 205 kg (452 lbs.) SV201TB : 385 kg (849 lbs.) Support stand Support stand SV201-1-06004 SV201-1-06004 WARN ING The hydraulic oil in the machine is hot and compressed immediately after the machine is stopped. Disconnecting the hydraulic hoses in this condition can cause burns.
  • Page 103 : 1,550 kg (3,417 lbs.) SV201TF : 2,265 kg (4,993 lbs.) SV201TB : 1,550 kg (3,417 lbs.) Support stand Support stand SV201-1-06007 SV201-1-06007 7) Put chocks or the like under removed vibratory drum (12) to prevent it from moving. Chock Chock SV201-1-06090...

  • Page 104: Installation Of Vibratory Drum

    VIBRATORY DRUM • REAR AXLE 2-1-2. Installation of vibratory drum 1) Install vibratory drum in the reverse order in which it was removed. • Tightening torque for bolts where particular care is required when installing vibratory drum. (2) Bolts M12×70 : 108 N·m (80 lbf·ft) N•m (Vibratory drum) (3) Bolts M20×100 : 539 N·m (398 lbf·ft)

  • Page 105: Vibratory Drum Assy

    VIBRATORY DRUM • REAR AXLE 2-2. Vibratory Drum ASSY (1) Drum (2) Ring (3) Bolt : M16×50 (4) Plug (5) Bolt : M 8×16 (6) Bolt : M16×50 (7) O-ring (8) Holder (9) Vibrator bearing 21,22 45,46 (10) Eccentric shaft (11) Vibrator bearing (12) Axle shaft (13) O-ring...

  • Page 107: Disassembly And Reassembly Of Vibratory Drum

    1) Remove plugs (35-1) and (35-2). • Drain gear oil. • Quantity of gear oil : 4.0 L (1.0 gal.) 35-2 35-2 SV201-1-06008 SV201-1-06008 W AR N ING Vibratory drum ASSY Vibratory drum ASSY • When standing the vibratory drum, use wooden blocks of sufficient strength to securely support the vibratory drum.
  • Page 108 VIBRATORY DRUM • REAR AXLE 4) Remove bolts (27). • Remove vibrator motor (28). Vibrator motor : 15 kg (33 lbs.) SV201-1-06011 SV201-1-06011 5) Remove sleeve (33). SV201-1-06012 SV201-1-06012 6) Remove bolts (32). SV201-1-06013 SV201-1-06013 6-009...
  • Page 109 VIBRATORY DRUM • REAR AXLE 7) Lift flange (26) using two pulling bolts (M10×35). • Remove flange (26). Pulling bolt Pulling bolt SV201-1-06014 SV201-1-06014 8) Remove bolts (30). • Remove cover (31). • Remove shim (17). SV201-1-06015 SV201-1-06015 9) Put a piece of wooden board on end of axle shaft (12).
  • Page 110 VIBRATORY DRUM • REAR AXLE WARN ING When installing lifting bolts, screw in the threads fully Lifting bolt Lifting bolt before using. 10) Install lifting bolts (M12) to axle (19). SV201-1-06017 SV201-1-06017 11) Remove axle SUBASSY. Axle Axle SUBASSY SUBASSY Axle SUBASSY : 60 kg (132 lbs.)
  • Page 111 VIBRATORY DRUM • REAR AXLE 13) Lift axle shaft (12) using two pulling bolts (M16×50). Pulling bolt Pulling bolt SV201-1-06020 SV201-1-06020 14) Install lifting bolts (M16) to axle shaft (12). Lifting bolt Lifting bolt SV201-1-06021 SV201-1-06021 15) Remove axle shaft SUBASSY.
  • Page 112 VIBRATORY DRUM • REAR AXLE 16) Install lifting bolts (M10) to eccentric shaft (10). Lifting bolt Lifting bolt SV201-1-06023 SV201-1-06023 17) Remove eccentric shaft (10). (10) Eccentric shaft : 70 kg (154 lbs.) SV201-1-06024 SV201-1-06024 WARN ING Drum Drum SUBASSY SUBASSY Be careful because reversing the drum involves risk.
  • Page 113 VIBRATORY DRUM • REAR AXLE 19) Remove bolts (47). • Remove dampers (44). SV201-1-06026 SV201-1-06026 20) Install lifting bolts (M12) to disc (39). Lifting bolt Lifting bolt SV201-1-06027 SV201-1-06027 21) Lift disc SUBASSY. Disc Disc • Remove bolts (41) and nuts (42).
  • Page 114 VIBRATORY DRUM • REAR AXLE 22) Remove disc SUBASSY. Disc Disc SUBASSY SUBASSY Disc SUBASSY : 40 kg (88 lbs.) SV201-1-06029 SV201-1-06029 23) Install lifting bolts (M16) and nuts to propulsion motor (43). Lifting bolt Lifting bolt SV201-1-06030 SV201-1-06030 24) Remove bolts (40).
  • Page 115 VIBRATORY DRUM • REAR AXLE 25) Remove propulsion motor SUBASSY. Propulsion Propulsion motor motor Propulsion motor SUBASSY : 105 kg (231 lbs.) SUBASSY SUBASSY SV201-1-06032 SV201-1-06032 26) Install lifting bolts (M16) to holder (8). • Remove bolts (6). Lifting bolt Lifting bolt SV201-1-06033 SV201-1-06033 27) Lift holder (8) using two pulling bolts (M16×50).
  • Page 116 VIBRATORY DRUM • REAR AXLE 28) Remove holder SUBASSY. Holder Holder Holder SUBASSY : 65 kg (143 lbs.) SUBASSY SUBASSY SV201-1-06035 SV201-1-06035 29) Remove bolts (5). SV201-1-06037 SV201-1-06037 30) Remove vibrator bearing (9) from holder (8) using long bolts (M8).

  • Page 117: Reassembly Of Vibratory Drum

    1) Stand drum (1) with side without round pipe facing up. • Place marks to upper side of drum at holes on extended line from round pipe. Drum SUBASSY SV201D 970 kg (2,138 lbs.) SV201-1-06038 SV201-1-06038 SV201T : 1,105 kg (2,436 lbs.) SV201TF : 1,825 kg (4,023 lbs.) SV201TB : 1,105 kg (2,436 lbs.)
  • Page 118 Install plugs (36) to holder SUBASSY. • Install bolts (5) and seal washers to holder ASSY. Holder Holder SUBASSY SUBASSY SV201-1-06041 SV201-1-06041 2-4) Apply screw locking agent to plugs (4). • Install plugs (4) to holder SUBASSY. Holder Holder SUBASSY...
  • Page 119 • Apply grease to O-ring (7). • Install O-ring (7) to holder SUBASSY. Holder Holder SUBASSY SUBASSY SV201-1-06044 SV201-1-06044 5) Lower holder SUBASSY on mounting surface of drum (1). Holder Holder SUBASSY SUBASSY Holder SUBASSY : 65 kg (143 lbs.) (NOTICE) •...
  • Page 120 7) Secure holder SUBASSY to drum (1) with twelve bolts (6) and washers. Holder Holder SUBASSY SUBASSY (6) Bolt M16×50 : 265 N·m (195 lbf·ft) N•m SV201-1-06046 SV201-1-06046 8) Reassembly of propulsion motor SUBASSY Filler/Drain port a Filler/Drain port a Filler/Drain port c Filler/Drain port c Filler/Drain port b...
  • Page 121 VIBRATORY DRUM • REAR AXLE 8-2) Secure ring (2) to propulsion motor (43) with nine bolts (3) and washers. (3) Bolt M16×50 : 265 N·m (195 lbf·ft) N•m SV201-1-06048 SV201-1-06048 9) Reverse propulsion motor SUBASSY. Lifting bolt Lifting bolt Lifting bolt Lifting bolt Propulsion motor SUBASSY : 105 kg (231 lbs.)
  • Page 122 • Align filler/drain port “a” with plug (4). port a port a Align Align SV201-1-06051 SV201-1-06051 12) Secure propulsion motor SUBASSY to holder (8) with twelve bolts (40) and washers. (40) Bolt M16×50 : 265 N·m (195 lbf·ft) Propulsion Propulsion N•m...
  • Page 123 VIBRATORY DRUM • REAR AXLE 14) Lift disc SUBASSY. Disc Disc SUBASSY SUBASSY SV201-1-06054 SV201-1-06054 15) Lower disc SUBASSY on mounting surface of propulsion motor (43). Disc Disc SUBASSY SUBASSY Disc SUBASSY : 40 kg (88 lbs.) SV201-1-06055 SV201-1-06055 16) Position disc SUBASSY as shown right.
  • Page 124 41, 42 41, 42 SUBASSY SUBASSY (42) Nut M16 : 265 N·m (195 lbf·ft) N•m SV201-1-06057 SV201-1-06057 18) Secure four dampers (44) to disc (39) with sixteen bolts (47) and spring washers. (47) Bolt M12×25 : 108 N·m (80 lbf·ft) N•m...
  • Page 125 VIBRATORY DRUM • REAR AXLE 20) Install lifting bolts (M10) to eccentric shaft (10). Lifting bolt Lifting bolt SV201-1-06059 SV201-1-06059 21) Apply a coat of gear oil to bearing mounting surface of eccentric shaft (10). • Lower eccentric shaft (10).
  • Page 126 Apply a coat of gear oil to axle shaft (12) at where bearing will be press-fitted. • Drive in vibrator bearing (11). Wooden block Wooden block SV201-1-06062 SV201-1-06062 WARN ING Wear heat resistant gloves when handling heated parts to avoid burns. Axle shaft...
  • Page 127 Apply grease to O-ring (13). • Install O-ring (13) to axle shaft (12). Axle shaft Axle shaft SUBASSY SUBASSY SV201-1-06065 SV201-1-06065 27) Lower axle shaft SUBASSY on mounting surface of drum slowly. Axle shaft SUBASSY : 45 kg (99 lbs.) Pipe Pipe...
  • Page 128 Axle shaft Axle shaft SUBASSY SUBASSY (14) Bolt M16×50 : 265 N·m (195 lbf·ft) N•m SV201-1-06068 SV201-1-06068 29) Install lifting bolt (M10) to end of eccentric shaft (10). Lifting bolt Lifting bolt SV201-1-06069 SV201-1-06069 30) Slowly lift eccentric shaft with a crane and check that there is an axial play of 1 to 3 mm (0.04 to 0.12 in.).
  • Page 129 Apply liquid packing to periphery of oil seal (15). • Drive in oil seal (15). • Apply lithium-based grease to lip of oil seal (15). SV201-1-06071 SV201-1-06071 32) Install lifting bolts (M12) to axle (19). Lifting bolt Lifting bolt SV201-1-06072...
  • Page 130 (16) inner race. • Drive in roller bearing (16) inner race until rollers come in contact with outer race. SV201-1-06074 SV201-1-06074 35) Preload adjustment of roller bearing ① Install a shim of about 1 mm (0.04 in.) and secure cover (31) to axle shaft (12) with three bolts (30) and spring washers.
  • Page 131 • Remove shim. (NOTICE) • Do not turn the housing after the cover is removed. Shim Shim SV201-1-06077 SV201-1-06077 ④ Without inserting shim, install cover (31) to axle shaft (12) with three bolts (30) and spring washers. SV201-1-06078 SV201-1-06078 6-032...
  • Page 132 VIBRATORY DRUM • REAR AXLE ⑤ Using a thickness gauge, measure clearance “A”. Preload adjusting ★ = A + 0.1 mm (0.04 in.) shim thickness SV201-1-06079 SV201-1-06079 ⑥ Remove bolts (30). • Remove cover (31). SV201-1-06080 SV201-1-06080 ⑦  I nstall shim (17) of preload adjusting shim thickness = A + 0.1 mm (0.04 in.).
  • Page 133 VIBRATORY DRUM • REAR AXLE 36) Apply grease to O-ring (18). • Install O-ring (18) to flange (26). SV201-1-06082 SV201-1-06082 37) Bring breather mounting hole in flange (26) to top as shown right. Breather Breather mounting hole mounting hole Axle...
  • Page 134 VIBRATORY DRUM • REAR AXLE 39) Drive two spring pins (34) into sleeve (33). SV201-1-06085 SV201-1-06085 40) Apply molybdenum-based grease to splined portion of sleeve (33). • Fit sleeve (33) to splined portion on eccentric shaft end. SV201-1-06086 SV201-1-06086 41) Apply grease to O-ring (29).
  • Page 135 Vibrator motor : 15 kg (33 lbs.) (27) Bolt M12×35 : 108 N·m (80 lbf·ft) N•m SV201-1-06011 SV201-1-06011 43) Secure two dampers (23) to axle (19) with eight bolts (20) and spring washers. (20) Bolt M12×25 : 108 N·m (80 lbf·ft) N•m...
  • Page 136 Supply gear oil from oil supply port. • Check that oil drips from gauge port. • Quantity of gear oil : 4.0 L (1.1 gal.) • Reinstall plugs (35-1) and (35-2). 35-2 35-2 Gauge port Gauge port SV201-1-06089 SV201-1-06089 6-037...

  • Page 137: Rear Axle

    VIBRATORY DRUM • REAR AXLE 3. REAR AXLE 3-1. Rear Axle ASSY (1) Bolt (brake release) (2) Plug (brake drain) (3) Plug (brake filler and level gauge) (4) Bolt (brake release) (5) Brake (6) Differential (7) Brake (8) Parking brake release port [BR] : M14 P=1.5 (9) Parking brake release port [BL] : M14 P=1.5 (10) Tire (11) Hub nut...

  • Page 139: Rear Axle Lubrication

    3-2. Rear Axle Lubrication Center housing (differential + brake) Drain Hub reduction gear Supply Drain SV201-1-06094 (1) Filler port (2) Level gauge (3) Drain port • Change oil : Gear oil API-grade GL4 SAE90 (See recommended lubrication.) • Change oil quantity Center housing 6.8 L...

  • Page 140: Rear Axle Structure

    VIBRATORY DRUM • REAR AXLE 3-3. Rear Axle Structure 3-3-1. Center housing SV201-1-06095 SV201-1-06095 (1) O-ring (5) Vent (9) Snap ring (2) Cover (6) Housing (10) Magnet plug (3) Bolt (7) Plug (4) Seal washer (8) Plug 6-040...

  • Page 141: Differential

    VIBRATORY DRUM • REAR AXLE 3-3-2. Differential SV400-2-06053 SV400-2-06053 (1) Cylinder bolt (6) No spin differential (11) Spacer (2) Ring nut (7) Bolt (12) Shim (3) Taper roller bearing (8) Bevel gear set (13) Shim (4) Cylinder bolt (9) Ring nut (5) Differential carrier (10) Taper roller bearing 6-041...

  • Page 142: Hub Reduction Gear

    VIBRATORY DRUM • REAR AXLE 3-3-3. Hub reduction gear SV201-1-06096 SV201-1-06096 (1) Axle shaft (10) Stud bolt (19) Circlip (2) Spring washer (11) Plug (20) Planetary gear (3) Bolt (12) Magnet plug (21) Bearing (4) Seal (13) Nut (22) Friction washer...
  • Page 143 VIBRATORY DRUM • REAR AXLE 3-3-4. Brake SV201-1-06093 SV201-1-06093 (1) Spring (7) Intermediate cover (13) Brake disc (2) O-ring (8) Bolt (14) Spacer (3) Piston (9) O-ring (15) Shim (4) O-ring (10) Disc (16) Lock washer (5) Bolt (11) Cylinder bolt...

  • Page 145: Brake

    BRAKE...

  • Page 147: Brake

    BRAKE 1. BRAKE PEDAL SECTION A-A 0406-51801-0-10139-C (1) Brake pedal (7) Nut : M12 (13) Nut : M10 (2) Clevis (8) Rod end (14) Return spring (3) Nut : M10 (9) Rod end (Left-hand thread) (15) Nut : M10 (4) Foot brake switch (10) Nut : M10 (Left-hand thread) (16) Stopper bolt...

  • Page 149: Brake Hydraulic Piping

    BRAKE 2. BRAKE HYDRAULIC PIPING Hose Hose (VA2 Hose (TX1 Hose (VT2 Hose VP2) Hose Hose (VP2 VP2) SECTION A-A Propulsion pump Parking brake solenoid valve Hydraulic oil tank Rear axle The letters and figures (such as VA2 and VP2) show each port and the arrow ( ) symbols Propulsion motor (Rear) show the hose connection and the direction of the flow of the oil.

  • Page 151: Brake System

    BRAKE 3. BRAKE SYSTEM Fuse To P-interlock relay Foot brake switch To combination meter (Condition in which brake pedal pressed) Parking brake switch (Brake OFF condition) Brake (Brake ON condition) Parking brake solenoid valve when brake is ON. (without solenoid excited) Charge pump Parking brake solenoid valve when brake is OFF.

  • Page 152: 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 [VP2] : G1/4 (7) Port A [VA2] : G1/4 (8) Port T [VT2] : G1/4 Specifications...

  • Page 153: Inspection And Adjustment

    INSPECTION AND ADJUSTMENT...

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

    ③ Establish a condition in which machine propulsion load becomes maximum. (Pressure does not build up unless propulsion load is applied.) ④ With propulsion load at maximum, slowly move F-R lever SV201-1-08001 SV201-1-08001 to the side to be measured. • Then, read pressure indicated by pressure gauge.

  • Page 157: Inspection

    ⑤ After inspection, measure pressure again and check that pressure reaches maximum circuit pressure range. 1-12 1-12 Plug : 70 N·m (52 lbf·ft) SV201-1-08002 SV201-1-08002 N•m (NOTICE) • Carefully disassemble and reassemble after taking Plug Plug steps to prevent foreign material from getting in.

  • Page 158: Measurement And Adjustment Of Propulsion Charge Circuit Pressure

    ★ : 2.4 MPa (348 psi) ± 0.2 ± 29 SV201-1-08004 SV201-1-08004 PG001014 PG001014 • 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 4-008).

  • Page 159: Adjustment

    Pressure change rate : 0.27 MPa/ 1/4 turn 1-13 1-13 (39.2 psi/ 1/4 turn) SV201-1-08005 SV201-1-08005 ③ If there is no evidence of nut having loosened, remove charge relief valve. ④ Check removed charge relief valve for trapped dirt and scratches on its seat.

  • Page 160: Measurement Of Parking Brake Release Pressure

    ⑤  R elease parking brake by pressing parking brake switch button. • Then, read brake release pressure indicated by pressure gauge. Brake release pressure : 1.5 to 3.0 MPa (218 to 435 psi) ★ SV201-1-08006 SV201-1-08006 PG002002 PG002002 8-006...

  • Page 161: Measurement Of Vibrator Circuit Pressure

    ⑤ Keep pressing F-R lever vibration switch (ON). • Then, read pressure gauge for maximum value of vibrator circuit pressure. ⑥ Release F-R lever vibration switch (OFF) as soon as measurement is finished. SV201-1-08007 SV201-1-08007 Maximum circuit pressure ★ (relief valve pressure setting) : 17.2...

  • Page 162: Measurement And Inspection Of Steering Circuit Pressure

    ⑤  T urn steering wheel to operate relief valve. • Then, read pressure indicated by pressure gauge. Standard maximum circuit pressure ★ (orbitroll relief pressure) : 11.8 MPa (1,711 psi) ± 1.0 ± 145 SV201-1-08017 SV201-1-08017 PG002003 PG002003 8-008...

  • Page 163: Inspection

    ⑤  A fter inspection, measure pressure again and check that pressure reaches standard maximum circuit pressure range. (NOTICE) • Carefully disassemble and reassemble after taking SV201D SV201D steps to prevent foreign material from getting in. SW800-09017 SW800-09017 SV201TB SV201TB SV201-1-08008 SV201-1-08008 8-009...

  • Page 164: Measurement And Inspection Of Blade Circuit Pressure (Sv201Tb -1 )

    ⑤ Move blade control lever to operate relief valve. • Then, read pressure indicated by pressure gauge. Standard maximum circuit pressure ★ (stack valve relief pressure) : 11.8 MPa (1,711 psi) ± 1.0 ± 145 SV201-1-08017 SV201-1-08017 PG002003 PG002003 8-010...

  • Page 165: Inspection

    ⑤  A fter inspection, measure pressure again and check that pressure reaches standard maximum circuit pressure range. (3) Relief valve : 39.2 N·m (28.9 lbf·ft) ± 4 ± 3 N•m (NOTICE) • Carefully disassemble and reassemble after taking SV201-1-08009 SV201-1-08009 steps to prevent foreign material from getting in. 8-011...

  • Page 166: Measurement Of Propulsion Pump Case Pressure

    F-R lever is in “N”, “F”, and “R”, respectively. Pump case pressure : 0.25 MPa (36.3 psi) or less ★ 1-14 1-14 SV201-1-08010 SV201-1-08010 PG001033 PG001033 • The number “1-14” appearing in above illustrations is consistent with lead line numbers shown in illustration of propulsion pump in “2-2.

  • Page 167: Measurement Of Propulsion Motor Case Pressure

    (Pressure does not build up unless propulsion load is applied.) ④ With propulsion load at maximum, measure pressure when F-R lever in “N”, “F”, and “R”, respectively. Motor case pressure : 0.3 MPa (43.5 psi) or less ★ SV201-1-08011 SV201-1-08011 PG001006 PG001006 8-013...

  • Page 168: Measurement Of Rear Propulsion Motor

    (Pressure does not build up unless propulsion load is applied.) ④ With propulsion load at maximum, measure pressure when F-R lever in “N”, “F”, and “R”, respectively. Motor case pressure : 0.2 MPa (29.0 psi) or less ★ SV201-1-08012 SV201-1-08012 PG001019 PG001019 8-014...

  • Page 169: Adjustment Of Throttle Lever Linkage

    Standard minimum no-load rotational speed ★ : 1,000 ± 50 ⑦ Using lock nut (4), firmly secure stopper bolt (3). SV201-1-08013 SV201-1-08013 ⑧ Set throttle lever (1) to “FULL”. ⑨ Loosen lock nut (6). ⑩ Using stopper bolt (5), adjust so that standard maximum no-load rotational speed is achieved.

  • Page 170: Adjustment Of F-R Lever Linkage

    ① Set F-R lever in “N”. ② Attach control cable (4) to clevis (5). Specified dimension a: 233 mm (9.17 in.) ★ SV201-1-08015 SV201-1-08015 ③ Attach control cable to propulsion pump control lever (8). Specified dimension b: 209 mm (8.23 in.) ★...
  • Page 171 ⑤ Set F-R lever in “F”. ⑥ Loosen lock nut (7). ⑦ Bring bolt (6) into contact with F-R lever. ⑧ Using lock nut (7), firmly secure stopper bolt (6). SV201-1-08018 SV201-1-08018 ⑨ Set F-R lever in “R”. ⑩ Loosen lock nut (2).

  • Page 172: Brake Adjustment

    INSPECTION AND ADJUSTMENT 12. BRAKE ADJUSTMENT 12-1. Manually Releasing the Brake 1) Loosen 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 173: Adjustment After Manual Release Of Brake

    INSPECTION AND ADJUSTMENT 12-2. Adjustment after Manual Release of Brake ① Remove bolt (25), nut (24), and seal washer (26). ② Replace seal washer (26) with a new one. ③ Apply grease to bolt (25) threads. ④ As shown on the right, install bolt (25), nut (24), and seal washer (26).

  • Page 175: Troubleshooting

    TROUBLESHOOTING...

  • Page 177: 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 178: 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 179: 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 180: Inspection Procedures Using A Tester

    TROUBLESHOOTING 2-1-2. Inspection procedures using a tester Some of the various inspection procedures are presented here for reference, using a sample circuit below. Equipment A Main power source Ground of Signal from Power to of equipment B equipment A equipment A equipment A Battery Equipment B...
  • Page 181 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 182 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 183 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 184 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 185: 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 186 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 188 1.25LgW HEAT STARTER SAFETY FUSE BOX SWITCH RELAY 1.25LgW 1.25LW FUEL PUMP STARTER RELAY 2B X 8WLx3 ALTERNATOR GLOW RELAY GLOW PLUG ENGINE STOP SOLENOID STARTER MOTOR AV60 AV60 BATTERY RELAY 12V 80AH F.L.ｘ3 8WLx3 8Wx3 95D31R BATTERY SV201-1-09001 9-011...

  • Page 189: Engine

    TROUBLESHOOTING 2-2. Engine Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. • Check any ground circuit which belongs to components to be checked. 2-2-1. Engine will not start (Starter motor does not run) 1/3 •...
  • Page 190 1.25LgW HEAT STARTER SAFETY FUSE BOX SWITCH RELAY 1.25LgW 1.25LW FUEL PUMP STARTER RELAY 2B X 8WLx3 ALTERNATOR GLOW RELAY GLOW PLUG ENGINE STOP SOLENOID STARTER MOTOR AV60 AV60 BATTERY RELAY 12V 80AH F.L.ｘ3 8WLx3 8Wx3 95D31R BATTERY SV201-1-09001 9-013...

  • Page 191: Engine Will Not Start (Starter Motor Does Not Run) 2/3

    TROUBLESHOOTING 2-2-1. Engine will not start (Starter motor does not run) 2/3 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). Reference Fig.: 2-2-1 Check point Check/Cause Action...
  • Page 192 1.25LgW HEAT STARTER SAFETY FUSE BOX SWITCH RELAY 1.25LgW 1.25LW FUEL PUMP STARTER RELAY 2B X 8WLx3 ALTERNATOR GLOW RELAY GLOW PLUG ENGINE STOP SOLENOID STARTER MOTOR AV60 AV60 BATTERY RELAY 12V 80AH F.L.ｘ3 8WLx3 8Wx3 95D31R BATTERY SV201-1-09001 9-015...

  • Page 193: Engine Will Not Start (Starter Motor Does Not Run) 3/3

    TROUBLESHOOTING 2-2-1. Engine will not start (Starter motor does not run) 3/3 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is not depressed). Reference Fig.: 2-2-1 Check point Check/Cause Action...
  • Page 194 1.25LgW HEAT STARTER SAFETY FUSE BOX SWITCH RELAY 1.25LgW 1.25LW FUEL PUMP STARTER RELAY 2B X 8WLx3 ALTERNATOR GLOW RELAY GLOW PLUG ENGINE STOP SOLENOID STARTER MOTOR AV60 AV60 BATTERY RELAY 12V 80AH F.L.ｘ3 8WLx3 8Wx3 95D31R BATTERY SV201-1-09001 9-017...

  • Page 195: Engine Will Not Start (But Starter Motor Runs)

    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 196 1.25LgW HEAT STARTER SAFETY FUSE BOX SWITCH RELAY 1.25LgW 1.25LW FUEL PUMP STARTER RELAY 2B X 8WLx3 ALTERNATOR GLOW RELAY GLOW PLUG ENGINE STOP SOLENOID STARTER MOTOR AV60 AV60 BATTERY RELAY 12V 80AH F.L.ｘ3 8WLx3 8Wx3 95D31R BATTERY SV201-1-09001 9-019...

  • Page 197: No Charging

    TROUBLESHOOTING 2-2-4. No charging Reference Fig.: 2-2-1 Check point Check/Cause Action 1. Alternator • After starting engine, measure voltage between alternator Replace alternator or terminal B wire W and chassis ground. battery. Standard voltage : At least intermediate engine speed, 14 V or more •...
  • Page 198 2BrR TO PARKING INTERLOCK RELAY FOOT BRAKE SWITCH (WHEN NOT DEPRESS) TO COMBINATION METER PARKING BRAKE SWITCH (WHEN RELEASE BRAKE) FUSE BOX HEAT STARTER SWITCH TO STARTER MOTOR AV60 TO GLOW RELAY BATTERY RELAY 12V 80AH 95D31R BATTERY SV201-1-09002 9-021...

  • Page 199: Propulsion

    TROUBLESHOOTING 2-3. Propulsion Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. • Check any ground circuit which belongs to components to be checked. 2-3-1. Machine moves neither forward nor backward • Parking brake switch must be released. •...
  • Page 200 2BrR TO PARKING INTERLOCK RELAY FOOT BRAKE SWITCH (WHEN NOT DEPRESS) TO COMBINATION METER PARKING BRAKE SWITCH (WHEN RELEASE BRAKE) FUSE BOX HEAT STARTER SWITCH TO STARTER MOTOR AV60 TO GLOW RELAY BATTERY RELAY 12V 80AH 95D31R BATTERY SV201-1-09002 9-023...

  • Page 201: Brake Cannot Be Released

    TROUBLESHOOTING 2-3-2. Brake cannot be released • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). Reference Fig.: 2-3-1 Check point Check/Cause Action 1. Parking Brake Solenoid • Disconnect harness and measure resistance of coil. Replace parking brake Standard voltage : 12.3 Ω...
  • Page 202 2BrR TO PARKING INTERLOCK RELAY FOOT BRAKE SWITCH (WHEN NOT DEPRESS) TO COMBINATION METER PARKING BRAKE SWITCH (WHEN RELEASE BRAKE) FUSE BOX HEAT STARTER SWITCH TO STARTER MOTOR AV60 TO GLOW RELAY BATTERY RELAY 12V 80AH 95D31R BATTERY SV201-1-09002 9-025...

  • Page 203: Brake Does Not Work

    TROUBLESHOOTING 2-3-3. Brake does not work • Parking brake switch must be applied. • Foot brake switch must be OFF (Brake pedal is depressed). Reference Fig.: 2-3-1 Check point Check/Cause Action 1. Parking Brake Solenoid • Disconnect harness and measure resistance of coil. Replace parking brake Standard resistance : 12.3 Ω...
  • Page 204 VIBRATOR RELAY TO COMBINATION METER Br 11 VIBRATOR SOLENOID F-R LEVER VIBRATION VIBRATOR LAMP RELAY SWITCH VIBRATION MODE SELECT SWITCH FUSE BOX STARTER SWITCH HEAT TO STARTER MOTOR AV60 TO GLOW RELAY BATTERY RELAY 12V 80AH 95D31R BATTERY SV201-1-09003 9-027...

  • Page 205: Vibration

    TROUBLESHOOTING 2-4. Vibration Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. • Check any ground circuit which belongs to components to be checked. • Engine speed is higher than 1,800 min (rpm). 2-4-1.
  • Page 206 VIBRATOR RELAY TO COMBINATION METER Br 11 VIBRATOR SOLENOID F-R LEVER VIBRATION VIBRATOR LAMP RELAY SWITCH VIBRATION MODE SELECT SWITCH FUSE BOX STARTER SWITCH HEAT TO STARTER MOTOR AV60 TO GLOW RELAY BATTERY RELAY 12V 80AH 95D31R BATTERY SV201-1-09003 9-029...

  • Page 207: Vibration Mode Cannot Be Switched

    TROUBLESHOOTING 2-4-2. Vibration mode cannot be switched (F-R lever vibration switch does not work) • Vibration mode select switch must be “ ” (manual mode). Reference Fig. : 2-4-1 Check point Check/Cause Action 1. Vibration Mode Select (1) When starter switch is ON, measure voltage between Replace vibration mode Switch vibration mode select switch terminal 1 inlet wire RY...
  • Page 208 Charge warning indicator Hydraulic oil filter Engine oil pressure warning indicator warning Preheating indicator Hydraulic oil filter warning Lamp check Coolant temp. SEL.1 Coolant temp. SEL.2 System configuration diagram Note: The circuit in the dashed box is not mounted. SV201-1-09004 9-031...

  • Page 209: Lighting

    TROUBLESHOOTING 2-5. Lighting Check following items before troubleshooting. • No blown fuse and power is applied up to fuses. • When measuring voltage and current without disconnecting connectors, refer to “measuring voltage and current following using tester” (P. 9-006 to P. 9-008). •...
  • Page 210 Charge warning indicator Hydraulic oil filter Engine oil pressure warning indicator warning Preheating indicator Hydraulic oil filter warning Lamp check Coolant temp. SEL.1 Coolant temp. SEL.2 System configuration diagram Note: The circuit in the dashed box is not mounted. SV201-1-09004 9-033...

  • Page 211: Combination Meter Warning Lamp Or Indicator Lamp Is Abnormal

    TROUBLESHOOTING 2-5-2. Combination meter warning lamp or indicator lamp is abnormal Reference Fig. : 2-5-1 Check point Check/Cause Action 1. Harness • Measure resistance between alternator terminal L wire Repair or replace No. 32 wire BY and combination meter connector terminal harness.
  • Page 212 Charge warning indicator Hydraulic oil filter Engine oil pressure warning indicator warning Preheating indicator Hydraulic oil filter warning Lamp check Coolant temp. SEL.1 Coolant temp. SEL.2 System configuration diagram Note: The circuit in the dashed box is not mounted. SV201-1-09004 9-035...

  • Page 213: Tachometer Reading Is Abnormal

    TROUBLESHOOTING 2-5-3. Tachometer reading is abnormal Reference Fig. : 2-5-1 Check point Check/Cause Action 1. Combination Meter (1) When starter switch is ON, measure voltage between Replace tachometer (Tachometer) combination meter terminal wires and ground terminal sensor or combination wire. meter.
  • Page 214 Charge warning indicator Hydraulic oil filter Engine oil pressure warning indicator warning Preheating indicator Hydraulic oil filter warning Lamp check Coolant temp. SEL.1 Coolant temp. SEL.2 System configuration diagram Note: The circuit in the dashed box is not mounted. SV201-1-09004 9-037...

  • Page 215: Temperature Meter Is Abnormal

    TROUBLESHOOTING 2-5-5. Temperature meter is abnormal Reference Fig. : 2-5-1 Check point Check/Cause Action 1. Thermo Unit • Disconnect harness and measure resistance of thermo Replace thermo unit. unit. Standard resistance : 164.6 Ω [(at unit temperature of 50°C (122°F)] 22.29 Ω...
  • Page 216 Charge warning indicator Hydraulic oil filter Engine oil pressure warning indicator warning Preheating indicator Hydraulic oil filter warning Lamp check Coolant temp. SEL.1 Coolant temp. SEL.2 System configuration diagram Note: The circuit in the dashed box is not mounted. SV201-1-09004 9-039...

  • Page 217: Hydraulic Oil Filter Warning Lamp Remains On

    TROUBLESHOOTING 2-5-7. Hydraulic oil filter warning lamp remains ON Reference Fig. : 2-5-1 Check point Check/Cause Action 1. Hydraulic Oil Filter • When starter switch is OFF, check continuity between Replace hydraulic oil Switch hydraulic oil filter switch inlet terminal and chassis ground. filter switch.
  • Page 218 Engine oil pressure warning indicator warning Preheating indicator Hydraulic oil filter BATTERY warning RELAY 12V 80AH Lamp check 95D31R Coolant temp. SEL.1 BATTERY Coolant temp. SEL.2 System configuration diagram Note: The circuit in the dashed box is not mounted. SV201-1-09005 9-041...

  • Page 219: Vibration Indicator Lamp Does Not Light

    TROUBLESHOOTING 2-5-9. Vibration indicator lamp does not light • Check that vibrator can be operated. Reference Fig. : 2-5-2 Check point Check/Cause Action 1. Harness • Measure resistance between vibrator lamp relay terminal Repair or replace 5 wire Br and combination meter connector terminal wire harness.
  • Page 220 Engine oil pressure warning indicator warning Preheating indicator Hydraulic oil filter BATTERY warning RELAY 12V 80AH Lamp check 95D31R Coolant temp. SEL.1 BATTERY Coolant temp. SEL.2 System configuration diagram Note: The circuit in the dashed box is not mounted. SV201-1-09005 9-043...

  • Page 221: Parking Brake Indicator Lamp Does Not Light

    TROUBLESHOOTING 2-5-10. Parking brake indicator lamp does not light Reference Fig. : 2-5-2 Check point Check/Cause Action 1. Harness • Measure resistance between parking brake switch Repair or replace terminal 6 wire GL and combination meter connector harness. terminal wire No. 38 wire GL. Standard resistance : 10 Ω...
  • Page 222 Engine oil pressure warning indicator warning Preheating indicator Hydraulic oil filter BATTERY warning RELAY 12V 80AH Lamp check 95D31R Coolant temp. SEL.1 BATTERY Coolant temp. SEL.2 System configuration diagram Note: The circuit in the dashed box is not mounted. SV201-1-09005 9-045...

  • Page 223: Preheating Indicator Lamp Does Not Light

    TROUBLESHOOTING 2-5-11. Preheating indicator lamp does not light Reference Fig. : 2-5-2 Check point Check/Cause Action 1. Harness (1) Measure resistance between glow lamp timer terminal Repair or replace 6 wire Y and combination meter connector terminal wire harness. No. 27 wire Y. Standard resistance : 10 Ω...
  • Page 224 TROUBLESHOOTING Fig.: 2-5-3 BACKUP BUZZER SWITCH BACKUP BUZZER HORN HORN RELAY FUSE BOX STARTER SWITCH HEAT TO STARTER MOTOR AV60 TO GLOW RELAY BATTERY RELAY 12V 80AH 95D31R BATTERY SV201-1-09006 9-047...

  • Page 225: Horn Does Not Sound

    TROUBLESHOOTING 2-5-12. Horn does not sound Reference Fig. : 2-5-3 Check point Check/Cause Action 1. Horn • Disconnect horn and directly connect battery positive Replace horn. terminal to horn terminal wire Lg side and negative terminal to horn terminal wire B side. •...

  • Page 226: 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 227: 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 228: 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 11. Rear Axle Sticking of disc brakes causes brakes to Replace disc brakes. remain applied. 12. Flange Drive torque is not transmitted to pump due Replace flange. to faulty flange.

  • Page 229: 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 230: Abnormal Noise From Propulsion System

    TROUBLESHOOTING 3-2-6. Abnormal noise from propulsion system Check point Cause Check/Action 1. Axle Bearings Axle bearings supporting front drum are Replace axle bearings. damaged. 2. Gear Box Reduction gear of gear box is damaged. Replace reduction gear. 3. Rear Axle Rear axle gear is damaged.

  • Page 231: 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 232: 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. Vibrator Circuit Circuit does not obtain required pressure •...

  • Page 233: Abnormal Noise From Vibrator System

    TROUBLESHOOTING 3-3-5. Abnormal noise from vibrator system Check point Cause Check/Action 1. Vibrator Bearings Vibrator bearings supporting eccentric shaft Replace vibrator bearings. are damaged. 2. Hydraulic Hose Vibrator sound of hydraulic hose is Tighten bolts of loose hydraulic hose clamp Clamp generated because clamp securing to specified torque.

  • Page 234: 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 235: 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 236 TROUBLESHOOTING 3-5. Blade (SV201TB If a problem occurs in the blade control system, 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 237 TROUBLESHOOTING 3-5-3. Blade floating operation not possible Check point Cause Check/Action Stack Valve Blade floating operation is not possible If stack valve lever does not move, check because stack valve spool does not change. and clean spool, or replace stack valve. 3-5-4.
  • Page 238 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 © 2012 SAKAI HEAVY INDUSTRIES, LTD. All Rights Reserved. Printed in Japan 2012.11.50 ○ 0406-99004-0-30910-D...

This manual is also suitable for:

Sv201d-1Sv201t-1Sv201tf-1Sv201tb-1

Table of Contents