Sakai SW300-1 Shop Manual
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Sakai SW300-1 Shop Manual

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SHOP MANUAL
00̲Hyo1̲Intro̲Contents.indd   001
00̲Hyo1̲Intro̲Contents.indd   001
SW300
SW/TW320
TW/TW330
3498-64454-0
-1
-1
-1
2012/11/20   8:11:17
2012/11/20   8:11:17

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Summary of Contents for Sakai SW300-1

  • Page 1 SW300 SW/TW320 TW/TW330 SHOP MANUAL 3498-64454-0 00̲Hyo1̲Intro̲Contents.indd   001 00̲Hyo1̲Intro̲Contents.indd   001 2012/11/20   8:11:17 2012/11/20   8:11:17...
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  • 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.
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  • Page 5: Table Of Contents

    SW300 ○ CONTENTS 1. SAFETY 1. GENERAL SAFETY 1-1. Understanding the Safety Symbols and Words 1-001 1-2. General 1-001 1-3. Qualifi cations of Operators and Maintenance Personnel 1-002 1-4. Safety Practices and Policies 1-002 1-5. Pre Start Inspection 1-003 1-6. Safety Instructions 1-003 1-7.
  • Page 6 SW300 ○ 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. Installation of pump 3-006 4. HYDRAULIC SYSTEMS 1.
  • Page 7 SW300 ○ 4. STEERING SYSTEM 4-1. Steering Hydraulic Piping 4-022 4-2. Steering Wheel 4-023 4-3. Hydraulic Component Specifi cations 4-024 4-3-1. Steering charge pump 4-024 4-3-2. Orbitrol 4-025 4-4. Frame (Center Pin) 4-026 5. ELECTRICAL SYSTEM 1. SYSTEM CIRCUIT DIAGRAM 1-1.
  • Page 8 SW300 ○ 7. BRAKE 1. BRAKE PEDAL 7-001 2. BRAKE SYSTEM 7-002 2-1. SW types 7-002 2-2. TW types 7-003 8. SPRAY SYSTEMS 1. WATER SPRAY SYSTEM 8-001 1-1. Water Spray Piping (SW types) 8-001 1-2. Water Spray Piping (TW types) 8-002 2.
  • Page 9 SW300 ○ 8. MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE 8-1. Measurement 9-012 8-1-1. SW types: front and rear, TW types: front 9-012 8-1-2. TW types: rear 9-013 9. ADJUSTMENT OF THROTTLE LEVER LINKAGE 9-1. Adjustment 9-014 10. ADJUSTMENT OF F-R LEVER LINKAGE 10-1.
  • Page 10 SW300 ○ 2-5. Spray System 10-030 2-5-1. Water spray does not operate 10-030 2-5-2. Liquid spray does not operate (TW types) 10-032 2-6. Lighting 10-034 2-6-1. Head lamp does not light 10-034 2-6-2. Illumination of combination meter does not turn on 10-036 2-6-3.
  • Page 11 SW300 ○ 3-4. Steering System 10-061 3-4-1. Steering wheel is hard to turn 10-061 3-4-2. Steering response is slow 10-061 3-4-3. Steering wheel backlash or play is large 10-062 3-4-4. Steering system is overheating 10-062 3-4-5. Abnormal noise from steering system 10-062 00̲Hyo1̲Intro̲Contents.indd   011 00̲Hyo1̲Intro̲Contents.indd   011...
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  • Page 13: Safety

    SAFETY 01̲SAFETY̲P001-010.indd   1 01̲SAFETY̲P001-010.indd   1 2012/11/20   8:18:16 2012/11/20   8:18:16...
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  • 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: Qualifi Cations Of Operators And Maintenance Personnel

    SAFETY • The machine is designed specifi cally 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 fl ags, and warning devices, especially when parking in areas of heavy traffi c. 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 specifi ed fl uids 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.
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  • Page 23: Specifications

    SPECIFICATIONS 02̲SPECIFICATIONS̲P001-018.indd   1 02̲SPECIFICATIONS̲P001-018.indd   1 2012/11/05   13:56:37 2012/11/05   13:56:37...
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  • Page 26: Specification Data

    SPECIFICATIONS 1. SPECIFICATION DATA 1-1. SW300 1000 1950 1000 2650 0445-99012-0-10689-0 Model SW300 Operating weight 2,725 kg 6,010 lbs. Weight Front axle 1,315 kg 2,900 lbs. Rear axle 1,410 kg 3,110 lbs. Overall length 2,650 mm 104 in. Overall width 1,130 mm 44 in.
  • Page 27 SPECIFICATIONS Name KUBOTA D1703-M-ET01 Diesel Engine Water-cooled, 4-cycle, 3-cylinder, in-line, vertical mounted, Model overhead valve, swirl combustion chamber type Bore × Stroke 87.0 mm x 92.4 mm 3.425 in. x 3.638 in. ) Displacement 1.647 L 100.5 cu.in. Rated speed 2,800 min 2,800 rpm Rated output...

  • Page 28: Sw320

    SPECIFICATIONS 1-2. SW320 1200 1950 1200 2650 0445-99013-0-10690-0 Model SW320 Operating weight 2,890 kg 6,370 lbs. Weight Front axle 1,400 kg 3,085 lbs. Rear axle 1,490 kg 3,825 lbs. Overall length 2,650 mm 104 in. Overall width 1,330 mm 52 in. Overall height 1,750 mm 69 in.
  • Page 29 SPECIFICATIONS Name KUBOTA D1703-M-ET01 Diesel Engine Water-cooled, 4-cycle, 3-cylinder, in-line, vertical mounted, Model overhead valve, swirl combustion chamber type Bore × Stroke 87.0 mm x 92.4 mm 3.425 in. x 3.638 in. ) Displacement 1.647 L 100.5 cu.in. Rated speed 2,800 min 2,800 rpm Rated output...

  • Page 30: Sw330

    SPECIFICATIONS 1-3. SW330 1300 1950 1300 2650 0445-99014-0-10691-0 Model SW330 Operating weight 2,970 kg 6,550 lbs. Weight Front axle 1,440 kg 3,175 lbs. Rear axle 1,530 kg 3,375 lbs. Overall length 2,650 mm 104 in. Overall width 1,430 mm 56 in. Overall height 1,750 mm 69 in.
  • Page 31 SPECIFICATIONS Name KUBOTA D1703-M-ET01 Diesel Engine Water-cooled, 4-cycle, 3-cylinder, in-line, vertical mounted, Model overhead valve, swirl combustion chamber type Bore × Stroke 87.0 mm x 92.4 mm 3.425 in. x 3.638 in. ) Displacement 1.647 L 100.5 cu.in. Rated speed 2,800 min 2,800 rpm Rated output...

  • Page 32: Tw320

    SPECIFICATIONS 1-4. TW320 1200 1950 2645 0425-99008-0-10079-0 Model TW320 Operating weight 2,710 kg 5,975 lbs. Weight Front axle 1,410 kg 3,110 lbs. Rear axle 1,300 kg 2,865 lbs. Overall length 2,645 mm 104 in. Overall width 1,330 mm 52 in. Overall height 1,750 mm 69 in.
  • Page 33 SPECIFICATIONS Name KUBOTA D1703-M-ET01 Diesel Engine Water-cooled, 4-cycle, 3-cylinder, in-line, vertical mounted, Model overhead valve, swirl combustion chamber type Bore × Stroke 87.0 mm x 92.4 mm 3.425 in. x 3.638 in. ) Displacement 1.647 L 100.5 cu.in. Rated speed 2,800 min 2,800 rpm Rated output...

  • Page 34: Tw330

    SPECIFICATIONS 1-5. TW330 1300 1950 2645 0425-99009-0-10080-0 Model TW330 Operating weight 2,750 kg 6,060 lbs. Weight Front axle 1,450 kg 3,195 lbs. Rear axle 1,300 kg 2,865 lbs. Overall length 2,645 mm 104 in. Overall width 1,430 mm 56 in. Overall height 1,750 mm 69 in.
  • Page 35 SPECIFICATIONS Name KUBOTA D1703-M-ET01 Diesel Engine Water-cooled, 4-cycle, 3-cylinder, in-line, vertical mounted, Model overhead valve, swirl combustion chamber type Bore × Stroke 87.0 mm x 92.4 mm 3.425 in. x 3.638 in. ) Displacement 1.647 L 100.5 cu.in. Rated speed 2,800 min 2,800 rpm Rated output...

  • Page 36: Table Of Standard Values

    SPECIFICATIONS 2. TABLE OF STANDARD VALUES 2-1. Engine Item Standard value Remarks Engine model KUBOTA D1703-M-ET01 Diesel Engine Rated output 26.1/2,800 kW/min 35/2,800 HP/rpm ) Max. rpm under no load 3,000 rpm or less With fan, when net Min. rpm under no load 1,050 With fan, when net ±50...

  • Page 37: Hydraulic System

    SPECIFICATIONS 2-3. Hydraulic System Item Standard value Remarks High pressure relief valve setting 34.5 MPa ( 5,003 ±145 ±1.0 Cut off valve setting — Charge relief valve setting MPa ( 275.5 ±10.2 ± 0.07 Pump 0.3 MPa ( 43.5 Front SW types Case Rear...

  • Page 38: Brakes

    Bolt 3.5 mm (0.14 in.) Brake releasing condition Replacement standard brake stroke length Note 3 and Note 4: See dimensions Note 4 Brake stroke length = L2-L1 SW300-1-02001 2-6. Capacities Item Standard value Remarks Engine oil pan 7.0 L ( 1.8 gal.)

  • Page 39: 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 classifi cation Standards (5 to 86°F) (32 to 104°F) (59 to 131°F) Cold Moderate Tropical Engine oil API grade CD...

  • Page 40: 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 41: Engine And Controls

    ENGINE AND CONTROLS 03̲ENGINE̲AND̲CONTROLS.indb   1 03̲ENGINE̲AND̲CONTROLS.indb   1 2012/11/14   17:13:35 2012/11/14   17:13:35...
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  • Page 43: Engine

    ENGINE AND CONTROLS 1. ENGINE 1-1. Engine Mount VIEW B VIEW A 0445-01803-0-10600-A (1) Nut : M12 P=1.25 (7) Stopper (13) Bolt : M10×20 (2) Rubber isolator (8) Bolt : M12×30 P=1.25 (14) Bracket (3) Bolt : M12×30 (9) Engine (15) Bolt : M12×30 P=1.25 (4) Bolt...
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  • Page 45: Engine Exterior

    Oil pan Oil drain plug Cylinder head cover Exhaust manifold Fan pulley Alternator pulley Oil pressure switch Engine stop solenoid Thermostat Alternator Starter motor Oil level gauge Flywheel Oil filter Crank pulley Fan belt SW300-1-03002 3-002 03̲ENGINE̲AND̲CONTROLS.indb   3-002 03̲ENGINE̲AND̲CONTROLS.indb   3-002 2012/11/14   17:13:36 2012/11/14   17:13:36...
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  • Page 47: Control System

    ENGINE AND CONTROLS 2. CONTROL SYSTEM 2-1. Throttle Control IDLE FULL IDLE FULL VIEW A DETAIL B SECTION C-C (Control cable both sides) 0445-12805-0-10682-B (1) Control cable (10) Bolt : M 6×30 (2) Throttle lever (11) Disc spring (3) Lock nut : M 8 (12) Plug (4) Stopper bolt (IDLE)

  • Page 48: Forward-Reverse Control

    ENGINE AND CONTROLS 2-2. Forward-reverse Control SECTION A-A SECTION B-B VIEW C 0445-12806-0-10683-A (1) Shaft (9) Lock nut : M 8 (17) Lock nut : M12 (2) Rod end (10) Stopper bolt (forward) : M 8×25 (18) Spring (Fill grease*) (3) F-R lever (11) Friction plate (19) Steel ball...
  • Page 49 ENGINE AND CONTROLS 3. PUMP MOUNT 3-1. Pump Mount VIEW A 0445-36801-0-20029-B (1) Cover Coupling (2) Bolt : M10×40 P=1.25 Pump (3) Bolt : M 8×20 Bolt : M14×40 N•m (2) Bolt M10×40 P=1.25 : 49 N·m ( 36 lbf·ft ) (3) Bolt M 8×20 17 N·m ( 13 lbf·ft ) (6) Bolt M14×40...

  • Page 50: Installation Of Pump

    (6) Bolt M14×40 : 167 N·m (123 lbf·ft) N•m ④ Spline of pump subassembly is united with spline of SW300-1-03001 coupling and then secure pump subassembly to fl ywheel housing with seven bolts (2), spring washers and washers. (NOTICE) •...

  • Page 51: Hydraulic Systems

    HYDRAULIC SYSTEMS 04̲HYDRAULIC̲SYSTEMS.indb   1 04̲HYDRAULIC̲SYSTEMS.indb   1 2012/11/15   16:46:00 2012/11/15   16:46:00...
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  • Page 54: 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 55 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: fl...
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  • Page 57: Hydraulic Circuit Diagram

    HYDRAULIC SYSTEMS 1-2. Hydraulic Circuit Diagram 1-2-1. Hydraulic circuit diagram (SW types) Propulsion motor (Front) Drum (Front) Brake 1.5MPa release bolt cc/rev M10X25 Steering cylinder SW300 :1000 SW320 :1200 50X 25-220 SW330 :1300 (1/4") (1/2") Propulsion motor (Rear) 13MPa Drum (Rear) Orbitrol Brake 1.5MPa...
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  • Page 59: Hydraulic Circuit Diagram (Tw Types)

    HYDRAULIC SYSTEMS 1-2-2. Hydraulic circuit diagram (TW types) Propulsion motor (Front) Drum (Front) Brake 1.5MPa release cc/rev bolt M10X25 Steering cylinder 50X 25-220 TW320 :1200 (3/8") TW330 :1300 (3/8") (1/4") (1/4") (1/4") (1/2") Propulsion motor Propulsion motor (Rear, Right) (Rear, Left) 13MPa (3/8") (3/8")
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  • Page 61: Propulsion Hydraulic System

    HYDRAULIC SYSTEMS 2. PROPULSION HYDRAULIC SYSTEM 2-1. Propulsion Hydraulic Piping 2-1-1. Propulsion hydraulic piping (1) (SW types: main) Hose (FPR Hose Hose Hose (PAF (PAF (RD1 Hose Hose (PBF (PBF Hose Hose Hose (PBR (PAR Hose DETAIL B Hose (PBR (PAR Hose Hose...
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  • Page 63: Propulsion Hydraulic Piping (1) (Tw Types: Main)

    HYDRAULIC SYSTEMS 2-1-2. Propulsion hydraulic piping (1) (TW types: main) Hose Hose Hose (FPR (PC2 Hose (PBR FPB) Hose (PAF Hose (PAF Hose Hose (RPR (PBF (PBF Differential lock valve Hose Hose Hose (PBR FPB) (PAR DETAIL B SECTION A-A Hose (PBR FPB)
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  • Page 65: Propulsion Hydraulic Piping (2) (Sw/Tw Types: Front)

    HYDRAULIC SYSTEMS 2-1-3. Propulsion hydraulic piping (2) (SW/TW types: front) Hose Hose FMP) (FMD To propulsion Hose Hose hydraulic piping (1) FMA) FMB) (SW/TW types: main) Propulsion motor The letters and figures (such as FP and FMP) show each port and the arrow ( ) symbols show the hose connection and the direction of the flow of the oil.

  • Page 66: Propulsion Hydraulic Piping (3) (Sw Types: Rear)

    HYDRAULIC SYSTEMS 2-1-4. Propulsion hydraulic piping (3) (SW types: rear) Hose (RMD Hose RMB) To propulsion Hose hydraulic piping (1) RMA) (SW types: main) Hose RPR) Propulsion motor The letters and figures (such as RMD and RD) show each port and the arrow ( ) symbols show the hose connection and the direction of the flow of the oil.

  • Page 67: Propulsion Hydraulic Piping (3) (Tw Types: Rear)

    HYDRAULIC SYSTEMS 2-1-5. Propulsion hydraulic piping (3) (TW types: rear) Hose (LM3 RLP) To propulsion hydraulic piping (1) Hose (TW types: main) RLB) Hose (RLD LDR) Hose (TLA RLA) Propulsion motor (L) Propulsion motor (R) Hose (RM3 RRP) Hose RRA) Hose (RRD RDR)
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  • Page 70: Hydraulic Component Specifi Cations

    HYDRAULIC SYSTEMS 2-2. Hydraulic Component Specifi cations 2-2-1. Propulsion pump 1-10 1-11 1-14 1-13 1-12 VIEW A 1-9 1-5 1-14 Pump circuit diagram SW300-1-04005 4-010 04̲HYDRAULIC̲SYSTEMS.indb   4-010 04̲HYDRAULIC̲SYSTEMS.indb   4-010 2012/11/15   16:46:01 2012/11/15   16:46:01...
  • Page 71 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 1/16-12UN (1-5) High pressure gauge port (For port A) 9/16-18UNF (1-6) Port A (Forward)

  • Page 72: Propulsion Hydraulic Motor (Sw Types: Front And Rear, Tw Types: Front)

    HYDRAULIC SYSTEMS 2-2-2. Propulsion hydraulic motor (SW types: front and rear, TW types: front) Motor circuit diagram SW300-1-04001 (1) Motor (5) Port A [FMA] [RMA] : G1/2 (2) Parking brake pilot port : G1/4 (6) Parking brake pilot port [FMP] [RMP] : G1/4...

  • Page 73: Propulsion Hydraulic Motor (Tw Types: Rear)

    HYDRAULIC SYSTEMS 2-2-3. Propulsion hydraulic motor (TW types: rear) Motor circuit diagram SW300-1-04006 (1) Motor (5) Port A [RLA] [RRA] : G1/2 (2) Parking brake pilot port [RLP] : G1/4 (6) Parking brake pilot port [RRP] : G1/4 (3) Port B...

  • Page 74: Differential Lock Valve (Tw Types)

    HYDRAULIC SYSTEMS 2-2-4. Differential lock valve (TW types) VIEW A Hydraulic diagram SW300-1-04004 Body Port C [DC] : 9/16-18UNF Port A [DA] : 3/4-16UNF Orifi ce D Check valve BC Port B1 [B1] : 3/4-16UNF Port B2 [B2] : 3/4-16UNF Flow control valve A Specifi...

  • Page 75: Vibrator Hydraulic System

    HYDRAULIC SYSTEMS 3. VIBRATOR HYDRAULIC SYSTEM 3-1. Vibrator Hydraulic Piping 3-1-1. Vibrator hydraulic piping (1) (SW types: main) To vibrator hydraulic piping (3) (SW types: rear) Vibrator pump Hose (VAR VRB) Hose Hose (VAR VRB) (VAR VRB) Hose (VRD RD3) Hose (VRA SECTION B-B...
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  • Page 77: Vibrator Hydraulic Piping (1) (Tw Types: Main)

    HYDRAULIC SYSTEMS 3-1-2. Vibrator hydraulic piping (1) (TW types: main) Vibrator pump Hose (VO2 VBR) Hose Vibrator solenoid valve (VO1 VBF) (Front) DETAIL A Hose Hose VIN) (VTR To vibrator hydraulic piping (2) (SW/TW types: front) Hose Hose Hose in front : VO2 (VPF VFB) (VFA...
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  • Page 79: Vibrator Hydraulic Piping (2) (Sw/Tw Types: Front)

    HYDRAULIC SYSTEMS 3-1-3. Vibrator hydraulic piping (2) (SW/TW types: front) Hose Hose (FVA VFA) (VFB FVB) Hose (FVD VFD) To vibrator hydraulic piping (1) (SW types: main) Vibrator motor (Front) The letters and figures (such as FVA and FVB) show each port and the arrow ( ) symbols show the hose connection and the direction of the flow of the oil.

  • Page 80: Vibrator Hydraulic Piping (3) (Sw Types: Rear)

    HYDRAULIC SYSTEMS 3-1-4. Vibrator hydraulic piping (3) (SW types: rear) Hose (RVD VRD) Hose (RVA VRA) To vibrator Hose hydraulic (VRB RVB) piping (1) (SW types: main) Vibrator motor (Rear) The letters and figures (such as RVA and RVB) show each port and the arrow ( ) symbols show the hose connection and the direction of the flow of the oil.

  • Page 81: Hydraulic Component Specifi Cations

    HYDRAULIC SYSTEMS 3-2. Hydraulic Component Specifi cations 3-2-1. Vibrator pump VIEW A Hydraulic circuit diagram SW300-1-04007 (1) Inlet port [VIN] : G1 (2) No.2 outlet port [VO2] : G1/2 (3) No.1 outlet port [VO1] : G1/2 Specifi cations • Displacement (No.1 pump) : 12.5 cm...

  • Page 82: Vibrator Hydraulic Motor

    HYDRAULIC SYSTEMS 3-2-2. Vibrator hydraulic motor VIEW A VIEW B cc/rev Hydraulic circuit diagram SW300-1-04002 (1) Drain port [FVD] [RVD] : 9/16-18UNF (2) Port A [FVA] [RVA] : 7/8-14UNF (3) Port B [FVB] [RVB] : 7/8-14UNF Specifi cations • Displacement 8.4 cm...

  • Page 83: Vibrator Solenoid Valve

    HYDRAULIC SYSTEMS 3-2-3. Vibrator solenoid valve Hydraulic circuit diagram SW300-1-04003 (1) Port B [VBF] [VBR] : G3/4 (2) Solenoid valve (3) Body (4) Port A [VAR] : G3/4 (5) Port T [VTF] [VTR] : G3/4 (6) Port P [VPF] : G3/4 Specifi...
  • Page 84 04̲HYDRAULIC̲SYSTEMS.indb   36 04̲HYDRAULIC̲SYSTEMS.indb   36 2012/11/15   16:46:03 2012/11/15   16:46:03...
  • Page 85 HYDRAULIC SYSTEMS 4. STEERING SYSTEM Hose Hose (SPO 4-1. Steering Hydraulic Piping Hose Hose (SPO Orbitrol DETAIL A SECTION B-B Hose Hydraulic oil tank SPS) Hose Hose Hydraulic filter Steering charge pump Steering cylinder Suction filter Hose Hose The letters and figures (such as SPO and SP) show each port and the arrow ( ) symbols show the hose connection and the direction of the flow of the oil.
  • Page 86 04̲HYDRAULIC̲SYSTEMS.indb   38 04̲HYDRAULIC̲SYSTEMS.indb   38 2012/11/15   16:46:03 2012/11/15   16:46:03...
  • Page 87 HYDRAULIC SYSTEMS 4-2. Steering Wheel 0446-32803-0-20620-0 (1) Nut : M12 P=1.25 (4) Bolt : M10×35 (2) Steering wheel (5) Orbitrol (3) Column shaft N•m (1) Nut M12 P=1.25 : 64 N·m ( 47 lbf·ft ) (4) Bolt M10×35 : 39 N·m ( 29 lbf·ft ) •...
  • Page 88 HYDRAULIC SYSTEMS 4-3. Hydraulic Component Specifi cations 4-3-1. Steering charge pump SW300-1-04008 (1) Inlet port [SPS] : Ø28 pipe (2) Outlet port [SPO] : Ø15 hole Specifi cations • Theoretical discharge 8.14 cm /rev ( 0.5 cu.in./rev ) • Maximum pressure 14.7 MPa...
  • Page 89 HYDRAULIC SYSTEMS 4-3-2. Orbitrol Hydraulic circuit diagram SW300-1-04009 (1) Port L : 3/4-16UNF (2) Port R : 3/4-16UNF (3) Port P : 3/4-16UNF (4) Port T : 3/4-16UNF (5) Relief valve Specifi cations • Displacement 96 cm /rev ( 5.9 cu.in./rev ) •...
  • Page 90 HYDRAULIC SYSTEMS 4-4. Frame (Center Pin) 0445-61801-0-10043-B (1) Bolt : M16×60 (4) Swing bearing (7) Cover (2) Bolt : M16×60 (5) Ball bearing (8) Bracket (lower) (3) Bolt : M16×50 (6) Bracket (upper) N•m Bolt M16×60 : 265 N·m ( 195 lbf·ft ) Bolt M16×60 : 265 N·m ( 195 lbf·ft ) Bolt M16×50...
  • Page 91 ELECTRICAL SYSTEM 05̲ELECTRICAL̲SYSTEM.indb   1 05̲ELECTRICAL̲SYSTEM.indb   1 2012/11/14   17:58:11 2012/11/14   17:58:11...
  • Page 92 05̲ELECTRICAL̲SYSTEM.indb   2 05̲ELECTRICAL̲SYSTEM.indb   2 2012/11/14   17:58:11 2012/11/14   17:58:11...
  • Page 93 ELECTRICAL SYSTEM 1. SYSTEM CIRCUIT DIAGRAM 1-1. Electrical Circuit Diagram (SW types) (OPTION) HEAD LAMP (R) (OPTION) TURN SIGNAL LAMP (R) (55W) (20W) HEAD LAMP (L) FLOOD LAMP (R) (55W) (55W) BACKUP F-R LEVER LIGHTING BUZZER TURN SIGNAL LAMP (L) SWITCH (20W) WATER SPRAY...
  • Page 94 05̲ELECTRICAL̲SYSTEM.indb   4 05̲ELECTRICAL̲SYSTEM.indb   4 2012/11/14   17:58:12 2012/11/14   17:58:12...
  • Page 95 ELECTRICAL SYSTEM 1-2. Electrical Circuit Diagram (TW types) (OPTION) HEAD LAMP (R) TURN SIGNAL LAMP (R) (OPTION) (55W) (20W) LIQUID LIQUID SPRAY SPRAY SWITCH HEAD LAMP (L) PUMP FLOOD LAMP (R) (55W) (55W) BACKUP 1.25BrW F-R LEVER LIGHTING BUZZER SWITCH TURN SIGNAL LAMP (L) (20W) FLOOD LAMP (L) (55W)
  • Page 96 05̲ELECTRICAL̲SYSTEM.indb   6 05̲ELECTRICAL̲SYSTEM.indb   6 2012/11/14   17:58:12 2012/11/14   17:58:12...
  • Page 97 ELECTRICAL SYSTEM 2. ELECTRICAL COMPONENTS 2-1. Electrical Component Layout Liquid spray pump Combination meter Parking brake switch Oil pressure switch (TW types only) Battery relay Battery Starter motor Thermo unit Fuel pump Backup buzzer Liquid spray switch Alternator (TW types only) Head lamp (R) AUTO Vibration mode select switch...
  • Page 98 05̲ELECTRICAL̲SYSTEM.indb   8 05̲ELECTRICAL̲SYSTEM.indb   8 2012/11/14   17:58:12 2012/11/14   17:58:12...
  • Page 99 Foot brake switch Water spray relay Water spray mode Interlock relay select switch (option) Starter switch Battery relay Battery relay SW300-1-05002 Harness color codes : White RY : Red/Yellow stripe : Red RG : Red/Green stripe : Green RL : Red/Blue stripe...
  • Page 100 Lamp check of connecting surfaces on the Coolant temp. SEL.1 connector side. Coolant temp. SEL.2 Wire number System configuration diagram Wire color Note: The circuit in the dashed box is not mounted. SW300-1-05004 5-005 05̲ELECTRICAL̲SYSTEM.indb   5-005 05̲ELECTRICAL̲SYSTEM.indb   5-005 2012/11/14   17:58:12 2012/11/14   17:58:12...
  • Page 101 VIBRATORY DRUM · REAR WHEEL 06̲VIBRATORY̲DRUM.indb   1 06̲VIBRATORY̲DRUM.indb   1 2012/11/20   8:26:03 2012/11/20   8:26:03...
  • Page 102 06̲VIBRATORY̲DRUM.indb   2 06̲VIBRATORY̲DRUM.indb   2 2012/11/20   8:26:03 2012/11/20   8:26:03...
  • Page 103 VIBRATORY DRUM · REAR WHEEL 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 104 VIBRATORY DRUM · REAR WHEEL 3) Precautions when work is completed • If coolant has been drained, securely retighten the drain cock and fi ll with coolant (mixing in long- life coolant) to the specifi ed level. Start the engine and allow the coolant to circulate through the piping.
  • Page 105 VIBRATORY DRUM · REAR WHEEL 2. VIBRATORY DRUM 2-1. Removal and Installation of Vibratory Drum • Hold vibratory drum with chocks. Chock Chock SW300-1-06001 • Lock front and rear frames with lock pin (1). SW300-1-06002 6-003 06̲VIBRATORY̲DRUM.indb   6-003 06̲VIBRATORY̲DRUM.indb   6-003 2012/11/20   8:26:03 2012/11/20   8:26:03...
  • Page 106 (NOTICE) • Plug both ends of the disconnected hoses or implement other actions to prevent entry of foreign matter. SW300-1-06003 1-2) Vibrator motor piping • Remove bolts (9). • Remove clamp (8). • Disconnect hydraulic hoses (10), (11) and (12) connecting to vibrator motor.
  • Page 107 : 1,450 kg (3,195 lbs.) • Flip up scraper blades (13) and (15). • Remove bolts (14) (left and right sides). Support stand SW300-1-06005 Lift with crane. 3) Removal of vibratory drum • Lift left plate (18), right plate (19) and hold them.
  • Page 108 (NOTICE) • Plug both ends of the disconnected hoses or implement other actions to prevent entry of foreign matter. SW300-1-06009 1-2) Vibrator motor piping • Remove bolts (27). • Remove clamp (26). • Disconnect hydraulic hoses (28), (29) and (30) connecting to vibrator motor.
  • Page 109 : 1,530 kg (3,375 lbs.) • Flip up scraper blades (31) and (33). • Remove bolts (32) (left and right sides). Support stand SW300-1-06011 3) Removal of vibratory drum Lift with crane. • Lift left plate (35), right plate (36) and hold them.
  • Page 110 • Hold vibratory drum (39) with chocks. • Remove nuts (38). • Remove plate (19), (35). (37) Plate : 45 kg (99 lbs.) Chock SW300-1-06007 2) Removal of vibrator motor side plate Lift with crane. 18, 36 • Remove nuts (41).
  • Page 111 VIBRATORY DRUM · REAR WHEEL 2-1-4. Installation of vibratory drum 1) Install vibratory drum in reverse order in which it was removed. • Tightening torque for bolts where particular care is required when installing vibratory drum. Bolt M 8 x 12 : 23 N·m ( 17 lbf·ft) N•m Bolt M 8 x 12 : 23 N·m ( 17 lbf·ft) (14) Bolt M16 x 60 : 265 N·m (195 lbf·ft) SW300...
  • Page 112 06̲VIBRATORY̲DRUM.indb   12 06̲VIBRATORY̲DRUM.indb   12 2012/11/20   8:26:04 2012/11/20   8:26:04...
  • Page 113 VIBRATORY DRUM · REAR WHEEL 3. VIBRATORY DRUM ASSY (1) O-ring 3-1. Vibratory Drum ASSY (2) Holder (3) O-ring (4) Vibrator bearing (5) Eccentric shaft (6) Drum (7) Vibrator bearing (8) Boss (9) O-ring (10) Bolt : M16x40 (11) Plug (12) Collar SW/TW320 SW/TW330...
  • Page 114 06̲VIBRATORY̲DRUM.indb   14 06̲VIBRATORY̲DRUM.indb   14 2012/11/20   8:26:04 2012/11/20   8:26:04...
  • Page 115 Vibratory drum ASSY SW300 : 515 kg (1,135 lbs.) SW/TW320 : 585 kg (1,290 lbs.) SW/TW330 : 615 kg (1,356 lbs.) Chock SW300-1-06013 2) Remove plugs (11-1) and (11-3). Supply • Drain gear oil. port 11-1 • Quantity of gear oil SW300 : 2.5 L (0.7 gal.)
  • Page 116 VIBRATORY DRUM · REAR WHEEL 4) Remove adapters. Adapter SW300-1-06016 5) Remove bolts (43). • Remove vibrator motor (45). • Remove breather (16). (45) Vibrator motor : 3 kg (7 lbs.) SW300-1-06017 6) Remove sleeve (21). SW300-1-06018 6-012 06̲VIBRATORY̲DRUM.indb   6-012 06̲VIBRATORY̲DRUM.indb   6-012 2012/11/20   8:26:04...
  • Page 117 VIBRATORY DRUM · REAR WHEEL 7) Remove bolts (25). SW300-1-06019 8) Lift cover (26) using two pulling bolts (M10×40). • Remove cover (26). Pulling bolt SW300-1-06020 9) Remove bolts (17). • Remove dampers (19). SW300-1-06021 6-013 06̲VIBRATORY̲DRUM.indb   6-013 06̲VIBRATORY̲DRUM.indb   6-013 2012/11/20   8:26:04 2012/11/20   8:26:04...
  • Page 118 VIBRATORY DRUM · REAR WHEEL 10) Remove bolts (23). • Remove cover (24). • Remove shim (28). SW300-1-06022 11) Put a piece of wooden board on end of boss (8). Wooden board Puller • Set a puller on disc (29).
  • Page 119 13) Lift disc SUBASSY with roller bearing from boss Disc SUBASSY SUBASSY. Boss Disc SUBASSY : 25 kg (55 lbs.) SUBASSY SW300-1-06025 14) Remove bolts (10). SW300-1-06026 15) Lift boss SUBASSY using two pulling bolts (M16×40). Pulling bolt SW300-1-06027 6-015 06̲VIBRATORY̲DRUM.indb   6-015...
  • Page 120 VIBRATORY DRUM · REAR WHEEL 16) Install lifting bolts (M16) to boss SUBASSY. Lifting bolt SW300-1-06028 Wooden Wooden 17) Remove boss SUBASSY. hammer (NOTICE) • In order not to lift eccentric shaft together with boss SUBASSY, tap on the shaft end with a wooden hammer via a wooden bar during lifting.
  • Page 121 : 15 kg (33 lbs.) SW/TW320 : 20 kg (44 lbs.) SW/TW330 : 20 kg (44 lbs.) SW300-1-06031 WA RNING Be careful because reversing the drum involves risk. Drum Confi rm that the surrounding area is safe, and work in a SUBASSY natural, unstrained posture.
  • Page 122 VIBRATORY DRUM · REAR WHEEL 22) Lift disc SUBASSY. Disc • Remove bolts (39). SUBASSY SW300-1-06034 23) Remove disc SUBASSY. Disc SUBASSY : 20 kg (44 lbs.). Disc SUBASSY SW300-1-06035 24) Install lifting bolts (M16) to propulsion motor (44). Lifting bolt •...
  • Page 123 VIBRATORY DRUM · REAR WHEEL 25) Remove propulsion motor (44). (44) Propulsion motor : 45 kg (99 lbs.) SW300-1-06037 26) Remove bolts (32). SW300-1-06038 27) Lift holder SUBASSY using two pulling bolts (M16×40). Holder SUBASSY Pulling bolt • Remove holder SUBASSY.
  • Page 124 VIBRATORY DRUM · REAR WHEEL 28) Install lifting bolts (M16) to holder SUBASSY. Holder SUBASSY Lifting bolt SW300-1-06040 29) Remove holder SUBASSY from drum. Holder • Remove vibrator bearing (4). SUBASSY Holder SUBASSY : 20 kg (44 lbs.) SW300-1-06041 6-020 06̲VIBRATORY̲DRUM.indb   6-020...
  • Page 125 : 435 kg (959 lbs.) (NOTICE) • Direction with tapping hole (M12) is propulsion motor side. SW300-1-06042 2) Reassembly of holder SUBASSY 2-1) Apply a coat of gear oil to holder (2) at where bearing will be press-fi tted. • Drive in vibrator bearing (4).
  • Page 126 VIBRATORY DRUM · REAR WHEEL 2-2) Apply grease to O-ring (3). • Install O-ring (3) to holder SUBASSY. Holder SUBASSY SW300-1-06044 3) Reverse holder SUBASSY. Holder SUBASSY : 20 kg (44 lbs.) SW300-1-06094 WARN ING When installing lifting bolts, screw in the threads fully Holder before using.
  • Page 127 Holder SUBASSY Holder SUBASSY : 20 kg (44 lbs.) (NOTICE) • Take care not to let O-ring to protrude from its groove. SW300-1-06046 5) Secure holder SUBASSY with eight bolts (32) and Holder washers. SUBASSY (32) Bolts M16×40 : 265 N·m (195 lbf·ft) N•m...
  • Page 128 VIBRATORY DRUM · REAR WHEEL 7) Apply grease to O-ring (1). • Install O-ring (1) to propulsion motor (44). SW300-1-06049 8) Lower propulsion motor (44) on mounting surface of holder SUBASSY. (44) Propulsion motor : 45 kg (99 lbs.) SW300-1-06096 9) Secure propulsion motor (44) with six bolts (33) and washers.
  • Page 129 VIBRATORY DRUM · REAR WHEEL 10) Lift disc SUBASSY. Disc SUBASSY SW300-1-06051 11) Lower disc SUBASSY on mounting surface of propulsion motor (44). Disc SUBASSY : 20 kg (44 lbs.) Disc SUBASSY SW300-1-06095 (NOTICE) • The longer direction of the disc must be parallel with the side of the propulsion motor port A.
  • Page 130 VIBRATORY DRUM · REAR WHEEL 12) Secure disc SUBASSY with six bolts (35) and washers. Disc (35) Bolt M16×40 : 265 N·m (195 lbf·ft) N•m SUBASSY SW300-1-06053 13) Apply grease to O-rings for adapters. • Install adapters. Adapter SW300-1-06033 WARN ING...
  • Page 131 VIBRATORY DRUM · REAR WHEEL 15) Install a lifting bolt (M5) to end of eccentric shaft (5). Lifting bolt SW300-1-06055 16) Apply a coat of gear oil to eccentric shaft (5) at where bearing will be installed. • Lower eccentric shaft (5).
  • Page 132 18) Reassembly of boss SUBASSY 18-1) Apply a coat of gear oil to boss (8) at where bearing will be press-fi tted. • Drive in vibrator bearing (7). Wooden block SW300-1-06057 18-2) Reverse boss SUBASSY. Boss SUBASSY : 25 kg (55 lbs.) Boss SUBASSY...
  • Page 133 VIBRATORY DRUM · REAR WHEEL 18-4) Apply grease to O-rings for plugs (11). • Install plugs (11). SW300-1-06060 19) Install lifting bolts (M16) to boss SUBASSY. Lifting bolt SW300-1-06061 20) Lift boss SUBASSY. • Apply grease to O-ring (9). • Install O-ring (9) to boss SUBASSY.
  • Page 134 (NOTICE) • Support shaft (5) with a pipe or the like, to prevent tilting of vibrator bearing inner race during installation. SW300-1-06063 22) Secure boss SUBASSY with eight bolts (10) and washers. Boss SUBASSY (10) Bolts M16×40 : 265 N·m (195 lbf·ft) N•m...
  • Page 135 24) Slowly lift shaft (5) with a crane and check that there is an axial play of 2 to 4 mm (0.08 to 0.16 in.). SW300-1-06066 25) Apply a coat of gear oil to disc (29) at where bearing outer races will be press-fi...
  • Page 136 SUBASSY of roller bearing (15) inner race. Disc SUBASSY : 25 kg (55 lbs.) SW300-1-06069 28) Apply suffi cient amount of lithium-based grease to rollers of roller bearing (15) inner race. • Drive in roller bearing (15) inner race until rollers come in Outer race contact with outer race.
  • Page 137 fl uctuates. (NOTICE) • Tighten bolts alternately in diagonal directions. Boss SUBASSY SW300-1-06072 (NOTICE) • It is necessary to rotate the bearing to lift the rollers while pressing in the inner race. Otherwise the End of rollers in close...
  • Page 138 VIBRATORY DRUM · REAR WHEEL ④ Without inserting shim, install cover (24) to boss SUBASSY with three bolts (23) and washers. Boss SUBASSY SW300-1-06074 ⑤ Using a thickness gauge, measure clearance “A”. ★ Preload adjusting = A + 0.1 mm (0.04 in.) shim thickness SW300-1-06075 ⑥...
  • Page 139 (23) Bolts M8×25 : 31 N·m (23 lbf·ft) N•m Boss SUBASSY SW300-1-06099 30) Apply grease to O-ring (18). • Install O-ring (18) to cover (26). SW300-1-06077 31) Secure cover (26) to disc SUBASSY with six bolts (25) and spring washers.
  • Page 140 32) Secure two dampers (19) to disc SUBASSY with four bolts (17) and washers. (17) Bolts M16×40 : 265 N·m (195 lbf·ft) N•m SW300-1-06079 33) Drive two spring pins (22) into sleeve (21). SW300-1-06080 34) Apply molybdenum-based grease to splined portion of sleeve (21).
  • Page 141 VIBRATORY DRUM · REAR WHEEL 35) Apply grease to O-ring (18). • Install O-ring to vibrator motor (45). SW300-1-06082 36) Wind seal tape around threaded portion of breather (16). • Install breather (16) to cover (26). • Secure vibrator motor (45) to cover (26) with two bolts (43) and washers.
  • Page 142 : 580 kg (1,279 lbs.) SW/TW330 : 610 kg (1,345 lbs.) 11-2 11-3 Chock SW300-1-06013 39) Remove plugs (11-1) and (11-2). 11-1 Supply • Supply gear oil from oil supply port. port • Check that oil drips from gauge port.
  • Page 143 VIBRATORY DRUM · REAR WHEEL 4. REAR AXLE 4-1. Rear Axle ASSY (TW Types) 7, 8 21 20 15,16 SW300-1-06097 (1) Adapter (11) Adapter (21) Hose (2) Hose (12) Bolt : M14×50 (22) Bolt : M20×80 (3) Hose (13) Hose...
  • Page 144 VIBRATORY DRUM · REAR WHEEL 4-2. Removal and Installation of Rear Axle (TW Types) • Hold vibratory drum with chocks. Chock SW300-1-06087 • Lock front and rear frames with lock pin (1). SW300-1-06002 6-040 06̲VIBRATORY̲DRUM.indb   6-040 06̲VIBRATORY̲DRUM.indb   6-040 2012/11/20   8:26:07 2012/11/20   8:26:07...
  • Page 145 • Place support stands under frame when tires are slightly off ground to support machine body. • Flip up scraper blade. Rear axle TW320 : 1,430 kg (3,155 lbs.) TW330 : 1,430 kg (3,155 lbs.) Support stand SW300-1-06088 2) Remove bolts (12). SW300-1-06089 6-041 06̲VIBRATORY̲DRUM.indb   6-041 06̲VIBRATORY̲DRUM.indb   6-041 2012/11/20   8:26:07 2012/11/20   8:26:07...
  • Page 146 • Wheel SUBASSY of right side is also removed in the same procedure. Wheel SUBASSY SW300-1-06090 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 147 VIBRATORY DRUM · REAR WHEEL • Disconnect hydraulic hoses (2), (3), (4) and (5) connecting to rear propulsion motor. SW300-1-06100 5) Hold up propulsion motor SUBASSY with forklift. • Remove bolts (22). • Remove propulsion motor SUBASSY. Propulsion motor SUBASSY : 125 kg (276 lbs.)
  • Page 148 VIBRATORY DRUM · REAR WHEEL 4-2-2. Installation of rear axle 1) Install rear axle in reverse order in which it was removed. • Tightening torque for bolts where particular care is required when installing rear axle. (12) Bolt M14x50 : 167 N·m (123 lbf·ft) N•m (22) Bolt M20x80 : 265 N·m (195 lbf·ft) 2) Upon installing rear axle, pay particular attention to items...
  • Page 149 BRAKE 07̲BRAKE̲P000̲002.indd   7 07̲BRAKE̲P000̲002.indd   7 2012/10/05   9:39:43 2012/10/05   9:39:43...
  • Page 150 07̲BRAKE̲P000̲002.indd   7-008 07̲BRAKE̲P000̲002.indd   7-008 2012/10/05   9:39:44 2012/10/05   9:39:44...
  • Page 151 BRAKE 1. BRAKE PEDAL VIEW A 0445-51803-0-10686-0 (1) Rod (8) Nut : M10 P=1.25 (2) Nut : M10 (9) F-R lever (3) Rod end (10) Shaft (4) Brake pedal (11) Return spring (5) Nut : M10 P=1.25 (12) Ball (Apply lithium-based grease) (6) Bolt with rubber : M10×25 P=1.25 (13) Foot brake switch...
  • Page 152 ON. (without solenoid excited) Parking brake solenoid when brake is OFF. (with solenoid excited) Steering charge pump (On engine) The arrow ( ) symbol shows the direction of the hydraulic oil flow. SW300-1-07002 7-002 07̲BRAKE̲P000̲002.indd   7-002 07̲BRAKE̲P000̲002.indd   7-002 2012/10/05   9:39:44 2012/10/05   9:39:44...
  • Page 153 BRAKE 2-2. TW types Foot brake switch Brake Propulsion (Brake ON motor (Condition in which condition) (R. R) brake pedal pressed) To combination meter Parking brake switch (Brake OFF condition) Brake Propulsion Brake Propulsion (Brake ON motor (F) (Brake ON motor condition) condition)
  • Page 154 07̲BRAKE̲P000̲002.indd   7-004 07̲BRAKE̲P000̲002.indd   7-004 2012/10/05   9:39:44 2012/10/05   9:39:44...
  • Page 155 SPRAY SYSTEMS 08̲SPRAY̲SYSTEMS.indb   1 08̲SPRAY̲SYSTEMS.indb   1 2012/10/17   10:41:15 2012/10/17   10:41:15...
  • Page 156 08̲SPRAY̲SYSTEMS.indb   2 08̲SPRAY̲SYSTEMS.indb   2 2012/10/17   10:41:15 2012/10/17   10:41:15...
  • Page 157 SPRAY SYSTEMS 1. WATER SPRAY SYSTEM 1-1. Water Spray Piping (SW types) Water spray pipe (F) Hose Hose Filler cap Gauge (Tee 2 Water spray pipe (F)) (Water spray tank  3-Way valve (Filter IN)) Tee 1 Drain valve Filter Check valve Tee 1 IN OUT Drain...
  • Page 158 08̲SPRAY̲SYSTEMS.indb   4 08̲SPRAY̲SYSTEMS.indb   4 2012/10/17   10:41:16 2012/10/17   10:41:16...
  • Page 159 SPRAY SYSTEMS 1-2. Water Spray Piping (TW types) Water spray pipe (F) Hose Hose Filler cap Gauge (Tee 2 Water spray pipe (F)) (Water spray tank  3-Way valve (Filter IN)) Stop valve Filter Tee 1 Tee 1 Check valve Drain valve Water spray IN OUT...
  • Page 160 08̲SPRAY̲SYSTEMS.indb   6 08̲SPRAY̲SYSTEMS.indb   6 2012/10/17   10:41:16 2012/10/17   10:41:16...
  • Page 161 SPRAY SYSTEMS 2. LIQUID SPRAY SYSTEM (TW TYPES) Hose Liquid spray pump (Liquid spray pipe  Liquid spray tank) Hose Valve Hose Hose Filler cap Hose (Filter OUT   Liquid spray (Liquid spray pump OUT   Liquid spray pipe) (Filter OUT   Liquid spray pump IN) (Liquid spray pump OUT  ...
  • Page 162 08̲SPRAY̲SYSTEMS.indb   8 08̲SPRAY̲SYSTEMS.indb   8 2012/10/17   10:41:16 2012/10/17   10:41:16...
  • Page 163 INSPECTION AND ADJUSTMENT 09̲INSPECTION̲AND̲ADJUSTMENT.indd   1 09̲INSPECTION̲AND̲ADJUSTMENT.indd   1 2012/11/14   20:03:04 2012/11/14   20:03:04...
  • Page 164 09̲INSPECTION̲AND̲ADJUSTMENT.indd   2 09̲INSPECTION̲AND̲ADJUSTMENT.indd   2 2012/11/14   20:03:04 2012/11/14   20:03:04...
  • Page 165 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, fl at ground. •...
  • Page 166 ③ Establish a condition in which machine propulsion load becomes maximum. (Pressure does not build up unless propulsion load is applied.) SW300-1-09009 ④ With propulsion load at maximum, slowly move F-R lever to the side to be measured. • Then, read pressure indicated by pressure gauge.
  • Page 167 ③ If trapped dirt is present, disassemble and clean high pressure relief and bypass valves. ④ If pressure still deviates from maximum circuit pressure SW300-1-09023 range after valve is disassembled and cleaned, replace high pressure relief and bypass valves. ⑤ After inspection, measure pressure again and check that pressure reaches maximum circuit pressure range.
  • Page 168 : 9/16-18UNF • Pressure gauge : 0 to 5 MPa (0 to 725 psi) ② Apply parking brake by pressing parking brake switch SW300-1-09011 button. ③ Start the engine and set throttle lever to “Full”. ④ Check that F-R lever is in “N”.
  • Page 169 • To adjust pressure, loosen nut and turn adjustment screw (2). Adjustment screw turned clockwise 1-13 : Pressure rise SW300-1-09026 Adjustment screw turned counterclockwise : Pressure drop Pressure change rate : 0.19 MPa/turn (27.6 psi/turn) ③ If there is no evidence of nut having loosened, remove charge relief valve.
  • Page 170 ④ Start the engine and set throttle lever to “Full”. ⑤ Release parking brake by pressing parking brake switch button. • Then, read brake release pressure indicated by pressure gauge. SW300-1-09013 ★ Brake release pressure : More than 1.5 MPa (218 psi) PG002002 9-006 09̲INSPECTION̲AND̲ADJUSTMENT.indd   9-006...
  • Page 171 ④ Start the engine and set throttle lever to “Full”. ⑤ Release parking brake by pressing parking brake switch button. • Then, read brake release pressure indicated by pressure Left side gauge. SW300-1-09014 ★ Brake release pressure : More than 1.5 MPa (218 psi) Right side SW300-1-09015 PG002002 9-007 09̲INSPECTION̲AND̲ADJUSTMENT.indd   9-007...
  • Page 172 ⑤ Keep pressing F-R lever vibration switch (ON). • Then, read pressure indicated by pressure gauge. ⑥ Release F-R lever vibration switch (OFF) as soon as measurement is finished. SW300-1-09020 ★ Maximum circuit pressure (relief valve pressure setting) : 12.7...
  • Page 173 ④ Turn steering wheel to operate relief valve. • Then, read pressure indicated by pressure gauge. ★ Standard maximum circuit pressure (orbitroll relief pressure + charge relief pressure) : 14.9 MPa (2,161 psi) ± 1.0 ± 145 SW300-1-09006 PG002003 9-009 09̲INSPECTION̲AND̲ADJUSTMENT.indd   9-009 09̲INSPECTION̲AND̲ADJUSTMENT.indd   9-009 2012/11/14   20:03:05 2012/11/14   20:03:05...
  • Page 174 ④ If a scratch or any other abnormality is found on seat, replace relief valve. ⑤ After inspection, measure pressure again and check that pressure reaches standard maximum circuit pressure range. SW300-1-09007 (NOTICE) • Carefully disassemble and reassemble after taking steps to prevent foreign material from getting in. 9-010 09̲INSPECTION̲AND̲ADJUSTMENT.indd   9-010...
  • Page 175 F-R lever is in “N”, “F”, and “R”, respectively. 1-14 ★ Pump case pressure : 0.25 MPa (36.3 psi) or less SW300-1-09025 PG001027 • The number “1-14” appearing in above illustrations is consistent with lead line numbers shown in illustration of propulsion pump in “2-2.
  • Page 176 (Pressure does not build up unless propulsion load is applied.) ④ With propulsion load at maximum, measure pressure when F-R lever is in “N”, “F”, and “R”, respectively. ★ Motor case pressure : 0.3 MPa (43.5 psi) or less SW300-1-09017 PG002003 9-012 09̲INSPECTION̲AND̲ADJUSTMENT.indd   9-012 09̲INSPECTION̲AND̲ADJUSTMENT.indd   9-012 2012/11/14   20:03:05...
  • Page 177 ④ With propulsion load at maximum, measure pressure when F-R lever is in “N”, “F”, and “R”, respectively. Left side ★ Motor case pressure : 0.3 MPa (43.5 psi) or less SW300-1-09018 Right side SW300-1-09019 PG002003 9-013 09̲INSPECTION̲AND̲ADJUSTMENT.indd   9-013...
  • Page 178 ★ Standard minimum no-load rotational speed : 1,050 ± 50 ⑦ Using lock nut (4), firmly secure stopper bolt (3). SW300-1-09001 ⑧ Set throttle lever (1) to “FULL”. ⑨ Loosen lock nut (6). ⑩ Using stopper bolt (5), adjust so that standard maximum FULL no-load rotational speed is achieved.
  • Page 179 ① Set F-R lever in “N”. ② Attach control cable (2) to F-R lever (1). ★ Specifi ed dimension a: 235.5 mm (9.27 in.) SW300-1-09004 ③ Attach control cable (2) to propulsion hydraulic pump control lever (3). ★ Specifi ed dimension b: 253.2 mm (9.97 in.) ④...
  • Page 180 ⑤ Set F-R lever in “F”. ⑥ Loosen lock nut (5). ⑦ Touch stopper bolt (4) to F-R lever. ⑧ Tighten lock nut (5). SW300-1-09030 ⑨ Set F-R lever in “R”. ⑩ Loosen lock nut (6). ⑪ Touch stopper bolt (7) to F-R lever.
  • Page 181 TROUBLESHOOTING 10̲TROUBLESHOOTING̲oku.indd   1 10̲TROUBLESHOOTING̲oku.indd   1 2012/11/14   20:25:55 2012/11/14   20:25:55...
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  • Page 183 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, fl at ground. •...
  • Page 184 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 185 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 186 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 187 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 188 TROUBLESHOOTING 2) Measuring voltage and current fl owing 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...
  • Page 189 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 190 TROUBLESHOOTING 2-2) Measuring current fl owing 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 191 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 192 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 193 10̲TROUBLESHOOTING̲oku.indd   13 10̲TROUBLESHOOTING̲oku.indd   13 2012/11/14   20:25:56 2012/11/14   20:25:56...
  • Page 194 LEVER SWITCH COMBINATION METER STARTER SWITCH FUSE BOX HEAT STARTER SWITCH INTERLOCK RELAY ALTERNATOR COMBINATION METER GLOW PLUGS FUEL PUMP STARTER MOTOR AV60 BATTERY RELAY 12V 80AH 95D31R ENGINE STOP BATTERY SOLENOID F. L SW300-1-10001 10-011 10̲TROUBLESHOOTING̲oku.indd   10-011 10̲TROUBLESHOOTING̲oku.indd   10-011 2012/11/14   20:25:56 2012/11/14   20:25:56...
  • Page 195 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) 1/2 •...
  • Page 196 LEVER SWITCH COMBINATION METER STARTER SWITCH FUSE BOX HEAT STARTER SWITCH INTERLOCK RELAY ALTERNATOR COMBINATION METER GLOW PLUGS FUEL PUMP STARTER MOTOR AV60 BATTERY RELAY 12V 80AH 95D31R ENGINE STOP BATTERY SOLENOID F. L SW300-1-10001 10-013 10̲TROUBLESHOOTING̲oku.indd   10-013 10̲TROUBLESHOOTING̲oku.indd   10-013 2012/11/14   20:25:56 2012/11/14   20:25:56...
  • Page 197 TROUBLESHOOTING 2-2-1. Engine will not start (Starter motor does not run) 2/2 • F-R lever must be in “N”. Reference Fig.: 2-2-1 Check point Check/Cause Action 6. Interlock Relay (1) When starter switch is ON, measure voltage between Replace interlock relay. interlock relay terminal a inlet wire GY and chassis ground.
  • Page 198 LEVER SWITCH COMBINATION METER STARTER SWITCH FUSE BOX HEAT STARTER SWITCH INTERLOCK RELAY ALTERNATOR COMBINATION METER GLOW PLUGS FUEL PUMP STARTER MOTOR AV60 BATTERY RELAY 12V 80AH 95D31R ENGINE STOP BATTERY SOLENOID F. L SW300-1-10001 10-015 10̲TROUBLESHOOTING̲oku.indd   10-015 10̲TROUBLESHOOTING̲oku.indd   10-015 2012/11/14   20:25:56 2012/11/14   20:25:56...
  • Page 199 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 200 LEVER SWITCH COMBINATION METER STARTER SWITCH FUSE BOX HEAT STARTER SWITCH INTERLOCK RELAY ALTERNATOR COMBINATION METER GLOW PLUGS FUEL PUMP STARTER MOTOR AV60 BATTERY RELAY 12V 80AH 95D31R ENGINE STOP BATTERY SOLENOID F. L SW300-1-10001 10-017 10̲TROUBLESHOOTING̲oku.indd   10-017 10̲TROUBLESHOOTING̲oku.indd   10-017 2012/11/14   20:25:56 2012/11/14   20:25:56...
  • Page 201 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 terminal B wire WY and chassis ground. or battery. Standard voltage : At least intermediate engine speed, 14 V or more •...
  • Page 202 TROUBLESHOOTING Fig.: 2-3-1 PARKING BRAKE SOLENOID COMBINATION METER PARKING BRAKE SWITCH FOOT BRAKE SWITCH FUSE BOX STARTER SWITCH HEAT STARTER SWITCH AV60 BATTERY RELAY 12V 80AH 95D31R BATTERY F. L SW300-1-10002 10-019 10̲TROUBLESHOOTING̲oku.indd   10-019 10̲TROUBLESHOOTING̲oku.indd   10-019 2012/11/14   20:25:56 2012/11/14   20:25:56...
  • Page 203 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 204 TROUBLESHOOTING Fig.: 2-3-1 PARKING BRAKE SOLENOID COMBINATION METER PARKING BRAKE SWITCH FOOT BRAKE SWITCH FUSE BOX STARTER SWITCH HEAT STARTER SWITCH AV60 BATTERY RELAY 12V 80AH 95D31R BATTERY F. L SW300-1-10002 10-021 10̲TROUBLESHOOTING̲oku.indd   10-021 10̲TROUBLESHOOTING̲oku.indd   10-021 2012/11/14   20:25:56 2012/11/14   20:25:56...
  • Page 205 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 : 6.5 Ω...
  • Page 206 TROUBLESHOOTING Fig.: 2-3-1 PARKING BRAKE SOLENOID COMBINATION METER PARKING BRAKE SWITCH FOOT BRAKE SWITCH FUSE BOX STARTER SWITCH HEAT STARTER SWITCH AV60 BATTERY RELAY 12V 80AH 95D31R BATTERY F. L SW300-1-10002 10-023 10̲TROUBLESHOOTING̲oku.indd   10-023 10̲TROUBLESHOOTING̲oku.indd   10-023 2012/11/14   20:25:56 2012/11/14   20:25:56...
  • Page 207 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 : 6.5 Ω...
  • Page 208 (R. DRUM) VIBRATION MODE SELECT SWITCH VIBRATOR SOLENOID (F. DRUM) STARTER SWITCH HEAT FUSE BOX STARTER SWITCH AV60 BATTERY RELAY 12V 80AH 95D31R BATTERY F. L VIBRATOR RELAY COMBINATION METER VIBRATION INDICATOR LAMP RELAY SW300-1-10003 10-025 10̲TROUBLESHOOTING̲oku.indd   10-025 10̲TROUBLESHOOTING̲oku.indd   10-025 2012/11/14   20:25:57 2012/11/14   20:25:57...
  • Page 209 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 2,200 min‫( ¹־‬rpm). 2-4-1.
  • Page 210 (R. DRUM) VIBRATION MODE SELECT SWITCH VIBRATOR SOLENOID (F. DRUM) STARTER SWITCH HEAT FUSE BOX STARTER SWITCH AV60 BATTERY RELAY 12V 80AH 95D31R BATTERY F. L VIBRATOR RELAY COMBINATION METER VIBRATION INDICATOR LAMP RELAY SW300-1-10003 10-027 10̲TROUBLESHOOTING̲oku.indd   10-027 10̲TROUBLESHOOTING̲oku.indd   10-027 2012/11/14   20:25:57 2012/11/14   20:25:57...
  • Page 211 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). • F-R lever position must be “F” or “R”. Reference Fig.: 2-4-1 Check point Check/Cause Action 1.
  • Page 212 LIQUID LIQUID SPRAY SPRAY SWITCH PUMP 1.25BrW WATER SPRAY PUMP WATER SPRAY SWITCH COMBINATION METER STARTER SWITCH FUSE BOX HEAT STARTER SWITCH AV60 BATTERY RELAY 12V 80AH 95D31R BATTERY F. L WATER SPRAY RELAY SW300-1-10004 10-029 10̲TROUBLESHOOTING̲oku.indd   10-029 10̲TROUBLESHOOTING̲oku.indd   10-029 2012/11/14   20:25:57 2012/11/14   20:25:57...
  • Page 213 TROUBLESHOOTING 2-5. Spray System Check following item before troubleshooting. • No blown fuse and power is applied up to fuses. • Check any ground circuit which belongs to components to be checked. 2-5-1. Water spray does not operate • Water spray switch must be ON. Reference Fig.: 2-5-1 Check point Check/Cause...
  • Page 214 LIQUID LIQUID SPRAY SPRAY SWITCH PUMP 1.25BrW WATER SPRAY PUMP WATER SPRAY SWITCH COMBINATION METER STARTER SWITCH FUSE BOX HEAT STARTER SWITCH AV60 BATTERY RELAY 12V 80AH 95D31R BATTERY F. L WATER SPRAY RELAY SW300-1-10004 10-031 10̲TROUBLESHOOTING̲oku.indd   10-031 10̲TROUBLESHOOTING̲oku.indd   10-031 2012/11/14   20:25:57 2012/11/14   20:25:57...
  • Page 215 TROUBLESHOOTING 2-5-2. Liquid spray does not operate (TW types) • Liquid spray switch must be ON. Reference Fig.: 2-5-1 Check point Check/Cause Action 1. Liquid Spray Pump (1) When starter switch is ON, measure voltage between Replace liquid spray liquid spray pump terminal inlet wire BrW and chassis pump.
  • Page 216 Preheating indicator RELAY Hydraulic oil filter warning Lamp check 12V 80AH Coolant temp. SEL.1 95D31R BATTERY Coolant temp. SEL.2 System configuration diagram F. L Note: The circuit in the dashed box is not mounted. SW300-1-10008 10-033 10̲TROUBLESHOOTING̲oku.indd   10-033 10̲TROUBLESHOOTING̲oku.indd   10-033 2012/11/14   20:25:57 2012/11/14   20:25:57...
  • Page 217 TROUBLESHOOTING 2-6. Lighting Check following items before troubleshooting. • No blown fuse and power is applied up to fuses. • Check any ground circuit which belongs to components to be checked. 2-6-1. Head lamp does not light Reference Fig.: 2-6-1 Check point Check/Cause Action...
  • Page 218 Preheating indicator RELAY Hydraulic oil filter warning Lamp check 12V 80AH Coolant temp. SEL.1 95D31R BATTERY Coolant temp. SEL.2 System configuration diagram F. L Note: The circuit in the dashed box is not mounted. SW300-1-10008 10-035 10̲TROUBLESHOOTING̲oku.indd   10-035 10̲TROUBLESHOOTING̲oku.indd   10-035 2012/11/14   20:25:57 2012/11/14   20:25:57...
  • Page 219 TROUBLESHOOTING 2-6-2. Illumination of combination meter does not turn on Reference Fig. : 2-6-1 Check point Check/Cause Action 1. Harness • Measure resistance between lighting switch terminal 2 Repair or replace wire GB and combination meter connector terminal wire harness. No.
  • Page 220 Preheating indicator RELAY Hydraulic oil filter warning Lamp check 12V 80AH Coolant temp. SEL.1 95D31R BATTERY Coolant temp. SEL.2 System configuration diagram F. L Note: The circuit in the dashed box is not mounted. SW300-1-10008 10-037 10̲TROUBLESHOOTING̲oku.indd   10-037 10̲TROUBLESHOOTING̲oku.indd   10-037 2012/11/14   20:25:57 2012/11/14   20:25:57...
  • Page 221 TROUBLESHOOTING 2-6-4. Tachometer reading is abnormal Reference Fig. : 2-6-1 Check point Check/Cause Action 1. Combination Meter (1) When starter switch is ON, measure voltage between Replace tachometer (Tachometer) combination meter terminal wires and ground terminal sensor or combination wire. meter.
  • Page 222 Preheating indicator RELAY Hydraulic oil filter warning Lamp check 12V 80AH Coolant temp. SEL.1 95D31R BATTERY Coolant temp. SEL.2 System configuration diagram F. L Note: The circuit in the dashed box is not mounted. SW300-1-10008 10-039 10̲TROUBLESHOOTING̲oku.indd   10-039 10̲TROUBLESHOOTING̲oku.indd   10-039 2012/11/14   20:25:57 2012/11/14   20:25:57...
  • Page 223 TROUBLESHOOTING 2-6-6. Temperature meter is abnormal Reference Fig. : 2-6-1 Check point Check/Cause Action 1. Thermo Unit • Disconnect harness and measure resistance of thermo Replace thermo unit. unit. Standard resistance : 164.6 Ω [(at unit temperature of 50°C (122°F)] 26.44 Ω...
  • Page 224 Preheating indicator RELAY Hydraulic oil filter warning Lamp check 12V 80AH Coolant temp. SEL.1 95D31R BATTERY Coolant temp. SEL.2 System configuration diagram F. L Note: The circuit in the dashed box is not mounted. SW300-1-10008 10-041 10̲TROUBLESHOOTING̲oku.indd   10-041 10̲TROUBLESHOOTING̲oku.indd   10-041 2012/11/14   20:25:57 2012/11/14   20:25:57...
  • Page 225 TROUBLESHOOTING 2-6-8. Hydraulic oil fi lter warning lamp remains ON Reference Fig. : 2-6-1 Check point Check/Cause Action 1. Hydraulic Oil Filter • When starter switch is OFF, check continuity between Replace hydraulic oil Switch hydraulic oil fi lter switch inlet terminal wire LR and chassis fi...
  • Page 226 System configuration diagram Note: The circuit in the dashed box is not mounted. FUSE COMBINATION METER GW G WB OW VIBRATOR RELAY VIBRATION INDICATOR LAMP RELAY AV60 BATTERY RELAY 12V 80AH 95D31R BATTERY F. L SW300-1-10009 10-043 10̲TROUBLESHOOTING̲oku.indd   10-043 10̲TROUBLESHOOTING̲oku.indd   10-043 2012/11/14   20:25:57 2012/11/14   20:25:57...
  • Page 227 TROUBLESHOOTING 2-6-10. Vibration indicator lamp does not light • Check that vibrator can be operated. Reference Fig. : 2-6-2 Check point Check/Cause Action 1. Harness • Measure resistance between vibrator indicator lamp Repair or replace relay terminal 5 wire Br and combination meter harness.
  • Page 228 Coolant temp. SEL.2 System configuration diagram STARTER SWITCH Note: The circuit in the dashed box is not mounted. FUSE COMBINATION METER GW G WB OW AV60 BATTERY RELAY 12V 80AH 95D31R BATTERY F. L SW300-1-10011 10-045 10̲TROUBLESHOOTING̲oku.indd   10-045 10̲TROUBLESHOOTING̲oku.indd   10-045 2012/11/14   20:25:58 2012/11/14   20:25:58...
  • Page 229 TROUBLESHOOTING 2-6-11. Parking brake indicator lamp does not light Reference Fig. : 2-6-3 Check point Check/Cause Action 1. Harness • Measure resistance between parking brake switch Repair or replace terminal 5 wire YL and combination meter connector harness. terminal wire No. 32 wire YL. Standard resistance : 10 Ω...
  • Page 230 The circuit in the dashed box is not mounted. FUSE BOX COMBINATION METER FUSE STARTER SWITCH HEAT STARTER SWITCH GW G WB OW AV60 BATTERY RELAY 12V 80AH 95D31R BATTERY WATER SPRAY F. L RELAY SW300-1-10012 10-047 10̲TROUBLESHOOTING̲oku.indd   10-047 10̲TROUBLESHOOTING̲oku.indd   10-047 2012/11/14   20:25:58 2012/11/14   20:25:58...
  • Page 231 TROUBLESHOOTING 2-6-12. Water spray indicator lamp does not light • Check that water spray pump can be activated. Reference Fig. : 2-6-4 Check point Check/Cause Action 1. Harness • Measure resistance between water spray switch terminal Repair or replace 2 wire LW and combination meter connector terminal wire harness.
  • Page 232 The circuit in the dashed box is not mounted. COMBINATION METER FUSE F. L FUSE BOX GW G STARTER SWITCH WB OW GLOW GLOW PLUGS LAMP TIMER AV60 BATTERY RELAY 12V 80AH 95D31R BATTERY SW300-1-10006 10-049 10̲TROUBLESHOOTING̲oku.indd   10-049 10̲TROUBLESHOOTING̲oku.indd   10-049 2012/11/14   20:25:58 2012/11/14   20:25:58...
  • Page 233 TROUBLESHOOTING 2-6-14. Preheating indicator lamp does not light Reference Fig. : 2-6-5 Check point Check/Cause Action 1. Harness (1) Measure resistance between glow lamp timer terminal 6 Repair or replace wire YW and combination meter connector terminal wire harness. No. 22 wire YW. Standard resistance : 10 Ω...
  • Page 234 The circuit in the dashed box is not mounted. COMBINATION METER FUSE F. L FUSE BOX GW G STARTER SWITCH WB OW GLOW GLOW PLUGS LAMP TIMER AV60 BATTERY RELAY 12V 80AH 95D31R BATTERY SW300-1-10006 10-051 10̲TROUBLESHOOTING̲oku.indd   10-051 10̲TROUBLESHOOTING̲oku.indd   10-051 2012/11/14   20:25:58 2012/11/14   20:25:58...
  • Page 235 TROUBLESHOOTING 2-6-15 Horn does not sound Reference Fig. : 2-6-5 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 236 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 237 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 238 TROUBLESHOOTING 3-2-1. Machine moves neither forward nor backward 2/2 Check point Cause Check/Action 8. Propulsion Pump Discharge fl ow rate is insuffi cient due to • Measure discharge fl ow rate of propulsion effi ciency degradation of propulsion pump. pump with fl ow meter. •...
  • Page 239 TROUBLESHOOTING 3-2-3. Slow machine speed or small drive force 2/2 Check point Cause Check/Action 5. Propulsion Motor Propulsion motor inlet pressure is low. • Measure propulsion motor inlet pressure. • If low, inspect high pressure relief valve or replace it if necessary. Propulsion circuit pressure is not held in If pressure in propulsion motor case is not propulsion motor case.
  • Page 240 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 effi ciency is reduced due to clogged Clean oil cooler fi...
  • Page 241 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 242 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 243 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 specifi...
  • Page 244 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 245 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 246 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 0445-99015-0-30697-C 0425-99006-0-30073-C 10̲TROUBLESHOOTING̲oku.indd   68 10̲TROUBLESHOOTING̲oku.indd   68 2012/11/14   20:25:59...

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Sw/tw320-1Tw/tw330-1

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