Sakai SV400D-2 Shop Manual
  1. Manuals
  2. Brands
  3. Sakai Manuals
  4. Construction Equipment
  5. SV400D-2
  6. Shop manual

Sakai SV400D-2 Shop Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
SV400
-2
SHOP MANUAL
0404-99027-0-31649-B

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the SV400D-2 and is the answer not in the manual?

Questions and answers

Related Manuals for Sakai SV400D-2

Summary of Contents for Sakai SV400D-2

  • Page 1 SV400 SHOP MANUAL 0404-99027-0-31649-B...
  • Page 3 Introduction This manual provides important information to familiarize you with safe operating and maintenance procedures for your SAKAI roller. Even though you may be familiar with similar equipment you must read and understand this manual before operating or servicing this unit.

  • Page 5: Table Of Contents

    1-10. Maintenance   1-004 1-11. Transporting the Machine   1-006 2. SPECIFICATIONS 1. SPECIFICATION DATA   2-001 1-1. SV400D-2    2-001   1-2. SV400T-2 2-003   1-3. SV400TB-2 2-005   1-4. SV400TF-2 2-007 ...
  • Page 6   1-2. Engine Exterior 3-002 1-3. Cooling System    3-003 2. CONTROL SYSTEM    3-004 2-1. Throttle Control   3-004 2-2. Forward-reverse Control    3-005 3. PUMP MOUNT    3-006 3-1.
  • Page 7 5-2-2. Internal structure of cylinder    4-026 5-2-3. Flow dividing valve   4-027 5. ELECTRICAL SYSTEM 1. GENERAL SYSTEM CIRCUIT   5-001 1-1. Electrical Wiring Diagram   5-001 2. ELECTRICAL COMPONENTS   5-002 2-1. Electrical Component Layout (1) ...
  • Page 8    1-4. Brake Solenoid 7-005 2. BRAKE STRUCTURE   7-006 3. BRAKE ADJUSTMENT   7-007 3-1. Brake Clearance Adjustment   7-007 3-2. Manually Releasing the Brake   7-008 8. INSPECTION AND ADJUSTMENT 1. INSPECTION AND ADJUSTMENT ...
  • Page 9 9. TROUBLESHOOTING 1. TROUBLESHOOTING   9-001 1-1. Safety Precautions for Troubleshooting   9-001 1-2. Important Information for Troubleshooting    9-002    1-3. Before Starting a Troubleshooting Session 9-002 1-4. Wire Color Code   9-002 2.
  • Page 10 3. HYDRAULIC SYSTEM TROUBLESHOOTING   9-038 3-1. When Performing Hydraulic System Troubleshooting   9-038 3-2. Propulsion  9-039 3-2-1. Vehicle moves neither forward nor backward   9-039 3-2-2. Vehicle moves in one direction only (forward or backward) ...

  • Page 11: Safety

    SAFETY...

  • Page 13: General Safety

    GENERAL SAFETY 1. GENERAL SAFETY 1-1. Understanding the Safety Symbols and Signal 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 infromation that is not hazard related.

  • Page 14: Qualifications Of Operators And Maintenance Personnel

    GENERAL SAFETY 1-3. Qualifications of Operators and Maintenance Personnel Work on the machine must be performed by qualified personnel only. Individual responsibilities • of personnel regarding operation, maintenance, repair of the machine must be clearly stated. Define the operator’s responsibilities; the operator should have authority to refuse instructions •...

  • Page 15: Pre Start Inspection

    GENERAL SAFETY 1-5. Pre Start Inspection • Inspect your machine daily. Ensure that the routine maintenance and lubrication are properly performed. Repair or replace any malfunctioning, broken or missing parts before using the machine. Refer to the maintenance schedule in the Operator’s Manual. •...

  • Page 16: Stopping

    GENERAL SAFETY • Do not work close to edges or in the vicinity of overhanging banks or on grades that could cause the compactor to slide or roll over. Avoid any areas that may be a risk to machine stability. •...
  • Page 17 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 18: Transporting The Machine

    GENERAL SAFETY • Never use your hands to check for leaks when inspecting a hydraulic system. Use a piece of cardboard and always wear gloves and safety glasses. Get immediate medical attention if fluid has been injected under your skin. Fluid penetration from •...

  • Page 19: Specifications

    SPECIFICATIONS...

  • Page 21: Specification Data 1-1. Sv400D-2

    SPECIFICATION DATA 1. SPECIFICATION DATA 1-1. SV400D-2 1700 1700 2650 2650 1410 1410 1300 1300 1920 1920 4980 4980 SV400-2-02001 SV400-2-02001 Model SV400D-2 Operating weight 7,430 kg (16,380 lbs.) Weight Front axle 3,630 kg (8,000 lbs.) Rear axle 3,800 kg (8,380 lbs.) Overall length 4,980 mm (196 in.)
  • Page 22 SPECIFICATION DATA Rated rotating speed 2,300 min (2,300 rpm) Rated output 74.9 kW (100 HP) Performance Maximum torque 350 N·m (258 lbf·ft) at 1600 min Fuel consumption rate 230 g/kW·h (0.378 lb/HP·h) Fuel Diesel oil Fuel system Speed governor Mechanical all-speed type Lubrication method Forced circulation Lubrication...

  • Page 23: Sv400T-2

    SPECIFICATION DATA 1-2. SV400T-2 1415 1415 1700 1700 2650 2650 1920 1920 5000 5000 1300 1300 SV400-2-02002 SV400-2-02002 Model SV400T-2 Operating weight 7,650 kg (16,865 lbs.) Weight Front axle 3,880 kg (8,555 lbs.) Rear axle 3,770 kg (8,310 lbs.) Overall length 5,000 mm (197 in.) Overall width 1,920 mm (76 in.)
  • Page 24 SPECIFICATION DATA Rated rotating speed 2,300 min (2,300 rpm) Rated output 74.9 kW (100 HP) Performance Maximum torque 350 N·m (258 lbf·ft) at 1600 min Fuel consumption rate 230 g/kW·h (0.378 lb/HP·h) Fuel Diesel oil Fuel system Speed governor Mechanical all-speed type Lubrication method Forced circulation Lubrication...

  • Page 25: Sv400Tb-2

    SPECIFICATION DATA 1-3. SV400TB-2 1700 1700 1265 1265 2650 2650 1415 1415 5330 5330 1920 1920 1300 1300 2250 2250 SV400-2-02003 SV400-2-02003 Model SV400TB-2 Operating weight 8,050 kg (17,745 lbs.) Weight Front axle 4,380 kg (9,655 lbs.) Rear axle 3,670 kg (8,090 lbs.) Overall length 5,330 mm (210 in.) Overall width...
  • Page 26 SPECIFICATION DATA Rated rotating speed 2,300 min (2,300 rpm) Rated output 74.9 kW (100 HP) Performance Maximum torque 350 N·m (258 lbf·ft) at 1600 min Fuel consumption rate 230 g/kW·h (0.378 lb/HP·h) Fuel Diesel oil Fuel system Speed governor Mechanical all-speed type Lubrication Lubrication method Forced circulation...

  • Page 27: Sv400Tf-2

    SPECIFICATION DATA 1-4. SV400TF-2 1700 1700 2650 2650 1415 1415 1920 1920 5000 5000 1300 1300 SV400-2-02004 SV400-2-02004 Model SV400TF-2 Operating weight 8,840 kg (19,490 lbs.) Weight Front axle 5,110 kg (11,265 lbs.) Rear axle 3,730 kg (8,225 lbs.) Overall length 5,000 mm (197 in.) Overall width 1,920 mm (76 in.)
  • Page 28 SPECIFICATION DATA Rated rotating speed 2,300 min (2,300 rpm) Rated output 74.9 kW (100 HP) Performance Maximum torque 350 N·m (258 lbf·ft) at 1600 min Fuel consumption rate 230 g/kW·h (0.378 lb/HP·h) Fuel Diesel oil Fuel system Speed governor Mechanical all-speed type Lubrication Lubrication method Forced circulation...

  • Page 29: Sv400Fb-2

    SPECIFICATION DATA 1-5. SV400FB-2 1415 1415 1700 1700 1265 1265 2650 2650 1300 1300 1920 1920 5330 5330 2250 2250 SV400-2-02005 SV400-2-02005 Model SV400FB-2 Operating weight 9,250 kg (20,390 lbs.) Weight Front axle 5,630 kg (12,410 lbs.) Rear axle 3,620 kg (7,980 lbs.) Overall length 5,330 mm (210 in.) Overall width...
  • Page 30 SPECIFICATION DATA Rated rotating speed 2,300 min (2,300 rpm) Rated output 74.9 kW (100 HP) Performance Maximum torque 350 N·m (258 lbf·ft) at 1600 min Fuel consumption rate 230 g/kW·h (0.378 lb/HP·h) Fuel Diesel oil Fuel system Speed governor Mechanical all-speed type Lubrication Lubrication method Forced circulation...

  • Page 31: Specifications And Setting

    SPECIFICATIONS AND SETTING 2. SPECIFICATIONS AND SETTING 2-1. Engine Classifi- Item Standard value Remarks cation Engine model DEUTZ TCD2011L04W 74.9/2,300 kW/rpm Rated output No fan net (100/2,300 HP/rpm) Max. rpm under no load 2,530 When vehicle is shipped Min. rpm under no load 750 ±...

  • Page 32: Hydraulic Devices

    SPECIFICATIONS AND SETTING 2-3. Hydraulic Devices Classifi- Item Standard value Remarks cation Relief valve pressure 41.8 ± 1.0 MPa (6061 ± 145 psi) When 1800 min setting Charge relief 2.5 ± 0.2 MPa (363 ± 30 psi) pressure setting Propulsion circuit Drive motor drainage Less than 5.5 L/min...

  • Page 33: Brakes

    SPECIFICATIONS AND SETTING 2-5. Brakes Classifi- Item Standard value Remarks cation Clearance between pedal brake 169 mm (6.7 in.) and floorboard (when attached) Note 1: See dimensions. Clearance between pedal brake 145 mm (5.7 in.) and floorboard (when pressed Note 2: See dimensions. down) Note 3 38.8 –...

  • Page 34: Fuel And Lubricants Specification

    FUEL AND LUBRICANTS SPECIFICATION 3. FUEL AND LUBRICANTS SPECIFICATION 3-1. Rating Ambient temp. and applicable viscosity rating Service Applicable -15 – 30 °C 0 – 40 °C 15 – 55 °C Lubricant classification Standards (5 – 86 °F) (32 – 104 °F) (59 –...

  • Page 35: Tightening Torque Chart

    TIGHTENING TORQUE CHART 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)

  • Page 37: Engine And Controls

    ENGINE AND CONTROLS...

  • Page 39: Engine

    ENGINE 1. ENGINE 1-1. Engine Mount VIEW A VIEW A SV400-2-03001 SV400-2-03001 (1) Damper (2) Nut M12 (3) Damper (4) Damper (5) Damper (6) Bolt M12×100 : 108 N·m (80 lbf·ft) • Engine dry weight : 268 kg (591 lbs.) • Engine oil quantity : 10.5 L (2.8 gal.) 3-001...

  • Page 40: Engine Exterior

    ENGINE 1-2. Engine Exterior SV400-2-03002 SV400-2-03002 * The actual equipment may differ from that shown above. (1) Crankcase breather (16) Shut-off lever (2) Coolant outlet from engine to cooler (17) Lube oil cooler (3) Coolant pump (18) Coolant inlet from the thermostat housing to the (4) Generator lubricating oil cooler (5) V-belts...

  • Page 41: Cooling System

    ENGINE 1-3. Cooling System SECTION B-B SECTION B-B SECTION C-C SECTION C-C SECTION A-A SECTION A-A SV400-2-03003 SV400-2-03003 (1) Charge air cooler (2) Plug (3) Rubber (4) Reservoir (5) Radiator (6) Hydraulic oil cooler (7) Bolt M10×25 : 49 N·m (36 lbf·ft) (8) Bolt M10×20 : 49 N·m (36 lbf·ft) (9) Bolt M10×20 : 49 N·m (36 lbf·ft) (10) Bolt M10×25 : 49 N·m (36 lbf·ft)

  • Page 42: Control System

    CONTROL SYSTEM 2. CONTROL SYSTEM 2-1. Throttle Control IDEL IDEL FULL FULL IDLE IDLE FULL FULL VIEW C VIEW C SECTION B-B SECTION B-B SECTION A-A SECTION A-A SV400-2-03004 SV400-2-03004 (1) Throttle lever (6) Locknut (2) Control cable (7) Shaft (3) Adjusting bolt (Full) (8) Nut (4) Locknut (9) Rod end...

  • Page 43: Forward-Reverse Control

    CONTROL SYSTEM 2-2. Forward-reverse Control VIEW A-A VIEW A-A SECTION B-B SECTION B-B SV400-2-03005 SV400-2-03005 (1) Control cable (5) Bolt (2) Forward-reverse lever (6) Spring (3) Interlock switch (7) Steel ball (4) Backup buzzer switch (8) Rod end 3-005...

  • Page 44: Pump Mount

    PUMP MOUNT 3. PUMP MOUNT 3-1. Pump Mount SECTION A-A SECTION A-A SECTION B-B SECTION B-B SV400-2-03006 SV400-2-03006 (1) Propulsion pump (2) Flange (3) Hub (4) Snap ring (5) Vibrator pump (6) Steering pump (charge pump) (7) Housing (8) Hexagon socket head bolt M10×35 : 49 N·m (36.1 lbf·ft) (9) Hexagon socket head bolt M12×35 : 86 N·m (63.4 lbf·ft) (10) Bolt M10×25 : 59 N·m (43.5 lbf·ft) (11) Bolt M14×45 : 167 N·m (123.2 lbf·ft)

  • Page 45: Pump Attachment

    PUMP MOUNT 3-2. Pump Attachment • After removing the pump assembly from the engine for repair or replacement, reattach it in accordance according to the following procedure: Apply an ample amount of molybdenum grease to the spline surface of the hub (3) and pump (1).

  • Page 47: Hydraulic Systems

    HYDRAULIC SYSTEMS...

  • Page 50: System Circuit Diagram

    SYSTEM CIRCUIT DIAGRAM 1. SYSTEM CIRCUIT DIAGRAM 1-1. Graphic Symbols for Hydraulic Basic Symbols Pump, Motors and Cylinders DESCRIPTION SYMBOL DESCRIPTION SYMBOL Hydraulic pumps: Solid line: Fixed displacement Electric signal line Unidirectional Dashed line: Pilot control Bidirectional Connected lines Variable displacement Not connected Unidirectional Chain line:...
  • Page 51 SYSTEM CIRCUIT DIAGRAM Valves Methods of Operation DESCRIPTION SYMBOL DESCRIPTION SYMBOL Check valve Spring Stop valve Manual Pressure compensation Relief valve Rotating electric actuator Pilot control: Variable orifice Hydraulic pilot control Two-port two-position Direct pilot control direction-control valve Solenoid: Four-port three-position direction-control valve Single winding Multiple winding...

  • Page 53: Hydraulic Circuit Diagram (Sv400D/T/Tf-2)

    SYSTEM CIRCUIT DIAGRAM 1-2. Hydraulic Circuit Diagram (SV400D/T/TF-2) ｓｔ Orbitrol φ70Xφ35-380 1/2" Steering cylinder 3/4-16UNF ｃｃ \/ｒ 3/8" ４００ -16UNF -16UNF ｅｖ 3/4-16UNF 3/8" 1 1/16-12UN １５．０ＭＰａ 3/4-16UNF Line filter -16UNF -16UNF Steering cylinder 3/4-16UNF AVG.BETA 1/2" ｓｔ 1 1/16-12UN 2 at 5μm Parking brake φ70Xφ35-380...

  • Page 55: Hydraulic Circuit Diagram (Sv400Tb/Fb-2)

    SYSTEM CIRCUIT DIAGRAM 1-3. Hydraulic Circuit Diagram (SV400TB/FB-2) Orbitrol ｓｔ φ70Xφ35‑380 φ60Xφ30-260 Blade cylinder 1/2" Steering cylinder 3/4‑16UNF G3/8 G3/8 3/8" ｃｃ ¥/ ４００ ‑16UNF ‑16UNF ｒｅｖ 3/4‑16UNF Control valve 3/8" 3/8" G1/2 1 1/16‑12UN １５．０ＭＰａ 3/4‑16UNF Line filter ‑16UNF ‑16UNF G1/2 3/8"...

  • Page 57: Propulsion Hydraulic System

    PROPULSION HYDRAULIC SYSTEM 2. PROPULSION HYDRAULIC SYSTEM 2-1. Propulsion Hydraulic Piping (1) (Front) (1) Propulsion motor (front) (1-1) Drain port : 7/8-14UNF-2B (1-2) Port B (forward) : SAE 1″ (1-3) Port A (reverse) : SAE 1″ (2) Block (2-1) Port BB : 1 1/16-12UNF-2B (2-2) Port BP : 1 1/16-12UNF-2B (2-3) Port BX : 3/4-16UNF-2B (2-4) Port BA : 1 1/16-12UNF-2B...

  • Page 59: Propulsion Hydraulic Piping (2) (Rear)

    PROPULSION HYDRAULIC SYSTEM 2-2. Propulsion Hydraulic Piping (2) (Rear) (1) Propulsion motor (rear) (1-1) Port RA1 : SAE 1″ (1-2) Port RB2 : 3/4-16UNF-2B (1-3) Port RB2 : 1 1/16-12UNF-2B (1-4) Drain port : 1 1/16-12UN-2B (2) Block (2-1) Port BB : 1 1/16-12UNF-2B (2-2) Port BP : 1 1/16-12UNF-2B (2-3) Port BX : 3/4-16UNF-2B (2-4) Port BA : 1 1/16-UNF-2B...

  • Page 62: Hydraulic Equipment Specifications

    PROPULSION HYDRAULIC SYSTEM 2-3. Hydraulic Equipment Specifications 2-3-1. Propulsion pump (propulsion, vibrator, steering/charge) (SV400D/T/TF-2) SV400-2-04005 SV400-2-04005 4-007...

  • Page 63: Propulsion Pump (Propulsion, Vibrator, Steering/Charge) (Sv400D/T/Tf-2)

    PROPULSION HYDRAULIC SYSTEM Model: PV05541-604 (1) Propulsion pump (1-1) Port A1 (forward side) : SAE 1″ (1-2) Port B1 (reverse side) : SAE 1″ (1-3) Multifunction valve (port A) (1-4) Multifunction valve (port B) (1-5) High-pressure gauge port (port A) : 9/16-18UN-2B (1-6) High-pressure gauge port (port B) : 9/16-18UN-2B (1-7) Charge supply port : 7/6-14UNF-2B (1-8) Charge pressure gauge port : 7/16-20UNF-2B...
  • Page 64 PROPULSION HYDRAULIC SYSTEM 2-3-2. Propulsion pump (propulsion, vibrator, steering/charge) (SV400TB/FB-2) 1-10 1-10 1-11 1-11 SV400-2-04006 SV400-2-04006 4-009...

  • Page 65: Propulsion Pump (Propulsion, Vibrator, Steering/Charge) (Sv400Tb/Fb-2)

    PROPULSION HYDRAULIC SYSTEM Model: PV05541-605 (1) Propulsion pump (1-1) Port A1 (forward side) : SAE 1″ (1-2) Port B1 (reverse side) : SAE 1″ (1-3) Multifunction valve (port A) (1-4) Multifunction valve (port B) (1-5) High-pressure gauge port (port A) : 9/16-18UN-2B (1-6) High-pressure gauge port (port B) : 9/16-18UN-2B (1-7) Charge supply port : 7/6-14UNF-2B (1-8) Charge pressure gauge port : 7/16-20UNF-2B...

  • Page 66: Propulsion Hydraulic Motor (Front)

    PROPULSION HYDRAULIC SYSTEM 2-3-3. Propulsion hydraulic motor (front) SV400-2-04007 SV400-2-04007 (1) Port B (forward travel) : SAE 1″ (2) Port A (reverse travel) : SAE 1″ (3) High-pressure gauge port (port B side): 9/16-18UNF-2B (4) High-pressure gauge port (port A side): 9/16-18UNF-2B (5) Drain port : 7/8-14UNF-2B (6) Reduction gear (7) Filler cap : 7/8-14UNF-2B...

  • Page 67: Internal Structure Of Propulsion Hydraulic Motor (Front)

    PROPULSION HYDRAULIC SYSTEM 2-3-4. Internal structure of propulsion hydraulic motor (front) 2-1 1-1 2-2 1-2 2-3 2-1 1-1 2-2 1-2 2-3 SV400-2-04008 SV400-2-04008 (1) Motor (2) Reduction gear (1-1) Cylinder block kit (2-1) Floating seal kit (1-2) Roller bearing (2-2) Angular bearing (1-3) Oil seal (2-3) Shaft B (1-4) Swashplate assembly...

  • Page 68: Propulsion Hydraulic Motor (Rear)

    PROPULSION HYDRAULIC SYSTEM 2-3-5. Propulsion hydraulic motor (rear) SV400-2-04009 SV400-2-04009 Specifications (1) Drain port : 1 1/16-12UN-2B (2) Drain port : 1 1/16-12UN-2B • Model : MV075-611 (3) Pilot supply port : 9/16-18UNF-2B • Displacement (4) Servo pressure gauge port : 9/16-18UNF-2B Maximum : 75 cm³/rev (4.58 cu.in./rev) (5) Servo pressure gauge port : 9/16-18UNF-2B...

  • Page 69: Block

    PROPULSION HYDRAULIC SYSTEM 2-3-6. Block SV400-2-04010 SV400-2-04010 (1) Port BB : 1 1/16-12UNF-2B (2) Port BP : 1 1/16-12UNF-2B (3) Port BA : 1 1/16-12UNF-2B (4) Port BX : 3/4-16UNF-2B 4-014...
  • Page 71 VIBRATOR HYDRAULIC SYSTEM 3. VIBRATOR HYDRAULIC SYSTEM 3-1. Vibrator Hydraulic Piping (1) Vibrator motor 1-2 1 (1-1) Port VA : 1 1/16-12UN-2B (1-2) Port VB : 1 1/16-12UN-2B (1-3) Drain port : 7/8-14UNF-2B (2) Return filter Hydraulic oil tank (2-1) OUT : 1 1/16-12UN-2B (2-2) IN : 1 1/16-12UN-2B...

  • Page 73: Vibrator Hydraulic System

    VIBRATOR HYDRAULIC SYSTEM 3-2. Hydraulic Equipment Specifications 3-2-1. Vibrator hydraulic motor D1 D2 D3 D1 D2 D3 Hydraulic circuit diagram Hydraulic circuit diagram Flow of oil Flow of oil 　・A→B Clockwise rotation 　・A→B Clockwise rotation 　・B→A Counterclockwise rotation 　・B→A Counterclockwise rotation SV400-2-04012 SV400-2-04012 (1) Port B : 1 1/16-12UN-2B (2) Port A : 1 1/16-12UN-2B...

  • Page 75: Steering System

    STEERING SYSTEM 4. STEERING SYSTEM 4-1. Steering Hydraulic Piping (SV400D/T/TF-2) Hydraulic oil tank 10 11 (1) Steering/charge pump (1-1) Suction port : 1 5/16-12UN-2B (1-2) Discharge port : 1 1/16-12UN-2B (2) Propulsion pump (2-1) Charge supply port : 7/6-14UNF-2B (3) Power cylinder (R) (3-1) Port R1 : 2 3/4-16UNF (3-2) Port R2 : 2 3/4-16UNF (4) Power cylinder (L)

  • Page 77: Steering Hydraulic Piping (Sv400Tb/Fb-2)

    STEERING SYSTEM 4-2. Steering Hydraulic Piping (SV400TB/FB-2) Hydraulic oil tank 10 11 (1) Steering/charge pump (1-1) Suction port : SAE 1 1/4″ (1-2) Discharge port : SAE 1″ (2) Propulsion pump (2-1) Charge supply port : 7/6-14UNF-2B (3) Power cylinder (R) (3-1) Port R1 : 2 3/4-16UNF (3-2) Port R2 : 2 3/4-16UNF (4) Power cylinder (L)

  • Page 79: Frame (Center Pin)

    STEERING SYSTEM 4-3. Frame (Center Pin) SV400-2-04015 SV400-2-04015 (1) Swing bearing (2) Yoke (3) Cover (8) Bolt M16×60 : 265 N·m (195 lbf·ft) (4) Roller bearing (9) Bolt M16×80 : 265 N·m (195 lbf·ft) (5) Bracket (top side) (10) Nut M20 : 539 N·m (398 lbf·ft) (6) Bracket (bottom side) (11) Bolt M20×100...

  • Page 80: Steering Wheel

    STEERING SYSTEM 4-4. Steering Wheel SV400-2-04016 SV400-2-04016 (1) Steering wheel (2) Column shaft (6) Nut M12 P=1.25 : 35 N·m (101 lbf·ft) (3) Orbitrol (7) Bolt M10×30 : 49 N·m (36 lbf·ft) (4) Bracket (8) Bolt M 8×12 : 23 N·m (17 lbf·ft) (5) Damper (9) Nut M10 : 49 N·m (36 lbf·ft)

  • Page 81: Steering Valve (Orbitrol)

    STEERING SYSTEM 4-4-1. Steering valve (Orbitrol) SV400-2-04017 SV400-2-04017 (1) Dust seal (10) Spring (19) O-ring (2) Housing (11) Seat (20) Cover (3) O-ring (12) Ball (21) Washer (4) Bearing assembly (13) Bushing (22) Screw pin (5) Ring (14) Spring (23) Screw (6) Sleeve (15) Shaft (24) Port L : 3/4-16UNF...

  • Page 82: Steering Cylinder

    STEERING SYSTEM 4-5. Steering Cylinder SECTION A-A SECTION A-A SECTION B-B SECTION B-B SV400-2-04018 SV400-2-04018 (1) Steering cylinder (2) Pin (3) Collar (4) Plate (5) Bolt M10×25: 49 N·m (36 lbf·ft) 4-022...

  • Page 83: Internal Structure Of Steering Cylinder

    STEERING SYSTEM 4-5-1. Internal structure of steering cylinder (1) Grease nipple : R1/8 (11) Bush (2) Rod (12) U-packing (3) Spherical bearing (13) Backup ring (4) Snap ring (14) Slipper seal (5) Dust wiper (15) Wear ring (6) Stopper (16) Piston (7) Rod cover (17) Nylon nut : M24...
  • Page 85 BLADE (SV400TB/FB-2) 5. BLADE (SV400TB/FB-2) 5-1. Blade Hydraulic Piping (1) Control lever 4-1 4 (2) Control valve (2-1) Port A (up side) : G1/2″ (2-2) Port B (down side) : G1/2″ (2-3) Port P : G3/4″ (2-4) Port T : G3/4″ (3) Power cylinder (L) (3-1) Port L1 (up side) : G3/8″...

  • Page 87: Blade (Sv400Tb/Fb-2)

    BLADE (SV400TB/FB-2) 5-2. Hydraulic Equipment Specifications 5-2-1. Control valve Hydraulic circuit diagram Hydraulic circuit diagram (5) Port A (cylinder port) : G1/2″ (1) End cover (6) Port B (cylinder port) : G1/2″ (2) F block assembly (7) Port T (tank port) : G3/4″ (3) Inlet cover assembly (8) Port P (pump port) : G3/4″...

  • Page 88: Internal Structure Of Cylinder

    BLADE (SV400TB/FB-2) 5-2-2. Internal structure of cylinder (1) Rod (12) Packing (2) Grease nipple : R1/8 (13) Snap ring (3) Spherical bearing (14) U-ring holder (4) Snap ring (15) U-ring assembly (5) Wiper ring (16) Piston ring (6) Cylinder head (17) Piston (7) Lock washer (8) O-ring : G-65...

  • Page 89: Flow Dividing Valve

    BLADE (SV400TB/FB-2) 5-2-3. Flow dividing valve Hydraulic (oil) pressure symbol Hydraulic (oil) pressure symbol (1) Body (2) Spool (3) Cover (4) Spring (5) O-ring : 1BP 36 (6) Port A : G1/2˝ (7) Port B : G1/2˝ (8) Port P : G3/4˝...

  • Page 91: Electrical System

    ELECTRICAL SYSTEM...

  • Page 93: General System Circuit

    GENERAL SYSTEM CIRCUIT 1. GENERAL SYSTEM CIRCUIT 1-1. Electrical Wiring Diagram FOOT BRAKE SWITCH STOP PARKING REVERSE FORWARD BRAKE SOLENOID PARKING BRAKE VALVE SWITCH NC NOCOM BACKUP 67 BrY BUZZER SWITCH HYDRAULIC PUMP NEUTRAL SOLENOID VALVE HYDRAULIC.PUMP NEUTRAL RELAY(R5) F-R LEVER SWITCH NC NOCOM BACKUP BUZZER...
  • Page 95 ELECTRICAL COMPONENTS 2. ELECTRICAL COMPONENTS 2-1. Electrical Component Layout (1) Thermo unit Parking brake solenoid (DEUTZ installed) Neutral solenoid Backup buzzer Fuel unit OiI pressure switch Speed change solenoid valve Negative torque control solenoid Battery relay Shutdown solenoid Fusible link Horn switch Hydraulic oil filter switch Vibrator ON/OFF switch...

  • Page 97: Electrical Components

    ELECTRICAL COMPONENTS 2-2. Electrical Component Layout (2) 8 9 10 11 8 9 10 11 VIEW B VIEW B VIEW A VIEW A SV400-2-05003 SV400-2-05003 (1) Combination meter (9) P Interlock relay (2) Engine warning lamp (10) Horn relay (3) Speed change switch (11) Lamp check relay (4) Parking brake switch (12) Neutral holding relay...

  • Page 98: Battery Layout

    ELECTRICAL COMPONENTS 2-3. Battery Layout SV400-2-05004 SV400-2-05004 (1) Battery cable : L=1900 mm (74.8 in.) (5) Cushion (2) Battery relay (6) Battery (3) Battery cable : L=250 mm (9.8 in.) (7) Battery cable : L=350 mm (13.8 in.) (4) Plate (lauan) (8) Battery cable : L=350 mm (13.8 in.) 5-004...

  • Page 99: Electrical Component Specifications

    ELECTRICAL COMPONENT SPECIFICATIONS 3. ELECTRICAL COMPONENT SPECIFICATIONS 3-1. Fuse Box Fuse box Fuse box Relay panel Relay panel (BW) (BW) P interlock relay P interlock relay F-R lever switch F-R lever switch Starter relay (W) Starter relay (W) Backup buzzer switch Backup buzzer switch Foot brake switch Foot brake switch...

  • Page 100: Diode Unit

    ELECTRICAL COMPONENT SPECIFICATIONS 3-2. Diode Unit Schematic diagram Schematic diagram SV400-2-05006 SV400-2-05006 (1) Cover : Rubber (SC610-CP black) (2) Connector COMP : YAZAKI No.7118-3090 Specifications Maximum mean rectified current • : 3 A • Maximum surge current : 180 A : At least 3 MΩ...

  • Page 101: Vibratory Drum Rear Axle

    VIBRATORY DRUM REAR AXLE...

  • Page 103: Precautions For Disassembly And Reassembly

    PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY 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

    VIBRATORY DRUM 2. VIBRATORY DRUM 2-1. Removal and Installation of Vibratory Drum 2-1-1. Removal of vibratory drum 1) Using the steering lock bar (1), connect the front and rear frames. Firmly secure it so that the front and rear frames do not move. SV400-2-06001 SV400-2-06001 2) As shown in the figure on the right, lift the rear...
  • Page 105 Lift with crane slightly above the ground surface, place support stands at the right and left sides of the front frame. Firmly secure the vehicle body. Front axle weight SV400D-2 : 4,010 kg (8,841 lbs.) SV400T-2 : 4,290 kg (9,548 lbs.) SV400TB-2 : 4,840 kg (10,671 lbs.)
  • Page 106 VIBRATORY DRUM ➁ Vibrator motor piping Disconnect the hydraulic hoses (7, 8 and 9) that are connected to the vibrator motor. Either plug both sides of disconnected connections or take other steps to prevent dust from getting inside. SV400-2-06006 SV400-2-06006 6) Lift the drum (11) with a crane.

  • Page 107: Installation Of Vibratory Drum

    VIBRATORY DRUM 8) Place chock blocks at the front and rear of the removed drum assembly (11) to prevent the drum assembly from moving. Chock block Chock block Chock block Chock block SV400-2-06009 SV400-2-06009 2-1-2. Installation of vibratory drum 1) Install the vibratory drum in the reverse order in which it was removed.
  • Page 109 VIBRATORY DRUM 2-2. Vibratory Drum Assembly (1) Drum (2) O-ring (3) Vibrator bearing 11 12 13 14 15 (4) Eccentric shaft (5) Shaft (6) Bolt (M10×40) (7) Sleeve (8) Spring pin (9) Bolt (M16×50) (10) Plug (11) Housing (12) Oil seal (13) Roller bearing (14) Disc (15) Bolt (M12×40)

  • Page 111: Vibratory Drum Assembly

    Stabilize the drum so that it is not unsteady. Wooden Wooden block block Vibratory drum assembly SV400D-2 : 2,640 kg (5,820 lbs.) SV400T/TB-2 : 2,860 kg (6,305 lbs.) Wooden block Wooden block SV400-2-06013 SV400-2-06013 SV400TF/FB-2 : 4,210 kg (9,281 lbs.)
  • Page 112 VIBRATORY DRUM 3) Remove the two bolts (24). • Remove the vibrator motor (46). • Remove the breather (21). Use aids such as work stepladders when working, and work with a natural, unstrained posture. SV400-2-06014 SV400-2-06014 4) Remove the sixteen bolts (16). Lift with crane Lift with crane •...
  • Page 113 VIBRATORY DRUM 6) Attach the lifting bolts (M16×2.0) as shown in Lift with crane Lift with crane the figure on the right. Wooden block Wooden hammer Wooden block Wooden hammer • Using a crane, slowly lift and remove the axle shaft (32).
  • Page 114 VIBRATORY DRUM 9) Lift and invert the drum with a crane. Stand it up with the propulsion motor side upward. Lifted weight in figure on the right SV400D-2 : 2,240 kg (4,938 lbs.) SV400T/TB-2 : 2,460 kg (5,423 lbs.) SV400TF/FB-2 : 3,810 kg (8,400 lbs.)
  • Page 115 VIBRATORY DRUM 12) Remove the sixteen bolts (34). • Remove the axle shaft (36). Axle shaft: 100 kg (220 lbs.) SV400-2-06023 SV400-2-06023 13) The figure on the right shows the condition in which all parts have been removed from the vibratory drum assembly.
  • Page 116 VIBRATORY DRUM 15) Remove the eight bolts (23). • Remove the cover (27). SV400-2-06026 SV400-2-06026 16) Place the plate at the end of the axle shaft. With Puller Puller the puller against the housing (11), separate the housing, including the roller bearing, from the axle shaft.

  • Page 117: Reassembly Of Vibratory Drum

    VIBRATORY DRUM 2-3-2. Reassembly of vibratory drum Before reassembling, confirm that each part that was disassembled has been well cleaned and is free of any abnormality. 1) Lightly apply gear oil to the press-fitting surface of the roller bearing (13) outer race. •...
  • Page 118 VIBRATORY DRUM 4) Apply an ample amount of lithium-based grease to the rolling surfaces of the roller bearing (13). • Lightly apply the same grease to the lip surfaces of the oil seal (12). • Join the axle shaft (32) subassembly and housing (11).
  • Page 119 VIBRATORY DRUM 7) Roller bearing preload adjustment ➀ Remove the four bolts (23). • Remove the cover (27) and shim (31). SV400-2-06034 SV400-2-06034 ➁ Without inserting shims, install the cover (27). Then install washers to the four bolts (23) and There must be no gap There must be no gap tighten.
  • Page 120 VIBRATORY DRUM 8) Install the oil seal (28) to the cover (22). • Lightly apply grease to the lip surfaces of the oil seal (28). • Using the six bolts (29) and spring washers, firmly secure the cover (22) to the housing. (29) M12×40: 108 N·m (80 lbf·ft) SV400-2-06037 SV400-2-06037...
  • Page 121 SV400-2-06041 SV400-2-06041 13) Lifting with a crane, invert the drum as shown in the figure on the right. Lifted weight in figure on the right SV400D-2 : 2,240 kg (4,938 lbs.) SV400T/TB-2 : 2,460 kg (5,423 lbs.) SV400TF/FB-2 : 3,810 kg (8,400 lbs.) Inverting the drum can be dangerous work.
  • Page 122 VIBRATORY DRUM 14) Attach a lifting bolt (M10×1.5) to the end of the Lower with crane Lower with crane vibrator shaft (4). Then lift with a crane, slowly lower and attach. When inserting the vibrator shaft into the vibrator bearing for attachment, be careful not to allow the inner race of the vibrator bearing to lean.
  • Page 123 VIBRATORY DRUM 17) Attach a lifting bolt (M10×1.5) to the vibrator Lift with crane Lift with crane shaft end. Then slowly lift with a crane. Confirm Shaft must move 1 to 3 mm Shaft must move 1 to 3 mm that 1 to 3 mm (0.04 to 0.12 in.) of play exists in the axial direction.
  • Page 124 VIBRATORY DRUM 20) Attach the breather (21). • Attach the O-ring (25) to the vibrator motor (46). Using the two bolts (24) and washers, firmly secure it to the cover. Attach by aligning the top side of the vibrator motor (46) and breather (21) with the top side of the propulsion motor.

  • Page 125: Axle

    AXLE 3. AXLE 3-1. Rear Axle (1) Tire {Tire inflation pressure: 137.34 kPa (20 psi)} (2) Nut (M22 p=1.5) 785 N·m (579 lbf·ft) (3) Hub reduction gear (4) Brake (5) Differential (6) Center housing (7) Bolt (for brake release) (8) Plug (for brake component lubrication) (9) Plug (for brake and differential component lubrication and level gauge) (10) Bolt (for brake adjustment) (11) Plug (for differential component lubrication)

  • Page 127: Rear Axle Lubrication

    AXLE 3-2. Rear Axle Lubrication • Lubricating oil : Gear oil API-GL4 grade SAE90 (See recommended lubrication.) • Lubricating oil quantity Center housing component : 7.3 L (1.9 gal.) Hub reduction gear component : 1.25 L×2 (0.33 gal.×2) Center housing component (differential + brake) Center housing component (differential + brake) Hub reduction gear component Hub reduction gear component...

  • Page 128: Rear Axle Structure

    AXLE 3-3. Rear Axle Structure 3-3-1. Center housing SV400-2-06052 SV400-2-06052 (1) Cover (5) Bolt (9) Magnet plug (2) O-ring (6) Vent (10) Plug (3) Housing (7) Seal washer (11) Snap ring (4) Seal washer (8) Plug 6-023...

  • Page 129: Differential

    AXLE 3-3-2. Differential 10 13 10 13 SV400-2-06053 SV400-2-06053 (1) Cylinder bolt (6) No spin differential (11) Shim (2) Ring nut (7) Ring nut (12) Shim (3) Cylinder bolt (8) Bevel gear set (13) Spacer (4) Tapered roller bearing (9) Bolt (5) Differential carrier (10) Tapered roller bearing 6-024...

  • Page 130: Hub Reduction Gear

    AXLE 3-3-3. Hub reduction gear SV400-2-06054 SV400-2-06054 (1) Axle case (11) Bearing (21) Seal washer (2) Spring washer (12) Circlip (22) Countersunk bolt (3) Bolt (13) Ring gear (23) Planetary gear carrier (4) Plug (14) Ring gear support (24) Nut (5) Plug (15) Lock plate (25) Stud bolt...

  • Page 131: Brake

    AXLE 3-3-4. Brake SV400-2-06055 SV400-2-06055 (1) Spring (9) Ring (17) Intermediate brake disc (2) O-ring (10) Lock washer (18) Disc (3) Piston (11) Nut (19) Bolt (4) O-ring (12) Adjustment bolt (20) Seal washer (5) Cover (13) Hexagon bolt (21) Bolt (6) O-ring (14) Sheet (22) Vent...

  • Page 133: Brakes

    BRAKES...

  • Page 135: Brake System

    BRAKE SYSTEM 1. BRAKE SYSTEM 1-1. Brake Pedal SECTION A-A SECTION A-A SV400-2-07001 SV400-2-07001 (1) Brake pedal (2) Return spring (3) Foot brake switch (4) Bolt (M10×40) (5) Nut (M10) (6) Bolt (M10×25) 49 N·m (36 lbf·ft) 7-001...

  • Page 137: Brake Circuit Configuration

    BRAKE SYSTEM 1-2. Brake Circuit Configuration 1-2-1. Brake ON condition Speed change solenoid valve Rear axle Parking brake indicator lamp Spring Brake Brake piston Fuse Parking brake switch (Brake ON condition) Brake disc assembly Foot brake switch Rear propulsion motor Brake Condition in which brake pedal is pressed Neutral relay (without relay excited)

  • Page 139: Brake Off Condition

    BRAKE SYSTEM 1-2-2. Brake OFF condition Speed change solenoid valve Rear axle Parking brake indicator lamp Spring Brake Brake piston Fuse Parking brake switch (Brake OFF condition) Brake disc assembly Foot brake switch Rear propulsion motor Brake Condition in which brake pedal is not pressed Neutral relay (with relay excited)

  • Page 141: Brake Piping

    BRAKE SYSTEM 1-3. Brake Piping SV400-2-07003 SV400-2-07003 (1) Propulsion motor (rear) (4) Brake (right) (1-3) Pilot supply port: 9/16-18UNF (4-1) Port 1 : M14 Line filter (5) Brake (left) (2-1) OUT 1 1/16-12UN-2B (5-1) Port P1 : M14 (6) Hose (1-3)→(3-2) Brake solenoid valve (7) Hose (2-1)→(3-2) (3-1) Port A : 9/16-18UNF-2B...

  • Page 142: Brake Solenoid

    BRAKE SYSTEM 1-4. Brake Solenoid － － ＋ ＋ Electric circuit Electric circuit SV400-2-07004 SV400-2-07004 (1) Body (6) Port P (9/16-18UNF) (2) Spool (7) Connector (3) Spring (8) Port A (9/16-18UNF) (4) O-ring (1B P14) (9) Port T (9/16-18UNF) (5) Solenoid Specifications Rated pressure : 4.9 MPa (Ports A, P) (710 psi) : 0.5 MPa (Port T) (72 psi)

  • Page 143: Brake Structure

    BRAKE STRUCTURE 2. BRAKE STRUCTURE SV400-2-07005 SV400-2-07005 (1) Friction plate (2) Separating plate (3) Adjusting pinion (for brake adjustment) (4) Bolt (for brake adjustment) (5) Piston (6) Drain plug • Brake release pressure: 1.5 – 3.0 MPa (218 – 435 psi) 7-006...

  • Page 144: Brake Adjustment

    BRAKE ADJUSTMENT 3. BRAKE ADJUSTMENT 3-1. Brake Clearance Adjustment 1) Turning the adjusting pinion (3) counterclockwise reduces the clearance between the brake discs. • Required rotational torque: 8 – 10 N·m (5.9 – 7.4 lbf·ft) SV400-2-07006 SV400-2-07006 2) Initial adjustment after brake disc replacement •...

  • Page 145: Manually Releasing The Brake

    BRAKE ADJUSTMENT 3-2. Manually Releasing the Brake 1) Loosen the nut (11). • Loosen the nut on the opposite side, too. • An applicable bolt (10) and nut (11) can be found on the opposite side, too. SV400-2-07009 SV400-2-07009 2) Tighten the bolt (10), and press it into the pressure plate (14).
  • Page 146 BRAKE ADJUSTMENT ⑤ Adjust the bolt (10) to the dimensions shown in the figure on the right. • Similarly, adjust the bolt on the opposite side, too. +0.5 +0.5 SV400-2-07013 SV400-2-07013 ⑥ Tighten the nut (11), and firmly secure the bolt (10).

  • Page 147: Inspection And Adjustment

    INSPECTION AND ADJUSTMENT...

  • Page 149: Inspection And Adjustment

    INSPECTION AND ADJUSTMENT 1. INSPECTION AND ADJUSTMENT 1-1. Inspection and Adjustment 1-1-1. Safety precautions for inspection and adjustment WARNING Unexpected vehicle movement may cause a serious accident. When inspecting the machine while the engine is running, always follow the instructions below. Park the machine on level, flat ground.

  • Page 150: Preparation For Inspection And Adjustment

    INSPECTION AND ADJUSTMENT 1-1-2. Preparation for inspection and adjustment • Prepare the necessary measuring instruments. In addition, particularly when measuring pressure values, make sure to prepare the appropriate hoses, adapters and a plug removal tool for the pressure reading port. •...

  • Page 151: Measurement And Adjustment Of Propulsion Circuit Pressure

    MEASUREMENT AND ADJUSTMENT OF PROPULSION CIRCUIT PRESSURE 2. MEASUREMENT AND ADJUSTMENT OF PROPULSION CIRCUIT PRESSURE 2-1. Measurement Before performing to the following operation which mentioned ① to ⑤ , confirm that the parking brake operates properly. • Oil temperature during measurement : 50 ±...

  • Page 152: Adjustment

    MEASUREMENT AND ADJUSTMENT OF PROPULSION CIRCUIT PRESSURE 2-2. Adjustment • If the measurement results indicate the pressure values deviating from the maximum circuit pressure, make an adjustment in accordance with the procedure described below. ① Check for evidence that the locknut (2) of the multifunction valve (1-3 or 1-4) was loose.

  • Page 153: Measurement And Adjustment Of Propulsion Charge Circuit Pressure

    MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT PRESSURE 3. MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT PRESSURE Before measuring • Since charge circuit oil is being supplied from the steering circuit, first confirm that the steering operation is normal. • The propulsion charge circuits and vibration charge circuits consist of parallel circuits.

  • Page 154: Adjustment

    MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT PRESSURE 3-2. Adjustment If the measurement results indicate the pressure • values deviating from the standard charge relief pressure setting, make an adjustment in accordance with the procedure described below. ① Check for evidence that the locknut (2) of the charge relief valve (1-10) was loose.

  • Page 155: Measurement Of Vehicle High/Low-Speed Change Circuit Pressure

    MEASUREMENT OF VEHICLE HIGH/LOW-SPEED CHANGE CIRCUIT PRESSURE 4. MEASUREMENT OF VEHICLE HIGH/LOW-SPEED CHANGE CIRCUIT PRESSURE 4-1. Measurement Oil temperature during measurement • : 50 ± 5°C (122 ± 41°F) ① Remove the plugs from the rear propulsion motor’s gauge ports (4) and (5). Attach the pressure gauge through the adapter •...

  • Page 156: Measurement Of Parking Brake Release Pressure

    MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE 5. MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE 5-1. Measurement • Oil temperature during measurement : 50 ± 5°C (122 ± 41°F) ① Disconnect the hose (2) that is connected to the brake solenoid valve (1). Attach the pressure gauge through the adapter •...

  • Page 157: Measurement And Inspection Of Vibrator Circuit Pressure

    MEASUREMENT AND INSPECTION OF VIBRATOR CIRCUIT PRESSURE 6. MEASUREMENT AND INSPECTION OF VIBRATOR CIRCUIT PRESSURE 6-1. Measurement • Oil temperature during measurement: 50 ± 5°C (122 ± 41°F) ① Remove the plugs from the gauge ports (1) and (2) that are equipped with adapters attached to the vibrator pump.

  • Page 158: Inspection

    MEASUREMENT AND INSPECTION OF VIBRATOR CIRCUIT PRESSURE 6-2. Inspection If the measurement results indicate the pressure • values deviating from the maximum standard vibration pressure setting, conduct an inspection in accordance with the procedure described below. • Since the high-pressure relief valve is a fixed type, the pressure setting cannot be adjusted.

  • Page 159: Measurement And Inspection Of Vibration Charge Circuit Pressure

    MEASUREMENT AND INSPECTION OF VIBRATION CHARGE CIRCUIT PRESSURE 7. MEASUREMENT AND INSPECTION OF VIBRATION CHARGE CIRCUIT PRESSURE Before measuring • Since charge circuit oil is being supplied from the steering circuit, first confirm that the steering operation is normal. • The propulsion charge circuits and vibration charge circuits consist of parallel circuits.

  • Page 160: Measurement

    MEASUREMENT AND INSPECTION OF VIBRATION CHARGE CIRCUIT PRESSURE 7-1. Measurement • Oil temperature during measurement: 50 ± 5°C (122 ± 41°F) ① Remove the plug from the charge pressure gauge port (2-5). Attach the pressure gauge through the adapter ⓖ . •...

  • Page 161: Inspection

    MEASUREMENT AND INSPECTION OF VIBRATION CHARGE CIRCUIT PRESSURE 7-2. Inspection If the measurement results indicate the pressure • values deviating from the standard charge relief pressure setting, conduct an inspection in accordance with the procedure described below. Since the vibration charge relief valve is a fixed •...

  • Page 162: Measurement And Inspection Of Steering Circuit Pressure

    MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE 8. MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE 8-1. Measurement Before turning the steering wheel, confirm that no one is near the vehicle’s bends spots. • Oil temperature during measurement: 50 ± 5°C (122 ±...

  • Page 163: Inspection

    MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE 8-2. Inspection If the measurement results indicate the pressure • values deviating from the maximum standard circuit pressure, make an adjustment in accordance with the procedure described below. Since the vibration charge relief valve is a fixed •...

  • Page 164: Adjustment Of Throttle Lever Linkage

    ADJUSTMENT OF THROTTLE LEVER LINKAGE 9. ADJUSTMENT OF THROTTLE LEVER LINKAGE 9-1. Adjustment If the throttle lever linkage was replaced or the • maximum no-load rotational speed (minimum IDLE IDLE no-load rotational speed) deviates from the s t a n d a r d v a l u e , m a k e a n a d j u s t m e n t i n accordance with the procedure described below.

  • Page 165: Adjustment Of Forward-Reverse Lever Linkage

    ADJUSTMENT OF FORWARD-REVERSE LEVER LINKAGE 10. ADJUSTMENT OF FORWARD-REVERSE LEVER LINKAGE 10-1. Adjustment If the forward-reverse lever linkage was • replaced, make an adjustment in accordance with the procedure described below. • The neutral position of the forward-reverse lever (1) and the maximum stroke on the forward- reverse side are positioned by notches.

  • Page 167: Troubleshooting

    TROUBLESHOOTING...

  • Page 169: Safety Precautions For Troubleshooting

    TROUBLESHOOTING 1. TROUBLESHOOTING 1-1. Safety Precautions for Troubleshooting WARNING Unexpected vehicle movement may cause a serious accident. When inspecting the machine while the engine is running, always follow the instructions below. Park the machine on level, flat ground. • • Apply the parking brake. • Set a stopper in front and behind each drum or tire. • Make sure that service personnel are given the appropriate information at the appropriate time. • Make sure that no one can enter any hazardous area. CAUTION Do not work on the hydraulic system while the engine is running and the system is hot and under pressure. Do not disconnect hydraulic hoses or fittings until the system has cooled and pressure has been properly relieved.

  • Page 170: Important Information For Troubleshooting

    TROUBLESHOOTING 1-2. Important Information for Troubleshooting Before conducting troubleshooting, it is important to carefully read the operation manual and workshop manual and understand the electric circuits for each component as well as the structure and function of each system. Sufficient knowledge of the systems will enable you to identify a possible cause much faster.

  • Page 171: Electrical System Troubleshooting

    ELECTRICAL SYSTEM TROUBLESHOOTING 2. ELECTRICAL SYSTEM TROUBLESHOOTING 2-1. When Performing Electrical System Fault Diagnosis WARNING When a failure occurs due to a faulty contact or other such cause, use caution because the equipment can return to normal during an inspection and suddenly operate properly. 2-1-1. Precautions to take during electric circuit fault diagnosis • When disconnecting or connecting a connector, be sure to turn the power supply OFF. Since connectors are not numbered, be sure to affix alignment marks so that you can restore •...
  • Page 172 ELECTRICAL SYSTEM TROUBLESHOOTING 2-3) How to find cause of failure when fuse burnout is reproduced 1) Turn the starter switch OFF, and remove the connector from the load (valve, pump). 2) Referring to the circuit diagram, remove electrical parts that are connected to the circuit, such as relays, timers and diodes.
  • Page 173 ELECTRICAL SYSTEM TROUBLESHOOTING 5) Solenoid valve inspection (Check ON/OFF operation by sound.) • Conduct without running the engine. (If you run the engine, you cannot hear the sound of operation.) Sound heard : The electrical system is normal. No sound heard : Check with a tester. Continuity : (1) Turn the starter switch OFF temporarily, disconnect the connector and check for continuity between the harness-side grounding terminal (color:...
  • Page 174 ELECTRICAL SYSTEM TROUBLESHOOTING Fig. : 2-2 Foot brake switch Foot brake switch F-R lever switch F-R lever switch NC NO COM NC NO COM NC NO COM NC NO COM Neutral Neutral Fuse box Fuse box relay relay Parking brake Parking brake Combination Combination switch switch meter parking brake...

  • Page 175: Engine

    ELECTRICAL SYSTEM TROUBLESHOOTING 2-2. Engine Check the following items before troubleshooting. • Forward/reverse lever is in “neutral” position. • No fuse blew. 2-2-1. Engine will not start (starter motor does not run) Reference Fig. : 2-2 Check point Check/Cause Action - Measure battery voltage or specific gravity. 1. Battery Capacity Charge or replace Standard voltage: 12 V or more the battery.
  • Page 176 ELECTRICAL SYSTEM TROUBLESHOOTING Fig. : 2-2 Foot brake switch Foot brake switch F-R lever switch F-R lever switch NC NO COM NC NO COM NC NO COM NC NO COM Neutral Neutral Fuse box Fuse box relay relay Parking brake Parking brake Combination Combination switch switch meter parking brake...
  • Page 177 ELECTRICAL SYSTEM TROUBLESHOOTING 2-2-1. Engine will not start (starter motor does not run) Reference Fig. : 2-2 Check point Check/Cause Action 7. L-Interlock Relay (1) When turning starter switch ON, measure voltage between Replace the L-interlock relay pin 1 inlet W wire and chassis ground. L-interlock relay. Standard voltage: 12 V or more (2) When starting starter switch, measure voltage between L-interlock relay pin 3 inlet Lg wire and chassis ground.
  • Page 178 ELECTRICAL SYSTEM TROUBLESHOOTING Fig. : 2-2 Foot brake switch Foot brake switch F-R lever switch F-R lever switch NC NO COM NC NO COM NC NO COM NC NO COM Neutral Neutral Fuse box Fuse box relay relay Parking brake Parking brake Combination Combination switch switch meter parking brake...

  • Page 179: Engine Will Not Start (But Starter Motor Runs)

    ELECTRICAL SYSTEM TROUBLESHOOTING 2-2-2. Engine will not start (but starter motor runs) • Check that fuel is being supplied to the injection pump inlet. Reference Fig. : 2-2 Check point Check/Cause Action 1. Shutdown Solenoid - When turning starter switch ON, measure voltage between Replace the shutdown shutdown solenoid inlet WB wire and chassis ground. solenoid.
  • Page 180 ELECTRICAL SYSTEM TROUBLESHOOTING Fig. : 2-2 Foot brake switch Foot brake switch F-R lever switch F-R lever switch NC NO COM NC NO COM NC NO COM NC NO COM Neutral Neutral Fuse box Fuse box relay relay Parking brake Parking brake Combination Combination switch switch meter parking brake...

  • Page 181: Starting Engine Is Difficult

    ELECTRICAL SYSTEM TROUBLESHOOTING 2-2-6. Starting engine is difficult Reference Fig. : 2-2 Check point Check/Cause Action 1. Negative Torque - When starting starter switch, measure voltage between Replace the negative Control Solenoid negative torque control solenoid inlet wire and chassis torque control ground. solenoid. It is normal that electricity flows. - If electricity flows but starting engine is difficult, the solenoid is faulty.
  • Page 182 ELECTRICAL SYSTEM TROUBLESHOOTING Fig. : 2-3 F-R lever switch F-R lever switch Foot brake switch Foot brake switch Diode unit Diode unit L-interlock relay L-interlock relay Neutral holding relay Neutral holding relay Neutral relay Neutral relay Neutral solenoid Neutral solenoid Parking brake Parking brake solenoid solenoid P-interlock relay...

  • Page 183: Propulsion

    ELECTRICAL SYSTEM TROUBLESHOOTING 2-3. Propulsion Check the following items before troubleshooting. • No fuse blew. 2-3-1. Vehicle speed does not change Reference Fig. : 2-3 Check point Check/Cause Action 1. Speed Change - Disconnect harness and measure resistance of coil. Replace the speed Standard resistance: 5.1 Ω Solenoid change solenoid. - If measured resistance is abnormal, the speed change solenoid is faulty.
  • Page 184 ELECTRICAL SYSTEM TROUBLESHOOTING Fig. : 2-3 F-R lever switch F-R lever switch Foot brake switch Foot brake switch Diode unit Diode unit L-interlock relay L-interlock relay Neutral holding relay Neutral holding relay Neutral relay Neutral relay Neutral solenoid Neutral solenoid Parking brake Parking brake solenoid solenoid P-interlock relay...
  • Page 185 ELECTRICAL SYSTEM TROUBLESHOOTING 2-3-2. Brake does not release Reference Fig. : 2-3 Check point Check/Cause Action 3. Neutral Relay (1) When the starter switch is ON, measure the voltage between the Replace the neutral relay pin 1 inlet BrW wire and chassis ground. neutral relay. Standard voltage: 12 V or more (2) When the starter switch is ON, measure the voltage between the neutral relay pin 3 inlet GW wire and chassis ground.
  • Page 186 ELECTRICAL SYSTEM TROUBLESHOOTING Fig. : 2-3 F-R lever switch F-R lever switch Foot brake switch Foot brake switch Diode unit Diode unit L-interlock relay L-interlock relay Neutral holding relay Neutral holding relay Neutral relay Neutral relay Neutral solenoid Neutral solenoid Parking brake Parking brake solenoid solenoid P-interlock relay...

  • Page 187: Brake Does Not Operate

    ELECTRICAL SYSTEM TROUBLESHOOTING 2-3-3. Brake does not operate • When the parking brake switch is ON or the foot brake switch is OFF (the brake pedal is depressed). Reference Fig. : 2-3 Check point Check/Cause Action 1. Foot Brake Switch - When the starter switch is ON, measure the voltage between Replace the foot the foot brake switch NO terminal inlet LgR wire and chassis brake switch.
  • Page 188 ELECTRICAL SYSTEM TROUBLESHOOTING Fig. : 2-3 F-R lever switch F-R lever switch Foot brake switch Foot brake switch Diode unit Diode unit L-interlock relay L-interlock relay Neutral holding relay Neutral holding relay Neutral relay Neutral relay Neutral solenoid Neutral solenoid Parking brake Parking brake solenoid solenoid P-interlock relay...

  • Page 189: Vehicle Moves Neither Forward Nor Backward

    ELECTRICAL SYSTEM TROUBLESHOOTING 2-3-4. Vehicle moves neither forward nor backward • The parking brake switch is turned OFF. • The foot brake switch is turned ON (the brake pedal is not depressed). Reference Fig. : 2-3 Check point Check/Cause Action 1. F-R Lever Switch (1) When turning the forward/reverse lever to forward with the Replace the F-R starter switch is OFF, check the continuity between the F-R lever switch.
  • Page 190 ELECTRICAL SYSTEM TROUBLESHOOTING Fig. : 2-3 F-R lever switch F-R lever switch Foot brake switch Foot brake switch Diode unit Diode unit L-interlock relay L-interlock relay Neutral holding relay Neutral holding relay Neutral relay Neutral relay Neutral solenoid Neutral solenoid Parking brake Parking brake solenoid solenoid P-interlock relay...
  • Page 191 ELECTRICAL SYSTEM TROUBLESHOOTING 2-3-4. Vehicle moves neither forward nor backward Reference Fig. : 2-3 Check point Check/Cause Action 7. Foot Brake Switch (1) When turning starter switch is ON, measure the voltage Replace the foot between foot brake switch COM terminal inlet R wire and brake switch. chassis ground. Standard voltage: 12 V or more (2) When turning starter switch ON, measure voltage between foot brake switch NO terminal inlet LgR wire and chassis ground.
  • Page 192 ELECTRICAL SYSTEM TROUBLESHOOTING Fig. : 2-4 F-R lever vibrator F-R lever vibrator ON/OFF switch ON/OFF switch Vibrator Vibrator solenoid solenoid HIGH HIGH Vibrator Vibrator selector selector switch switch Vibrator L-H Vibrator L-H change switch change switch Fuse Fuse SV400-2-09004 SV400-2-09004 9-024...

  • Page 193: Vibrator

    ELECTRICAL SYSTEM TROUBLESHOOTING 2-4. Vibrator Check the following items before troubleshooting. • No fuse blew. 2-4-1. No vibration occurs • The vibrator L-H change switch on the control panel is not turned OFF. Reference Fig. : 2-4 Check point Check/Cause Action 1. Vibrator Solenoid - Disconnect the harness of the a or b vibrator solenoid and Replace the vibrator measure the coil resistance.
  • Page 194 ELECTRICAL SYSTEM TROUBLESHOOTING Fig. : 2-4 F-R lever vibrator F-R lever vibrator ON/OFF switch ON/OFF switch Vibrator Vibrator solenoid solenoid HIGH HIGH Vibrator Vibrator selector selector switch switch Vibrator L-H Vibrator L-H change switch change switch Fuse Fuse SV400-2-09004 SV400-2-09004 9-026...

  • Page 195: When The Forward/Reverse Lever Is Operated

    ELECTRICAL SYSTEM TROUBLESHOOTING 2-4-3. V ibrator control is continuously engaged or does not change when the forward/ reverse lever is operated • The vibrator L-H switch on the control panel must not be turned OFF. Reference Fig. : 2-4 Check point Check/Cause Action 1. Vibrator Selector - When the starter switch is ON, measure the voltage between Replace the vibrator Switch vibrator selector switch pins 1 inlet RY wire and chassis selector switch.
  • Page 196 ELECTRICAL SYSTEM TROUBLESHOOTING Fig. : 2-5 Diode unit Diode unit G H I G H I Vibrator Vibrator solenoid solenoid HIGH HIGH Vibrator L-H Vibrator L-H change switch change switch Combination meter Combination meter Backup Backup Light Light buzzer buzzer Backup Backup buzzer buzzer switch switch Fuse box...

  • Page 197: Lighting And Accessories

    ELECTRICAL SYSTEM TROUBLESHOOTING 2-5. Lighting and Accessories Check the following items before troubleshooting. • No fuse blew. 2-5-1. Combination meter monitor lamps do not light Reference Fig. : 2-5 Check point Check/Cause Action 1. Each Bulb - Check that none of the combination meter bulbs is burned out Replace each bulb. or has a contact failure (oil pressure warning lamp, hydraulic oil filter warning lamp, parking brake indicator lamp, vibrator operation indicator lamp and battery charge lamp).
  • Page 198 ELECTRICAL SYSTEM TROUBLESHOOTING Fig. : 2-5 Diode unit Diode unit G H I G H I Vibrator Vibrator solenoid solenoid HIGH HIGH Vibrator L-H Vibrator L-H change switch change switch Combination meter Combination meter Backup Backup Light Light buzzer buzzer Backup Backup buzzer buzzer switch switch Fuse box...

  • Page 199: Hour Meter Is Abnormal

    ELECTRICAL SYSTEM TROUBLESHOOTING 2-5-3. Hour meter is abnormal • The other lamps light correctly. Reference Fig. : 2-5 Check point Check/Cause Action 1. Hour Meter - When turning starter switch ON, measure voltage between Replace the hour meter plus (+) terminal YG wire and chassis ground. combination meter. Standard voltage: 12 V or more - If above measurement is normal, the hour meter is faulty.
  • Page 200 ELECTRICAL SYSTEM TROUBLESHOOTING Fig. : 2-5 Diode unit Diode unit G H I G H I Vibrator Vibrator solenoid solenoid HIGH HIGH Vibrator L-H Vibrator L-H change switch change switch Combination meter Combination meter Backup Backup Light Light buzzer buzzer Backup Backup buzzer buzzer switch switch Fuse box...

  • Page 201: Hydraulic Oil Filter Warning Lamp Remains On

    ELECTRICAL SYSTEM TROUBLESHOOTING 2-5-6. Hydraulic oil filter warning lamp remains ON • Check without starting the engine. Reference Fig. : 2-5 Check point Check/Cause Action 1. Hydraulic Oil Filter - Turn the starter switch ON and check continuity between the Replace the hydraulic oil filter switch inlet terminal and chassis ground. hydraulic oil filter Switch - No continuity indicates normal condition.
  • Page 202 ELECTRICAL SYSTEM TROUBLESHOOTING Fig. : 2-5 Diode unit Diode unit G H I G H I Vibrator Vibrator solenoid solenoid HIGH HIGH Vibrator L-H Vibrator L-H change switch change switch Combination meter Combination meter Backup Backup Light Light buzzer buzzer Backup Backup buzzer buzzer switch switch Fuse box...

  • Page 203: Parking Brake Indicator Lamp Does Not Light

    ELECTRICAL SYSTEM TROUBLESHOOTING 2-5-9. Parking brake indicator lamp does not light Reference Fig. : 2-5 Check point Check/Cause Action 1. Bulb - Check if bulb has burnt out or is poorly connected. Replace the bulb. - Bulb is faulty or poorly connected. 2. Parking Brake - When turning starter switch ON, measure voltage between Replace the parking Switch parking brake switch pin 4 inlet GR wire and chassis ground.
  • Page 204 ELECTRICAL SYSTEM TROUBLESHOOTING Fig. : 2-5 Diode unit Diode unit G H I G H I Vibrator Vibrator solenoid solenoid HIGH HIGH Vibrator L-H Vibrator L-H change switch change switch Combination meter Combination meter Backup Backup Light Light buzzer buzzer Backup Backup buzzer buzzer switch switch Fuse box...

  • Page 205: Backup Buzzer Does Not Beep

    ELECTRICAL SYSTEM TROUBLESHOOTING 2-5-11. Backup buzzer does not beep Reference Fig. : 2-5 Check point Check/Cause Action 1. Buzzer - Disconnect buzzer and connect the buzzer terminal to the Replace the buzzer. battery directly. - If the buzzer does not beep, it is faulty. 2. Backup Buzzer (1) When the forward/reverse lever is in the reverse position, Replace the backup Switch measure the voltage between the backup buzzer switch...

  • Page 206: Hydraulic System Troubleshooting

    HYDRAULIC SYSTEM 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 207: Propulsion

    HYDRAULIC SYSTEM TROUBLESHOOTING 3-2. Propulsion If a problem occurs in the propulsion system such as propulsion pump, propulsion motor or brake, determine the cause and carry out action as required, according to the following general troubleshooting items. When checking whether or not the pressure is correct, refer to the pressure standard value for each hydraulic circuit.

  • Page 208: Vehicle Moves In One Direction Only (Forward Or Backward)

    HYDRAULIC SYSTEM TROUBLESHOOTING 3-2-1. Vehicle moves neither forward nor backward Check point Cause Check/Action 12. Coupling Dirive torque is not transmitted to pump Replace the coupling. due to faulty coupling. The oil flow is not divided because the Clean the spool or replace the flow 13. Flow Dividing Valve (type SV400TB-2 &...

  • Page 209: Vehicle Speed Does Not Change

    HYDRAULIC SYSTEM TROUBLESHOOTING 3-2-4. Vehicle speed does not change Check point Cause Check/Action 1. Charge Pressure The propulsion motor swash plate does Measure the charge pressure. If low, not move because the charge pressure check the propulsion or vibrator charge is low. relief valve, and then adjust or replace the valve.

  • Page 210: Propulsion System Is Overheating

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

  • Page 211: Vibrator

    HYDRAULIC SYSTEM TROUBLESHOOTING 3-3. Vibrator If a problem occurs in the vibrator system such as vibrator pump, vibrator motor, or vibrator solenoid valve, determine the cause and carry out action as required, according to the following general troubleshooting items. When checking whether or not the pressure is correct, refer to the pressure standard value for each hydraulic circuit.

  • Page 212: Vibrator Frequency Is Too Low

    HYDRAULIC SYSTEM TROUBLESHOOTING 3-3-2. Vibrator frequency is too low Check point Cause Check/Action 1. Oil Level of Hydraulic Oil Oil level in hydraulic oil tank is low. Fill the tank until the correct oil level is Tank obtained. 2. Charge Pressure The stroke of the vibrator pump Measure the charge pressure.

  • Page 213: Vibrator System Is Overheating

    HYDRAULIC SYSTEM TROUBLESHOOTING 3-3-5. Vibrator system is overheating Check point Cause Check/Action 1. Oil Level of Hydraulic Oil Oil level in hydraulic oil tank is low. Fill the tank until the correct oil level is Tank obtained. Cooling efficiency is reduced due to Clean the oil cooler fin. 2.

  • Page 214: Steering

    HYDRAULIC SYSTEM TROUBLESHOOTING 3-4. Steering If a problem occurs in steering system such as steering pump or orbitroll, determine the cause and carry out action as required, according to the following general troubleshooting items. When checking whether or not the pressure is correct, refer to the pressure standard value for each hydraulic circuit.

  • Page 215: Steering Wheel Backlash Or Play Is Large

    HYDRAULIC SYSTEM 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 Replace the column shaft or orbitrol. worn. Column shaft bearing is worn. Replace the column shaft bearings. 2. Steering Wheel Serration (spline) of wheel or column Replace the wheel or column shaft.

  • Page 216: Blade (Sv400Tb/Fb-2)

    HYDRAULIC SYSTEM TROUBLESHOOTING 3-5. Blade (SV400TB/FB-2) 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. When checking whether or not the pressure is correct, refer to the pressure standard value for each hydraulic circuit.

  • Page 217: Blade Floating Operation Not Possible

    HYDRAULIC SYSTEM TROUBLESHOOTING 3-5-3. Blade floating operation not possible Check point Cause Check/Action Blade floating operation is not possible 1. Control Valve If the control valve lever does not move, because the control valve spool does check and clean the spool, or replace not change.
  • Page 218 SAKAI HEAVY INDUSTRIES, LTD. Head office: 1-4-8, Shiba-Daimon, Minato-ku Tokyo, Japan Telephone: Tokyo (03) 3431-9971 Facsimile: (03) 3431-6212 Printed in japan 2008.10.100...

This manual is also suitable for:

Sv400t-2Sv400tb-2Sv400tf-2Sv400fb-2

Table of Contents