Sakai R2-4 Shop Manual
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Sakai R2-4 Shop Manual

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R2
-4
SHOP MANUAL
3498-6634A-0

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Summary of Contents for Sakai R2-4

  • Page 1 SHOP MANUAL 3498-6634A-0...
  • Page 3 Introduction This manual provides important information to familiarize you with safe operating and maintenance procedures for your SAKAI roller. Even though you may be familiar with similar equipment you must read and understand this manual before operating or servicing this unit.

  • Page 5: Table Of Contents

    ○ CONTENTS 1. SAFETY 1. GENERAL SAFETY 1-1. Understanding the Safety Symbols and Words  1-001 1-2. General  1-001 1-3. Qualifications of Operators and Maintenance Personnel  1-002 1-4. Safety Practices and Policies 1-002 1-5. Pre Start Inspection   1-003 1-6.
  • Page 6 ○ 3. ENGINE AND CONTROLS 1. ENGINE 1-1. Engine Mount  3-001 1-2. Engine Exterior  3-002 2. CONTROL SYSTEMS 2-1. Throttle Control   3-003 2-2. Forward-reverse Control  3-004 3. PUMP MOUNT 3-1. Pump Mount   3-005 3-1-1.
  • Page 7 ○ 5. ELECTRICAL SYSTEM 1. PRECAUTIONS FOR wORK 1-1. wire Numbers, wire Sizes, wire Colors and Connectors Shown in Electrical Circuit Diagram, wiring Harness Layout and wiring Harnesses  5-001 2. SYSTEM CIRCUIT DIAGRAM 2-1. Electrical Circuit Diagram  5-003 3.
  • Page 8 ○ 2-3. Drum (R) (R2 )  6-005 2-4. Drum (R) (R2H )  6-006 7. BRAKE 1. BRAKE PEDAL  7-001 2. BRAKE SYSTEM   7-002 8. WATER SPRAY SYSTEM 1. wATER SPRAY PIPING  8-001 9. INSPECTION AND ADJUSTMENT 1.
  • Page 9 ○ 10. ADJUSTMENT OF THROTTLE LEVER 10-1. Adjustment of Potentiometer   9-015 10-2. Adjustment of Operating Force  9-017 11. ADJUSTMENT OF F-R LEVER LINKAGE 11-1. Adjustment  9-018 10. TROUBLESHOOTING 1. TROUBLESHOOTING 1-1. Safety Precautions for Troubleshooting  1 0-001 1-2.
  • Page 10 ○ 2-5-2. Continuous water spray works, but intermittent water spray does not operate  1 0-037 2-6. Lighting   1 0-039 2-6-1. Head lamp, side marker lamp, tail lamp and license lamp do not light 1/2  1 0-039 2-6-1.
  • Page 11 ○ 3-3. Steering System  1 0-071 3-3-1. Steering wheel is hard to turn  1 0-071 3-3-2. Steering response is slow   1 0-071 3-3-3. Steering wheel backlash or play is large   1 0-072 3-3-4. Steering system is overheating  1 0-072 3-3-5.

  • Page 13: Safety

    SAFETY...

  • Page 15: General Safety

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

  • Page 16: Qualifications Of Operators And Maintenance Personnel

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

  • Page 17: Pre Start Inspection

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

  • Page 18: Starting

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

  • Page 19: Maintenance

    • Never fill the fuel tank with the engine running, while near an open flame or while smoking. Always clean up any spilled fuel. • Ensure safe operation, optimum performance of the machine and its warranty by using only genuine SAKAI replacement parts. 1-005...
  • Page 20 SAFETY • Use only the specified fluids and lubricants. Substitute only products known to be equivalent from reputable manufacturers. • Disconnect the battery cables when working on the electrical system or when welding on the compactor. • Be sure the battery area is well ventilated (clear of fumes) should it be necessary to connect a jumper cable or battery charger.

  • Page 21: Transporting The Machine

    SAFETY 1-11. Transporting the Machine • Use only suitable and approved trailers and haul vehicles and lifting equipment of sufficient capacity. • Entrust to experienced personnel the fastening and lifting of loads and instructing of crane operators. • Only experienced persons familiar with the operation of the machine may load and unload the machine.

  • Page 23: Specifications

    SPECIFICATIONS...

  • Page 26: Specification Data

    SPECIFICATIONS 1. SPECIFICATION DATA 1-1. R2 1000 1100 3400 5020 0634-99374-0-11527-0 Model SAKAI R2 with AWNING Model & Type Type STATIC THREE-wHEEL ROLLER without ballast 9,800 kg 21,605 lbs. Operating weight with ballast N/A kg N/A lbs. Maximum weight 10,180 kg 22,445 lbs.
  • Page 27 SPECIFICATIONS Centrifugal Low amplitude N/A kN N/A lbf. force High amplitude N/A kN N/A lbf. Low amplitude N/A Hz N/A vpm Front Frequency High amplitude N/A Hz N/A vpm Low amplitude N/A mm N/A in. Amplitude High amplitude N/A mm N/A in.
  • Page 28 SPECIFICATIONS Model KUBOTA V3307-CR-T-EF05 (Diesel, EPA-Tier4) 4-cycle, water-cooled, 4-cylinder in-line, overhead valve, Type direct injection type, with turbo charger Cylinders - Bore × Stroke 94 mm × 120 mm (3.701 in. × 4.724 in.) Displacement 3.331 L 203.3 cu.in. ) Rated speed 2,200 min Rated output...

  • Page 29: Rops

    ROPS SPECIFICATIONS 1-2. R2 ROPS 1000 1100 3400 5020 0634-99375-0-11528-0 Model SAKAI R2 with ROPS Model & Type Type STATIC THREE-wHEEL ROLLER without ballast 10,060 kg 22,180 lbs. Operating weight with ballast N/A kg N/A lbs. Maximum weight 10,520 kg 23,190 lbs.
  • Page 30 SPECIFICATIONS ROPS Centrifugal Low amplitude N/A kN N/A lbf. force High amplitude N/A kN N/A lbf. Low amplitude N/A Hz N/A vpm Front Frequency High amplitude N/A Hz N/A vpm Low amplitude N/A mm N/A in. Amplitude High amplitude N/A mm N/A in.
  • Page 31 ROPS SPECIFICATIONS Model KUBOTA V3307-CR-T-EF05 (Diesel, EPA-Tier4) 4-cycle, water-cooled, 4-cylinder in-line, overhead valve, Type direct injection type, with turbo charger Cylinders - Bore × Stroke 94 mm × 120 mm (3.701 in. × 4.724 in.) Displacement 3.331 L 203.3 cu.in. ) Rated speed 2,200 min Rated output...

  • Page 32: R2H -4

    SPECIFICATIONS 1-3. R2H 1000 1100 3400 5020 0634-99376-0-11529-0 Model SAKAI R2H with AWNING Model & Type Type STATIC THREE-wHEEL ROLLER without ballast 10,560 kg 23,280 lbs. Operating weight with ballast 13,700 kg 30,205 lbs. Maximum weight 14,080 kg 31,040 lbs.
  • Page 33 SPECIFICATIONS Centrifugal Low amplitude N/A kN N/A lbf. force High amplitude N/A kN N/A lbf. Low amplitude N/A Hz N/A vpm Front Frequency High amplitude N/A Hz N/A vpm Low amplitude N/A mm N/A in. Amplitude High amplitude N/A mm N/A in.
  • Page 34 SPECIFICATIONS Model KUBOTA V3307-CR-T-EF05 (Diesel, EPA-Tier4) 4-cycle, water-cooled, 4-cylinder in-line, overhead valve, Type direct injection type, with turbo charger Cylinders - Bore × Stroke 94 mm × 120 mm (3.701 in. × 4.724 in.) Displacement 3.331 L 203.3 cu.in. ) Rated speed 2,200 min Rated output...

  • Page 35: Rops

    ROPS SPECIFICATIONS 1-4. R2H ROPS 1000 1100 3400 5020 0634-99377-0-11530-0 Model SAKAI R2H with ROPS Model & Type Type STATIC THREE-wHEEL ROLLER without ballast 10,900 kg 24,030 lbs. Operating weight with ballast 14,040 kg 30,955 lbs. Maximum weight 14,420 kg 31,790 lbs.
  • Page 36 SPECIFICATIONS ROPS Centrifugal Low amplitude N/A kN N/A lbf. force High amplitude N/A kN N/A lbf. Low amplitude N/A Hz N/A vpm Front Frequency High amplitude N/A Hz N/A vpm Low amplitude N/A mm N/A in. Amplitude High amplitude N/A mm N/A in.
  • Page 37 ROPS SPECIFICATIONS Model KUBOTA V3307-CR-T-EF05 (Diesel, EPA-Tier4) 4-cycle, water-cooled, 4-cylinder in-line, overhead valve, Type direct injection type, with turbo charger Cylinders - Bore × Stroke 94 mm × 120 mm (3.701 in. × 4.724 in.) Displacement 3.331 L 203.3 cu.in. ) Rated speed 2,200 min Rated output...

  • Page 38: Table Of Standard Values

    SPECIFICATIONS 2. TABLE OF STANDARD VALUES 2-1. Engine Item Standard value Remarks KUBOTA V3307-CR-T-EF05 Diesel Engine Engine model with turbocharger Rated output 66.5 89.2 ± 3 ± 4 2,200 min Max. no-load rotational speed Min. no-load rotational speed 900 min Cylinder head tightening torque 187 to 196 N·m ( 137.9 to 144.6 lbf·ft...

  • Page 39: Steering

    SPECIFICATIONS 2-4. Steering Item Standard value Remarks Steering wheel 5 to 10 mm ( 0.2 to 0.4 in. ) circumference Play in steering wheel Steering column shaft 0.5 mm ( 0.02 in. ) or less direction When midpoint of chain at Steering chain tension 25 to 30 mm ( 1.0 to 1.2 in.

  • Page 40: Fuel And Lubricants Specification

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

  • Page 41: 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 43: Engine And Controls

    ENGINE AND CONTROLS...

  • Page 45: Engine

    ENGINE AND CONTROLS 1. ENGINE 1-1. Engine Mount 10,11 12 13 DETAIL B VIEW A 0634-01808-0-11231-B (1) Engine (7) Bracket (13) Bolt : M14×30 P=1.5 (2) Bracket (8) Bolt : M12×40 P=1.25 (14) Nut : M12 P=1.25 (3) Bolt : M12× 40 P=1.25 (9) Stopper (15) Stopper (4) Bolt...

  • Page 46: Engine Exterior

    ENGINE AND CONTROLS 1-2. Engine Exterior * The actual equipment may differ from that shown above. TZ703-03003 (1) Temperature sensor (12) Fan drive pulley (23) DPF (2) Differential pressure sensor (13) Oil drain plug (24) Flywheel (3) EGR pipe (14) Oil level gauge (25) EGR cooler (4) EGR valve (15) Oil filter cartridge...

  • Page 47: Control Systems

    ENGINE AND CONTROLS 2. CONTROL SYSTEMS 2-1. Throttle Control 11,12 13,14 IDEL FULL Apply grease SECTION B-B SECTION A-A 0634-12810-0-11239-A (1) Throttle lever (8) Bush (Apply grease) (2) Shaft (9) washer (Apply grease) (3) Washer (10) Bush (Apply grease) (4) Coned disc spring (Do not apply grease) (11) Lock nut : M8 (5) Nut...

  • Page 48: Forward-Reverse Control

    ENGINE AND CONTROLS 2-2. Forward-reverse Control VIEW C-C SECTION A-A SECTION B-B 0634-12809-0-11084-C (1) F-R lever (right) (8) Lock nut : M8 (15) Lock nut : M12 (2) Shaft (9) Stopper bolt (forward) : M8×25 (16) Spring (Fill grease) (3) Rod end (10) Lock nut : M8 (17) Steel ball...

  • Page 49: Pump Mount

    ENGINE AND CONTROLS 3. PUMP MOUNT 3-1. Pump Mount SECTION B-B VIEW A 0634-36815-0-11241-B (1) Bolt : M10×30 P=1.25 (5) Bolt : M14×40 (2) Flange (6) Pump (3) Hub (7) Bolt : M10×25 P=1.25 (4) Housing (8) Bolt : M12×35 N•m (1) Bolt M10×30 P=1.25 : 49 N·m ( 36 lbf·ft )

  • Page 50: Installation Of Pump

    (7) Bolt M10×25 P=1.25 : 69 N·m (51 lbf·ft) N•m ⑥ Engage hub (3) with flange (2). SECTION B-B SECTION B-B ⑦ Secure pump (6) to housing (4) with four bolts (5) and R2-4-03001 R2-4-03001 washers. (5) Bolt M14×40 : 167 N·m (123 lbf·ft) N•m (NOTICE) •...

  • Page 51: Hydraulic Systems

    HYDRAULIC SYSTEMS...

  • 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: flow paths and flow con-...

  • Page 57: Hydraulic Circuit Diagram

    HYDRAULIC SYSTEMS 1-2. Hydraulic Circuit Diagram (1/2") (1/2") Propulsion motor Propulsion motor (F,L) (F,R) (1/2") Drum (F,L) Drum (F,R) i=32.11 55.1/28.5 i=32.11 55.1/28.5 cc/rev cc/rev 1.7 MPa 1.7 MPa (1/4") (1/4") (1/4") (1/4") (1/2") MLV MSR (3/8") Valve (1/4") Propulsion pump (1/4") (1/4") 10μm (3/4")

  • Page 59: Propulsion Hydraulic System

    HYDRAULIC SYSTEMS 2. PROPULSION HYDRAULIC SYSTEM Propulsion motor (F,R) Hose (PA2 2-1. Propulsion Hydraulic Piping 2-1-1. Propulsion hydraulic piping (1) Hose (PB3 BV2) To propulsion hydraulic piping (R) Hose (P.4-007) (PA3 BV1) SECTION A-A SECTION B-B Propulsion motor (F,L) Bypass valve Hose (PB2 Propulsion pump...

  • Page 61: Propulsion Hydraulic Piping (2)

    HYDRAULIC SYSTEMS 2-1-2. Propulsion hydraulic piping (2) Speed change solenoid valve Parking brake Propulsion pump solenoid valve neutral solenoid valve Propulsion motor (F,R) Hose Hose (VDR PDV) (PD1 BPD) T3 T1 Hose DETAIL A (MSS To propulsion hydraulic piping (R) Hose (P.4-007) VNC)

  • Page 63: Propulsion Hydraulic Piping (3)

    HYDRAULIC SYSTEMS 2-1-3. Propulsion hydraulic piping (3) Hose (PCV VCP) Hose Hose (MRD PDR) (MLD PD2) Propulsion pump Hose Hose SECTION E-E (VPB MRV) (MSR MSL) Hose Hose (MPL MPR) MLV) (VSC VIEW D VIEW F DETAIL G The letters and numbers in the figure such as “VSC” and “MLV” show each port. Arrow “...

  • Page 65: Propulsion Hydraulic Piping (R)

    HYDRAULIC SYSTEMS 2-1-4. Propulsion hydraulic piping (R) Propulsion motor (R) To propulsion hydraulic piping (F) (P.4-005) Hose Hose Hose RMB) RMP) RMA) Pipe Pipe Pipe Pipe Pipe Hose (RMD Hose VIEW A RMS) The letters and numbers in the figure such as “RMB” and “RB” show each port. Arrow “...

  • Page 68: Hydraulic Component Specifications

    HYDRAULIC SYSTEMS 2-2. Hydraulic Component Specifications 2-2-1. Hydraulic pump assembly (propulsion + steering・charge) 1-10 1-15 1-11 1-12 1-16 VIEW A 1-14 1-13 B NA 1-3 1-5 1-2 1-1 1-14 24.9 16.2 cc/rev cc/rev 1-13 1-11 1-10 Pump circuit diagram R2-4-04001 4-008...
  • Page 69 HYDRAULIC SYSTEMS (1) Propulsion pump (1-1) Charge pressure gauge port (After oil filter) [PCV] : 9/16-18UNF (1-2) Charge pressure gauge port (Before oil filter) 9/16-18UNF (1-3) Servo pressure gauge port [PNC] : 9/16-18UNF (1-4) Drain port [PD1] : 1 1/16-12UN (1-5) Servo pressure gauge port [PND] : 9/16-18UNF...

  • Page 70: Propulsion Hydraulic Motor (F)

    HYDRAULIC SYSTEMS 2-2-2. Propulsion hydraulic motor (F,L) (F,R) Motor circuit diagram R2H-2-04002 (1) Port B1 : G3/4 (8) Parking brake pilot port [MLP] : G1/4 (2) Port A1 [ML1] [MR1] : G3/4 (9) Speed change port [MLS] [MRS] : 9/16-18UNF (3) Parking brake pilot port [MRP] : G1/4 (10) Shift valve assembly...
  • Page 71 HYDRAULIC SYSTEMS 1) Internal structure of propulsion hydraulic motor (F,L) (F,R) 11-1 12-1 12-2 11-2 11-3 12-3 12-4 12-5 12-6 12-7 12-8 12-9 12-10 11-12 11-11 11-9 11-8 11-7 11-6 11-5 12-13 12-12 12-11 11-10 11-4 R2H-2-04003 (11) Motor (12) Reduction gear (11-1) Cylinder block kit (12-1) Floating seal kit...

  • Page 72: Propulsion Hydraulic Motor (R)

    HYDRAULIC SYSTEMS 2-2-3. Propulsion hydraulic motor (R) 10 4 Motor circuit diagram R2H-2-04004 (1) Port B (Reverse) [RMB] : G3/4 (7) Speed change port [RMS] : G1/4 (2) Port A (Forward) [RMA] : G3/4 (8) Shift valve assembly (3) Drain port [RMD] : G1/2 (9) Motor (4) High pressure gauge port (For port B) : G1/4 (10) Reduction gear...
  • Page 73 HYDRAULIC SYSTEMS 1) Internal structure of propulsion hydraulic motor (R) 10-1 10-2 10-3 10-4 10-5 10-6 10-7 9-12 10-9 10-8 9-11 9-10 R2H-2-04005 (9) Motor (10) Reduction gear (9-1) Cylinder block kit (10-1) Floating seal kit (9-2) Control piston (10-2) Angular bearing (9-3) Bearing (10-3) Planetary gear 2nd...

  • Page 74: Valve

    HYDRAULIC SYSTEMS 2-2-4. Valve Hydraulic circuit diagram VIEW A Connection diagram R2-4-04004 (1) Parking brake solenoid valve (6) Port P [VCP] : G1/4 (2) Speed change solenoid valve (7) Port A [VPB] : G1/4 (3) Propulsion pump neutral solenoid valve...

  • Page 75: Block A

    HYDRAULIC SYSTEMS 2-2-5. Block A SECTION A-A R2-4-04005 (1) To propulsion motor (F,L) port A1 [PA1] : G3/4 (2) Body (3) To pipe [PA2] : G3/4 (4) To bypass valve [PA3] : G3/8 (5) From propulsion pump port A : φ 24.5...

  • Page 76: Block B

    HYDRAULIC SYSTEMS 2-2-6. Block B SECTION A-A R2-4-04006 (1) To propulsion motor (F,R) port A1 [PB1] : G3/4 (2) Body (3) To pipe [PB2] : G3/4 (4) To bypass valve [PB3] : G3/8 (5) From propulsion pump port B : φ 24.5...

  • Page 77: Steering System

    HYDRAULIC SYSTEMS 3. STEERING SYSTEM 3-1. Steering Hydraulic Piping Hose SCS) Steerig  charge pump Orbitrol SECTION A-A Hose Hose AD2) AD3) Hose Hose Hose (AD2 PCS) (AD1 AD4) Hose Hose (SC2 (SC1 AD1) Hose (AD3 Hydraulic oil tank Propulsion pump Valve Steering cylinder Hose Hose...

  • Page 79: Steering Wheel

    HYDRAULIC SYSTEMS 3-2. Steering Wheel 0634-32802-0-20337-A (1) Column shaft (5) Nut : M12 P=1.25 (2) Steering wheel (6) Column shaft (3) Nut : M12 P=1.25 (7) Roller chain (4) Steering wheel N•m (3) Nut M12 P=1.25 : 64 N·m ( 47 lbf·ft ) (5) Nut M12 P=1.25 : 64 N·m ( 47 lbf·ft ) 4-018...

  • Page 80: Hydraulic Component Specifications

    HYDRAULIC SYSTEMS 3-3. Hydraulic Component Specifications 3-3-1. Orbitrol Hydraulic circuit diagram R2-4-04002 (1) Port L [L] : 3/4-16UNF (2) Port R [R] : 3/4-16UNF (3) Port P [P] : 3/4-16UNF (4) Port T [T] : 3/4-16UNF (5) Relief valve Specifications •...

  • Page 81: Valve

    HYDRAULIC SYSTEMS 3-3-2. Valve Hydraulic circuit diagram R2-4-04003 (1) Port B : G3/4 (2) Block (3) Solenoid valve (4) Port A : G3/4 (5) Port T [VT] : G3/4 (6) Port P [VP] : G3/4 Specifications • Maximum flow 75 L/min 19.8 gal./min...

  • Page 83: Electrical System

    ELECTRICAL SYSTEM...

  • Page 85: Precautions For Work

    ELECTRICAL SYSTEM 1. PRECAUTIONS FOR wORk 1-1. Wire Numbers, Wire Sizes, Wire Colors and Connectors Shown in Electrical Circuit Diagram, Wiring Harness Layout and Wiring Harnesses • Codes used in electrical circuit diagrams give the following information. • The wire size is AVS 0.85 unless otherwise specified. 26 Lg 24 1.25 BR Wire color...
  • Page 86 ELECTRICAL SYSTEM • Wire color code chart Black/ Black/ Black/ Black/ Black/ Yellow/ B Black Orange White stripe Yellow stripe Red stripe Green stripe Blue stripe Orange stripe white/ white/ white/ white/ white/ Blue/ W White Red stripe Black stripe Blue stripe Yellow stripe Green stripe...

  • Page 87: System Circuit Diagram

    ELECTRICAL SYSTEM 2. SYSTEM CIRCUIT DIAGRAM COMBINATION LAMP (F,R) FLOOD 2-1. Electrical Circuit Diagram 38 1.25RG LAMP (F,R) SPEED CHANGE TURN SIGNAL FLASHER 40 GB (55W) 13 GY 11 Gr SWITCH LAMP (F,R) (21W) UNIT HORN 45 RL SIDE MARKER 12 P 11 Gr FLOOD...

  • Page 89: Electrical Components

    ELECTRICAL SYSTEM 3. ELECTRICAL COMPONENTS 3-1. Wiring Harness Layout (1) Combination lamp harness (F,R) Air flow sensor AFS Flood lamp (F,R) Combination lamp (R,R) (P.5-030) (RG) (B),(GB),(GY),(RL),(RY) (B 2),(G),(L),(WB) Combination lamp (F,R) License lamp Flood lamp (R,R) (B),(GB),(RL) (RL) (RG) F.L. 65A (black) Horn switch (R) Parking brake solenoid PAR (B),(BrB)

  • Page 91: Wiring Harness Layout (2)

    ELECTRICAL SYSTEM 3-2. Wiring Harness Layout (2) Combination meter DPF harness Flood lamp switch Hazard switch Lighting switch harness Hazard switch harness (P.5-027) (GR),(Sb) (G 2),(GB),(GR) (P.5-021) (P.5-022) Mark ENG Mark DPF Mark H Mark G Mark S/P Mark STA Mark O Control switch harness Water spray harness...

  • Page 92: Wiring Harnesses

    ELECTRICAL SYSTEM 4. wIRING HARNESSES 4-1. Main Harness (1) 3 wire shield cable (AVSSCS 0.5sq 3C) 0.5B 3WL,50 Fuse (30A) 0.5W 41 3LB,50 0.5R 3WR,50 Fuse (30A) 66 3GR,50 0.5B 0.5W 48 3W,50 Ground Fuse (20A) 094 0.5R 3R,50 LA208 0.5B R,50 091 0.5W...
  • Page 93 ELECTRICAL SYSTEM CONNECTION and NUMBER CONNECTION and NUMBER CONNECTION and NUMBER CONTACT CONTACT CONTACT SIZE, SIZE, SIZE, OF CONTACT POINTS OF CONTACT POINTS OF CONTACT POINTS POINTS POINTS POINTS COLOR COLOR COLOR TOTAL TOTAL TOTAL Main harness (1) (2) (3) Main harness (1) (2) (3) Main harness (1)

  • Page 94: Main Harness (2)

    ELECTRICAL SYSTEM 4-2. Main Harness (2) Water spray ENGINE Combination meter DPF harness ECO lamp DPF meter Resistor Option Lighting switch harness Hazard switch Control switch harness Potentiometer Stater switch harness Turn signal switch Horn switch (R) (P.5-027) harness WARNING (120 (P.5-021) harness...
  • Page 95 ELECTRICAL SYSTEM CONNECTION and NUMBER CONNECTION and NUMBER CONNECTION and NUMBER CONTACT CONTACT CONTACT SIZE, SIZE, SIZE, OF CONTACT POINTS OF CONTACT POINTS OF CONTACT POINTS POINTS POINTS POINTS COLOR COLOR COLOR TOTAL TOTAL TOTAL Main harness (2) Main harness (2) Main harness (2) BRA -2262, 4643, FLA , 1 Combination meter-16M ×...

  • Page 96: Main Harness (3)

    ELECTRICAL SYSTEM 4-3. Main Harness (3) (120 ） 2 wire twist cable (AVSS 0.75sq) Main harness (2) 156 RW (P.5-008) CAN2-H Engine side connector Machine side connector 155 RB DPF meter CAN2-L MOLEX:80pf (BLUE) MOLEX:80pf (ST-GRAY) 34566-1903 34566-0803 CAN1-H CAN (Service tool) CAN1-L Shield cable Shield cable...
  • Page 97 ELECTRICAL SYSTEM CONNECTION and NUMBER CONNECTION and NUMBER CONNECTION and NUMBER CONTACT CONTACT CONTACT SIZE, SIZE, SIZE, OF CONTACT POINTS OF CONTACT POINTS OF CONTACT POINTS POINTS POINTS POINTS COLOR COLOR COLOR TOTAL TOTAL TOTAL (1) (2) Main harness (3) (1) (2) Main harness (3) (1) (2)

  • Page 98: Frame Harness (F)

    ELECTRICAL SYSTEM 4-4. Frame Harness (F) Horn PB104 Battery relay (NO) (COM) (NO) (COM) (BR) Ground LA308 LA308 LA308 LA308 LA104 LA208 Head lamp (F,L) Fuel pump 7323-3010 7123-2825 (RB3B-SL) (RB2B-SL) 1.25RW 1.25RB 16 13 10 003 1.25RW 1.25O SWP-8F Tape 407 42 1.25BrB...
  • Page 99 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS Battery relay-COM, Fusible link 65A B , Fusible link 65A NEU , PAR , SPE , Fuel pump, Ground, Head lamp (F,L), (F,R), C , Fusible link 75A B, 2B Load solenoid Battery relay-NO, Fusible link 65A...

  • Page 100: Frame Harness (R)

    ELECTRICAL SYSTEM 4-5. Frame Harness (R) Flood lamp Backup (R,R) buzzer CB104 CB104 33 31 1.25RG RY GR SWP-8M Tape BrW RL Main harness (1) (P.5-006) 2550 2600 SWP-6F Combination lamp (R,R) Corrugate  10 Corrugate  10 58X-1M Tape 2350 SWP-6F Combination lamp (R,L) Corrugate  10 CB104...
  • Page 101 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS F , Combination lamp (R,L), (R,R) 1.25RG F , Flood lamp (R,L), (R,R) G , Water spray pump F , Combination lamp (R,R) F , Combination lamp (R,L) F , Combination lamp (R,L), (R,R) F , Combination lamp (R,L), (R,R) F , Backup buzzer...

  • Page 102: Floor Board Harness

    ELECTRICAL SYSTEM 4-6. Floor Board Harness Combination lamp harness (F,R) Combination lamp harness (F,L) (P.5-030) (P.5-029) Fuel gauge unit CA104 CB104 CB104 CA104 CB104 CB104 CA104 CB104 1.25RG,50 1.25RG CB104 Flood lamp (F,R) Tape SWP-6M 1.25B 1000 1300 Main harness (1) (P.5-006) Corrugate  10 Corrugate  10...
  • Page 103 ELECTRICAL SYSTEM CONTACT SIZE, COLOR CONNECTION POINTS 0.5B, B, 1.25B AFS , D , Combination lamp harness (F,L), (F,R), Fuel gauge unit D , Fuel gauge unit D , Combination lamp harness (F,L) 1.25RG D , Flood lamp (F,L), (F,R) D , Combination lamp harness (F,R) D , Combination lamp harness (F,L), (F,R), License lamp 0.5WB...

  • Page 104: Engine Harness

    ELECTRICAL SYSTEM 4-7. Engine Harness Glow plug Thermo unit LE204 LA104 AV15 B,80 LA406 58Y-2M Tape Main harness (1) Alternator (P.5-006) Corrugate Corrugate Corrugate 28 21 6189-0443 SWP-3M Tape Tape LA408 PB104 Starter motor 1634-09119-0-21489-0 CONTACT SIZE, COLOR CONNECTION POINTS ALT , I ALT , I I , Thermo unit...

  • Page 105: Starter Switch Harness

    ELECTRICAL SYSTEM 4-8. Starter Switch Harness 5W,50 LCT RL-1A 5W,80 LA305 (B) 3BR,50 Main harness (2) LCR RL-1B R,80 LA105 (ACC) (P.5-008) Starter LgR,80 Corrugate switch LA105 (BR) SWP-2M 3BR,80 LA205 (C) 1310-09006-0-30165-0 CONTACT SIZE, COLOR CONNECTION POINTS STA , ACC STA , BR STA , C STA , B...

  • Page 106: Control Switch Harness

    ELECTRICAL SYSTEM 4-9. Control Switch Harness 1.25GW,100 BrR,100 Parking brake B,100 1.25GW SWP-4F switch WB,100 Main harness (2) (P.5-008) YL,100 Corrugate 1.25WB,100 SWP-3M 1.25O 1.25WB 1.25O,100 Speed change switch LY,100 406 (3) 1634-09125-0-31495-0 CONTACT SIZE, COLOR CONNECTION POINTS S/P , Parking brake switch-5 1.25O S/P , Speed change switch-2 1.25GW...

  • Page 107: Lighting Switch Harness

    ELECTRICAL SYSTEM 4-10. Lighting Switch Harness WG,100 RL,100 SWP-3F Lighting Lg WG RL switch WG,100 Main harness (2) (P.5-008) Corrugate Lg,100 SWP-2F GR,100 Flood lamp switch Sb,100 1634-09122-0-31492-A CONTACT SIZE, COLOR CONNECTION POINTS H , Lighting switch-5 H , Lighting switch-1, -4 H , Lighting switch-3 H , Flood lamp switch-1 H , Flood lamp switch-2...

  • Page 108: Hazard Switch Harness

    ELECTRICAL SYSTEM 4-11. Hazard Switch Harness G,200 Bypass GB,200 Main harness (2) Hazard switch SWP-6M (P.5-008) Corrugate G,200 GR,200 1634-09127-0-31534-0 CONTACT SIZE, COLOR CONNECTION POINTS G × 2, Hazard switch-1, -4 G , Hazard switch-5 G × 2 G , Hazard switch-2 5-022...

  • Page 109: F-R Lever Switch Harness

    ELECTRICAL SYSTEM 4-12. F-R Lever Switch Harness WL,20 WL,20 (COM) LE104 CA104 Main harness (2) F-R lever switch (P.5-008) Tape BW,30 BW,20 (NO) LE104 CB104 1634-09027-0-40466-A CONTACT SIZE, COLOR CONNECTION POINTS F-R lever switch-NO, Main harness (2) F-R lever switch-COM, Main harness (2) - 5-023...

  • Page 110: Backup Buzzer Switch Harness

    ELECTRICAL SYSTEM 4-13. Backup Buzzer Switch Harness WB,50 WB,40 (COM) LE104 CA104 W,60 W,40 Backup buzzer CB104 LE104 Main harness (2) switch (not in use) (not in use) Tape (P.5-008) RY,30 RY,40 (NO) LE104 CB104 1634-09132-0-41540-A CONTACT SIZE, COLOR CONNECTION POINTS Backup buzzer switch-COM, Main harness (2) Backup buzzer switch-NO, Main harness (2)

  • Page 111: Foot Brake Switch Harness

    ELECTRICAL SYSTEM 4-14. Foot Brake Switch Harness WB,60 WB,20 (COM) LE104 CA104 Main harness (2) Foot brake switch (P.5-008) Tape LgB,30 LgB,20 (NO) LE104 CB104 1634-09028-0-40467-0 CONTACT SIZE, COLOR CONNECTION POINTS Footbrake switch-NO, Main harness (2) - Footbrake switch-COM, Main harness (2) 5-025...

  • Page 112: Engine Warning Lamp Harness

    ELECTRICAL SYSTEM 4-15. ENGINE WARNING Lamp Harness WB,50 CB104 ENGINE WARNING lamp Tape G,50 021 CA104 WB,50 CB104 Main harness (2) ENGINE STOP SWP-4M (P.5-008) lamp Tape Corrugate L,50 020 CA104 WB,50 003 CB104 OVER HEAT lamp Tape Y,50 018 CA104 1634-09123-0-31493-A CONTACT SIZE, COLOR...

  • Page 113: Dpf Harness

    ELECTRICAL SYSTEM 4-16. DPF Harness WB,50 (X1) R1.25-3 DPF request lamp Tape L,50 R1.25-3 (X2) WB,50 (X1) R1.25-3 Main harness (2) SWP-6F DPF active lamp (P.5-008) Tape Corrugate W,50 R1.25-3 (X2) WB,50 DPF switch Tape G,50 1310-09008-0-30167-0 CONTACT SIZE, COLOR CONNECTION POINTS DPF , DRL -X1, DAL -X1, D/S -1...

  • Page 114: Water Spray Harness

    ELECTRICAL SYSTEM 4-17. Water Spray Harness LB,100 LY,100 Water spray mode select switch LB,100 LR,100 Main harness (2) SWP-3F RB4B-SL Water spray timer (P.5-008) LB B Corrugate Tape 1308-09023-0-30388-A CONTACT SIZE, COLOR CONNECTION POINTS O , Water spray timer Water spray mode select switch-5, Water spray timer O , Water spray mode select switch-2, Water spray timer O , Water spray mode select switch-1,-4, Water spray timer 5-028...

  • Page 115: Combination Lamp Harness (F,L)

    ELECTRICAL SYSTEM 4-18. Combination Lamp Harness (F,L) GR,50 GR,70 CA104 Turn signal lamp (F,L) CB104 B,30 B,90 Floor board harness Combination lamp (F,L) Ground CA104 CB104 Tape (P.5-016) RL,50 RL,70 Side marker lamp (F,L) CB104 CA104 1634-09047-0-40883-0 CONTACT SIZE, COLOR CONNECTION POINTS Combination lamp (F,L), Floor board harness...

  • Page 116: Combination Lamp Harness (F,R)

    ELECTRICAL SYSTEM 4-19. Combination Lamp Harness (F,R) GB,50 GB,70 Turn signal lamp (F,R) CB104 CA104 B,90 B,30 Floor board harness Combination lamp (F,R) Ground CA104 CB104 Tape (P.5-016) RL,50 RL,70 Side marker lamp (F,R) CB104 CA104 1634-09048-0-40884-0 CONTACT SIZE, COLOR CONNECTION POINTS Combination lamp (F,R), Floor board harness...

  • Page 117: Sub Power Harness

    ELECTRICAL SYSTEM 4-20. Sub Power Harness Fuse (10A) 2W,500 2Br,100 Sub power Fuse box LCT RL-1A DT04-2P-E005 Vinyl tube Vinyl tube 2B,600 LA208 Ground Vinyl tube 1634-70053-0-31218-A CONTACT SIZE, COLOR CONNECTION POINTS Sub power, Ground 2 , Fuse 10A Sub power, Fuse 10A 5-031...

  • Page 118: Electrical Component Specifications

    20A 15A 15A 15A 15A 15A Starter switch (BR) (WL) Battery relay (WR) Battery relay Flood lamp switch Flood lamp relay R2-4-05001 Harness color codes : white WB : white/Black stripe : Blue WL : white/Blue stripe BY : Black/Yellow stripe...

  • Page 119: Combination Meter

    Charge warning indicator Hydraulic oil filter Engine oil pressure warning indicator warning Preheating indicator Hydraulic oil filter warning Lamp check Coolant temp. SEL.1 Coolant temp. SEL.2 System configuration diagram Note: The circuit in the dashed box is not mounted. R2-4-05002 5-033...

  • Page 121: Drum

    DRUM...

  • Page 123: Precautions For Disassembly And Reassembly

    DRUM 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 124 DRUM 3) Precautions when work is completed • If coolant has been drained, securely retighten the drain valve and fill with coolant (mixing in long- life coolant) to the specified level. Start the engine and allow the coolant to circulate through the piping.

  • Page 125: Drum

    DRUM 2. DRUM 2-1. Drum (F) (R2 0634-24803-0-11400-0 (1) Drum (F,R) (3) Bolt : M16×50 (5) Propulsion motor (F,R) (2) Drum (F,L) (4) Propulsion motor (F,L) (6) Bolt : M16×50 N•m (3) Bolt M16×50 : 265 N·m (195 lbf·ft) (6) Bolt M16×50 : 265 N·m (195 lbf·ft) 6-003...

  • Page 126: Drum (F)

    DRUM 2-2. Drum (F) (R2H 0634-24804-0-11502-0 (1) Drum (F,R) (4) Propulsion motor (F,L) (7) Propulsion motor (F,R) (2) Drum (F,L) (5) Plug (8) Bolt : M16×50 (3) Bolt : M16×50 (6) Plug N•m (3) Bolt M16×50 : 265 N·m (195 lbf·ft) (8) Bolt M16×50 : 265 N·m (195 lbf·ft) 6-004...

  • Page 127: Drum (R)

    DRUM 2-3. Drum (R) (R2 0634-27802-0-11401-0 (1) Drum (R) (6) End plate (11) Bolt : M20×60 (2) Bolt : M16×70 (7) Retaining ring (12) Propulsion motor (R) (3) Ball bearing (8) Case (13) Bolt : M20×60 (4) Bolt : M16×60 (9) Flange (14) Bolt : M20×70 (5) Bolt : M12×40...
  • Page 128 DRUM 2-4. Drum (R) (R2H 0634-27803-0-11503-0 (1) Drum (R) (6) End plate (11) Propulsion motor (R) (2) Plug (7) Retaining ring (12) Bolt : M20×60 (3) Ball bearing (8) Case (13) Bolt : M20×70 (4) Bolt : M16×60 (9) Plate (Apply liquid sealant to the (5) Bolt : M12×40 (10) Bolt : M20×60...

  • Page 129: Brake

    BRAkE...

  • Page 131: Brake Pedal

    BRAKE 1. BRAkE PEDAL Return spring Bolt: M10 40 Nut: M10 Foot brake switch Damper Bolt: M10 40 P=1.25 Rod end Nut: M10 Bolt: M10 50 SECTION A-A SECTION B-B Shaft Brake pedal 0634-51802-0-11190-A 7-001...

  • Page 133: Brake System

    BRAKE 2. BRAkE SYSTEM Foot brake switch Brake Propulsion (Brake ON motor (Condition in which condition) (F,R) brake pedal pressed) Foot brake relay Parking (without relay excited) brake switch (Brake OFF Brake Propulsion Brake Propulsion condition) (Brake ON motor (Brake ON motor (R) condition) (F,L)

  • Page 135: Water Spray System

    wATER SPRAY SYSTEM...

  • Page 137: Water Spray Piping

    WATER SPRAY SYSTEM 1. wATER SPRAY PIPING To water spray pipe (F) Water spray tank Filler Water spray pipe (F) Water spray pipe (F) From filter OUT Water spray pipe (R) Drain valve Nozzle Level gauge SECTION A-A VIEW C-C Hose (Water spray tank Water spray pump)

  • Page 139: Inspection And Adjustment

    INSPECTION AND ADJUSTMENT...

  • Page 141: Safety Precautions For Inspection And Adjustment

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

  • Page 142: Measurement And Adjustment Of Propulsion Circuit Pressure

    ④ Set speed change switch to “ ”. ⑤ Start the engine and set throttle lever to “FULL”. ⑥ Establish a condition in which machine propulsion load R2-4-09001 R2-4-09001 becomes maximum. (Pressure does not build up unless propulsion load is applied.) ⑦...

  • Page 143: Adjustment

    Adjustment screw turned clockwise : Pressure rise 1-16 1-16 Adjustment screw turned counterclockwise : Pressure drop R2-4-09002 R2-4-09002 Pressure change rate : 9 MPa/turn (1,305 psi/turn) ③ If there is no evidence of nut having loosened, remove multifunction valve. ④ Check removed multifunction valve for trapped dirt and scratches on its seat.

  • Page 144: Measurement And Adjustment Of Propulsion Charge Circuit Pressure

    ③ Apply parking brake by pressing parking brake switch button. ④ Start the engine and set throttle lever to “FULL”. ⑤ Read pressure indicated by pressure gauge. Standard charge relief valve setting ★ R2-4-09003 R2-4-09003 : 2.4 MPa (348 psi) ± 0.2 ±...

  • Page 145: Adjustment

    : Pressure drop Pressure change rate : 0.39 MPa/turn (57 psi/turn) ③ If there is no evidence of nut having loosened, remove R2-4-09004 R2-4-09004 charge relief valve. ④ Check removed charge relief valve for trapped dirt and scratches on its seat.

  • Page 146: Measurement Of Propulsion Servo Circuit Pressure

    • with parking brake applied (ON), measured pressures of (1) and (2) are same. • with parking brake released (OFF), measured pressures of (1) and (2) are different. R2-4-09005 R2-4-09005 Standard charge relief pressure setting ★ : 2.4 MPa (348 psi) ±...

  • Page 147: Measurement Of Machine High/Low Speed Change Circuit Pressure

    ④ Set speed change switch to “ ”. ⑤ Start the engine and set throttle lever to “FULL”. ⑥ Read pressure indicated by pressure gauge. Standard charge relief valve setting ★ : 2.4 MPa (348 psi) ± 0.2 ± 29 R2-4-09006 R2-4-09006 PG002002 PG002002 9-007...

  • Page 148: Measurement Of Parking Brake Release Pressure

    ④ Start the engine and set throttle lever to “FULL”. ⑤ Release parking brake by pressing parking brake switch button. ⑥ Read brake release pressure indicated by pressure gauge. R2-4-09007 R2-4-09007 Brake release pressure ★ : 1.3 to 1.7 MPa (189 to 247 psi)

  • Page 149: Measurement Of Propulsion Motor (R)

    INSPECTION AND ADJUSTMENT 6-2. Measurement of propulsion motor (R) • Oil temperature during measurement : 50 °C (122 °F) ± 5 ± 9 ① Remove plug from parking brake pilot port (1). Attach pressure gauge with adapter ⓑ . • Adapter ⓑ...

  • Page 150: Measurement And Inspection Of Steering Circuit Pressure

    ⑤ Turn steering wheel to operate relief valve. ⑥ Read pressure indicated by pressure gauge. Standard maximum circuit pressure ★ (orbitroll relief pressure + charge relief pressure) : 17.6 MPa (2,552 psi) ± 1.0 ± 145 R2-4-09008 R2-4-09008 PG002004 PG002004 9-010...

  • Page 151: Inspection

    INSPECTION AND ADJUSTMENT 7-2. Inspection • If measurement results indicate the pressure deviating from standard maximum circuit pressure range, make an adjustment in accordance with procedure described below. ① Remove relief valve (2) from orbitrol. ② Check removed relief valve for trapped dirt, scratches on its seat and other abnormalities.

  • Page 152: Measurement Of Hydraulic Pump Case Pressure

    ⑦ With propulsion load at maximum, measure pressure when speed change switch is “ ” and “ ” and F-R R2-4-09009 R2-4-09009 lever is “N”, “F”, and “R”, respectively. Allowable pump case pressure ★ : 0.3 MPa (43.5 psi) or less...

  • Page 153: Measurement Of Propulsion Motor Case Pressure

    ⑤ Start the engine and set throttle lever to “FULL”. ⑥ Establish a condition in which machine propulsion load becomes maximum. (Pressure does not build up unless R2-4-09010 R2-4-09010 propulsion load is applied.) ⑦ With propulsion load at maximum, measure pressure when speed change switch is “...

  • Page 154: Measurement Of Propulsion Motor (R)

    INSPECTION AND ADJUSTMENT 9-2. Measurement of Propulsion Motor (R) • Oil temperature during measurement : 50 °C (122 °F) ± 5 ± 9 ① Remove plug from propulsion motor drain port (3). Attach pressure gauge with adapter ⓓ . • Adapter ⓓ...

  • Page 155: Adjustment Of Throttle Lever

    Oil temperature during measurement: 50 °C (122 °F) ± 5 ± 9 R2-4-09018 R2-4-09018 ① Apply grease to shaft of potentiometer (1). ② Insert potentiometer shaft to the groove on shaft (3), and fix it with two screws (2). SECTION A-A...
  • Page 156 ± 25 IDLE IDLE • After adjustment, fix stopper bolt (6) with locknut (5). R2-4-09014 R2-4-09014 ⑦ Set throttle lever (4) to “FULL”. ⑧ Loosen locknut (7), and adjust engine rotational speed to standard value with stopper bolt (8). Engine rotational speed : 2,400 ★...

  • Page 157: Adjustment Of Operating Force

    (4) knob to standard operating force. Do not turn nut to the loosening direction. Standard operating force : 45 N (10 lbf) ★ (NOTICE) • In case of loosen nut (10), replace it with a new one. R2-4-09016 R2-4-09016 SECTION A-A SECTION A-A R2-4-09017 R2-4-09017 9-017...

  • Page 158: Adjustment Of F-R Lever Linkage

    INSPECTION AND ADJUSTMENT 11. ADJUSTMENT OF F-R LEVER LINkAGE 11-1. Adjustment • In cases such as propulsion pump is replaced, control cable is replaced or F-R lever does not move smoothly, make an adjustment in accordance with procedure described below. •...

  • Page 159: Troubleshooting

    TROUBLESHOOTING...

  • Page 161: Safety Precautions For Troubleshooting

    TROUBLESHOOTING 1. TROUBLESHOOTING 1-1. Safety Precautions for Troubleshooting WARNING Unexpected machine movement may cause a serious accident. When inspecting the machine while the engine is running, always follow the instructions below. • Park the machine on level, flat ground. • Apply the parking brake.

  • Page 162: Before Starting

    TROUBLESHOOTING 1-3. Before Starting The information in this section is provided to assist the troubleshooter in understanding the systems and quickly determine the causes when operating abnormalities occur. The following steps are recommended: 1. If not familiar with the machine, study the Operator’s Manual and this Shop Manual. 2.

  • Page 163: Electrical System Troubleshooting

    TROUBLESHOOTING 2. ELECTRICAL SYSTEM TROUBLESHOOTING 2-1. When Performing Electrical System Fault Diagnosis wARNING Be very careful because equipment can return to normal during an inspection and suddenly operate properly when a failure occurs due to a faulty contact or other such cause. 2-1-1.

  • Page 164: Inspection Procedures Using A Tester

    TROUBLESHOOTING 2-1-2. Inspection procedures using a tester Some of the various inspection procedures are presented here for reference, using a sample circuit below. Equipment A Main power source Ground of Power to Signal from of equipment B equipment A equipment A equipment A Battery Equipment B...
  • Page 165 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 166 TROUBLESHOOTING 2) Measuring voltage and current flowing using tester 2-1) Measuring voltage of equipment A (measuring voltage between terminals 1 and 3) Equipment A Equipment A Equipment B Voltmeter (tester) Main power source Ground of Signal from Power to of equipment B equipment A equipment A equipment A...
  • Page 167 TROUBLESHOOTING Measurement using a test harness Test harness Equipment A Equipment B Measurement on a lead cable Measurement from the backside of connector Test probe Wire Connector Needle Lead cable TS-10006 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 168 TROUBLESHOOTING 2-2) Measuring current flowing from equipment B to equipment A (measuring current between terminal 2 of equipment B and terminal 1 of equipment A) Test harness Equipment A Equipment A Equipment B Harness Ammeter (connecting (tester) terminals) Main power source Ground of Signal from Power to...

  • Page 169: Inspection Of Electrical System

    TROUBLESHOOTING 2-1-3. Inspection of electrical system Operate the applicable switches and turn the relays ON and OFF. Ultimately, if the solenoid valve operates (makes a sound) and the pump runs, the electrical system is OK. If there is a failure (fault), narrow the range of the inspection to the six broad steps described below. 1) Ground inspection •...
  • Page 170 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 171: Engine Diagnosis Trouble Code

    STOP WATER PUMP ENGINE WARNING lamp ENGINE STOP lamp R2-4-10001 1) DTC display procedure using the DPF meter • A current or past DTC stored in the engine control unit (ECU) is displayed on the DPF meter by switching its display as described in the diagram below.

  • Page 172: Table Of The Diagnostic Trouble Code (Dtc)

    TROUBLESHOOTING 2-2-2. Table of the diagnostic trouble code (DTC) J1939-73 Diagnosis Description DTC Description • Short circuit in sensor/harness Accelerator sensor-2 High power supply Accelerator pedal or lever position sensor-2 abnormal • Open circuit in sensor/harness, Accelerator sensor-2 Low ground fault Accelerator pedal or lever Accelerator pedal sensor •...
  • Page 173 TROUBLESHOOTING J1939-73 Diagnosis Description DTC Description • Open circuit, short circuit, or Battery voltage High breakage in harness • Battery abnormal Battery voltage abnormal • Open circuit, short circuit, or Battery voltage Low breakage in harness • Battery abnormal Intake air temperature sensor •...
  • Page 174 TROUBLESHOOTING J1939-73 Diagnosis Description DTC Description G sensor pulse count abnormal • Open circuit in sensor/harness, Camshaft position sensor short-circuited (G sensor) abnormal G sensor pulse not inputted • Sensor failure ECU flash ROM and CPU ECU CPU abnormal 1077 •...
  • Page 175 TROUBLESHOOTING J1939-73 Diagnosis Description DTC Description Exhaust temperature rise Exhaust temperature rise • DOC inlet temperature (T0) abnormal T0 abnormal T0 abnormally high Exhaust temperature sensor 0 • Open circuit in sensor/harness, 4765 Exhaust temperature (T0 : DOC inlet) High +B short-circuited sensor 0 (T0 : DOC inlet) Exhaust temperature sensor 0...
  • Page 176 TROUBLESHOOTING J1939-73 Diagnosis Description DTC Description Short circuit in air heater relay • Short circuit in air heater relay driving circuit +B driving circuit +B Air heater relay drive 523544 abnormal Short circuit in air heater relay • Open circuit in air heater relay driving circuit GND driving circuit, ground fault •...
  • Page 177 TROUBLESHOOTING J1939-73 Diagnosis Description DTC Description Simultaneous open circuit Simultaneous open circuit in all • Simultaneous open circuit in all 523599 in all exhaust temperature exhaust temperature sensors exhaust temperature sensors sensors Warning on incomplete Warning on incomplete learning 523600 learning of individual of individual difference of •...
  • Page 178 SPEED SENSOR V14 RELAY STOP-SW. V32 GLOW BATTERY DPF INHIBIT SW. V74 HEATER 12V 115D31R LOAD #12 SUB-ECU LAMP #13 FUEL GND #16 PUMP BATTERY(+) #22 CAN-H #23 CAN-L #24 LOAD ON/OFF #35 INHIBIT SWITCHOUT #39 ACC #44 SUB-ECU R2-4-10002 10-018...

  • Page 179: Engine

    TROUBLESHOOTING 2-3. 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. • ENGINE wARNING lamp or ENGINE STOP lamp must not be lighting. If ENGINE wARNING lamp or ENGINE STOP lamp lights, refer to troubleshooting of engine manufacturer.
  • Page 180 SPEED SENSOR V14 RELAY STOP-SW. V32 GLOW BATTERY DPF INHIBIT SW. V74 HEATER 12V 115D31R LOAD #12 SUB-ECU LAMP #13 FUEL GND #16 PUMP BATTERY(+) #22 CAN-H #23 CAN-L #24 LOAD ON/OFF #35 INHIBIT SWITCHOUT #39 ACC #44 SUB-ECU R2-4-10002 10-020...

  • Page 181: Engine Will Not Start (Starter Motor Does Not Run) 2/2

    TROUBLESHOOTING 2-3-1. Engine will not start (Starter motor does not run) 2/2 • F-R lever must be in “N”. • Parking brake switch must be applied. Reference Fig.: 2-3-1 Check point Check/Cause Action 5. Battery Relay (1) when starter switch is OFF, measure voltage between Replace battery relay.
  • Page 182 SPEED SENSOR V14 RELAY STOP-SW. V32 GLOW BATTERY DPF INHIBIT SW. V74 HEATER 12V 115D31R LOAD #12 SUB-ECU LAMP #13 FUEL GND #16 PUMP BATTERY(+) #22 CAN-H #23 CAN-L #24 LOAD ON/OFF #35 INHIBIT SWITCHOUT #39 ACC #44 SUB-ECU R2-4-10002 10-022...

  • Page 183: Engine Will Not Start (But Starter Motor Runs)

    TROUBLESHOOTING 2-3-2. 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 184 SPEED SENSOR V14 RELAY STOP-SW. V32 GLOW BATTERY DPF INHIBIT SW. V74 HEATER 12V 115D31R LOAD #12 SUB-ECU LAMP #13 FUEL GND #16 PUMP BATTERY(+) #22 CAN-H #23 CAN-L #24 LOAD ON/OFF #35 INHIBIT SWITCHOUT #39 ACC #44 SUB-ECU R2-4-10002 10-024...

  • Page 185: Glow Plug Is Not Heated

    TROUBLESHOOTING 2-3-4. Glow plug is not heated (Engine starting performance is bad in cold weather) Reference Fig.: 2-3-1 Check point Check/Cause Action 1. Glow Heater • when starter switch is ON, measure voltage between Replace glow heater. glow heater terminal inlet wire W and chassis ground. Standard voltage : 12 V or more •...
  • Page 186 SPEED SENSOR V14 RELAY STOP-SW. V32 GLOW BATTERY DPF INHIBIT SW. V74 HEATER 12V 115D31R LOAD #12 SUB-ECU LAMP #13 FUEL GND #16 PUMP BATTERY(+) #22 CAN-H #23 CAN-L #24 LOAD ON/OFF #35 INHIBIT SWITCHOUT #39 ACC #44 SUB-ECU R2-4-10002 10-026...

  • Page 187: Engine Speed Does Not Change When Operating Throttle Lever

    TROUBLESHOOTING 2-3-6. Engine speed does not change when operating throttle lever • ENGINE WARNING lamp must not be lighting. • Refer to voltage measurement method when voltage is to be measured without disconnecting connector. Reference Fig. : 2-3-1 Check point Check/Cause Action 1.
  • Page 188 NC NOCOM STOP LAMP STOP LAMP RELAY 1.25GW 60 BW 42 1.25BrB BRAKE PLOPULSION RELAY PUMP FOOT BRAKE SWITCH NEUTRAL SOLENOID 1.25GW 22 1.25WB 39 YL COMBINATION METER PARKING PARKING INTERLOCK RELAY BRAKE SWITCH SPEED PULSE ON/OFF RELAY FUSE BOX R2-4-10003 10-028...

  • Page 189: Propulsion System

    TROUBLESHOOTING 2-4. Propulsion System Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. • when measuring voltage and current without disconnecting connectors, refer to “Measuring voltage and current flowing using tester” (P.10-006 to P.10-008). •...
  • Page 190 NC NOCOM STOP LAMP STOP LAMP RELAY 1.25GW 60 BW 42 1.25BrB BRAKE PLOPULSION RELAY PUMP FOOT BRAKE SWITCH NEUTRAL SOLENOID 1.25GW 22 1.25WB 39 YL COMBINATION METER PARKING PARKING INTERLOCK RELAY BRAKE SWITCH SPEED PULSE ON/OFF RELAY FUSE BOX R2-4-10003 10-030...

  • Page 191: Machine Moves Neither Forward Nor Backward 2/2

    TROUBLESHOOTING 2-4-1. Machine moves neither forward nor backward 2/2 • Parking brake switch must be released. • Foot brake switch must be ON (Brake pedal is not depressed). Reference Fig.: 2-4-1 Check point Check/Cause Action 6. Harness Connecting • Measure resistance of harness connecting between Repair or replace terminals.
  • Page 192 NC NOCOM STOP LAMP STOP LAMP RELAY 1.25GW 60 BW 42 1.25BrB BRAKE PLOPULSION RELAY PUMP FOOT BRAKE SWITCH NEUTRAL SOLENOID 1.25GW 22 1.25WB 39 YL COMBINATION METER PARKING PARKING INTERLOCK RELAY BRAKE SWITCH SPEED PULSE ON/OFF RELAY FUSE BOX R2-4-10003 10-032...

  • Page 193: Speed Cannot Be Changed

    TROUBLESHOOTING 2-4-3. Brake does not work 2/2 • Parking brake switch must be applied. • Foot brake switch must be OFF (Brake pedal is depressed). Reference Fig.: 2-4-1 Check point Check/Cause Action 3. Parking Brake Switch (1) when starter switch is ON, measure voltage between Replace parking brake parking brake switch terminal 1 inlet wire WB and switch.
  • Page 194 41 3LB 19 3LW 19 3LW 41 LB 27 LR 34 LY 2 2B WATER SPRAY WATER SPRAY RELAY PUMP (150W) 52 5WL BATTERY STARTER MOTOR RELAY 21 LgR 21 LgR STARTER SWITCH STARTER SWITCH BATTERY 12V 115D31R R2-4-10004 10-034...

  • Page 195: Water Spray

    TROUBLESHOOTING 2-5. Water Spray 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. 2-5-1. Continuous water spray does not operate • water spray mode select switch must be ON.
  • Page 196 41 3LB 19 3LW 19 3LW 41 LB 27 LR 34 LY 2 2B WATER SPRAY WATER SPRAY RELAY PUMP (150W) 52 5WL BATTERY STARTER MOTOR RELAY 21 LgR 21 LgR STARTER SWITCH STARTER SWITCH BATTERY 12V 115D31R R2-4-10004 10-036...

  • Page 197: Continuous Water Spray Works, But Intermittent Water Spray

    TROUBLESHOOTING 2-5-2. Continuous water spray works, but intermittent water spray does not operate • Water spray mode select switch must be “INT”. Reference Fig.: 2-5-1 Check point Check/Cause Action 1. Water Spray Timer (1) when starter switch is ON, measure voltage between Replace water spray water spray timer terminal 1 inlet wire LR and terminal 3 timer.
  • Page 198 SIGNAL G(3) 1-2,4-6 SWITCH 1-3,4-6 1-3,4-5 COMBINATION METER TURN SIGNAL SWITCH FUSE 50 8WR TURN SIGNAL SWITCH (LIGHT L-H CHANGE SWITCH) HIGH-BEAM LOW-BEAM STARTER MOTOR BATTERY STARTER SWITCH RELAY 21 LgR 21 LgR STARTER SWITCH BATTERY 12V 115D31R R2-4-10005 10-038...

  • Page 199: Lighting

    TROUBLESHOOTING 2-6. Lighting Check following items before troubleshooting. • No blown fuse and power is applied up to fuses. 2-6-1. Head lamp, side marker lamp, tail lamp and license lamp do not light 1/2 Reference Fig.: 2-6-1 Check point Check/Cause Action 1.
  • Page 200 SIGNAL G(3) 1-2,4-6 SWITCH 1-3,4-6 1-3,4-5 COMBINATION METER TURN SIGNAL SWITCH FUSE 50 8WR TURN SIGNAL SWITCH (LIGHT L-H CHANGE SWITCH) HIGH-BEAM LOW-BEAM STARTER MOTOR BATTERY STARTER SWITCH RELAY 21 LgR 21 LgR STARTER SWITCH BATTERY 12V 115D31R R2-4-10005 10-040...

  • Page 201: Head Lamp, Side Marker Lamp, Tail Lamp And License Lamp

    TROUBLESHOOTING 2-6-1. Head lamp, side marker lamp, tail lamp and license lamp do not light 2/2 Reference Fig.: 2-6-1 Check point Check/Cause Action 5. Lighting LO/HI Relay (1) when starter switch is ON, lighting switch is “ ” and Replace lighting LO/HI relay.
  • Page 202 SIGNAL G(3) 1-2,4-6 SWITCH 1-3,4-6 1-3,4-5 COMBINATION METER TURN SIGNAL SWITCH FUSE 50 8WR TURN SIGNAL SWITCH (LIGHT L-H CHANGE SWITCH) HIGH-BEAM LOW-BEAM STARTER MOTOR BATTERY STARTER SWITCH RELAY 21 LgR 21 LgR STARTER SWITCH BATTERY 12V 115D31R R2-4-10005 10-042...

  • Page 203: High-Beam Of Head Lamp Does Not Light

    TROUBLESHOOTING 2-6-2. Flood lamp does not light 2/2 Reference Fig.: 2-6-1 Check point Check/Cause Action 4. Harness Connecting • Measure resistance of harness connecting between Repair or replace Between Terminals terminals. harness. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
  • Page 204 SIGNAL G(3) 1-2,4-6 SWITCH 1-3,4-6 1-3,4-5 COMBINATION METER TURN SIGNAL SWITCH FUSE 50 8WR TURN SIGNAL SWITCH (LIGHT L-H CHANGE SWITCH) HIGH-BEAM LOW-BEAM STARTER MOTOR BATTERY STARTER SWITCH RELAY 21 LgR 21 LgR STARTER SWITCH BATTERY 12V 115D31R R2-4-10005 10-044...

  • Page 205: Turn Signal Lamp Does Not Blink

    TROUBLESHOOTING 2-6-4. Turn signal lamp does not blink Reference Fig.: 2-6-1 Check point Check/Cause Action 1. Each Bulb • Check that none of lamp bulbs is burned out or has a Replace each bulb. contact failure. • Bulb is faulty or poorly connected. 2.
  • Page 206 SIGNAL G(3) 1-2,4-6 SWITCH 1-3,4-6 1-3,4-5 COMBINATION METER TURN SIGNAL SWITCH FUSE 50 8WR TURN SIGNAL SWITCH (LIGHT L-H CHANGE SWITCH) HIGH-BEAM LOW-BEAM STARTER MOTOR BATTERY STARTER SWITCH RELAY 21 LgR 21 LgR STARTER SWITCH BATTERY 12V 115D31R R2-4-10005 10-046...

  • Page 207: Hazard Lamp Does Not Light (Turn Signal Blinks)

    TROUBLESHOOTING 2-6-5. Hazard lamp does not light (Turn signal blinks) • Hazard switch must be ON. Reference Fig.: 2-6-1 Check point Check/Cause Action 1. Each Bulb • Check that none of lamp bulbs is burned out or has a Replace each bulb. contact failure.
  • Page 208 SIGNAL G(3) 1-2,4-6 SWITCH 1-3,4-6 1-3,4-5 COMBINATION METER TURN SIGNAL SWITCH FUSE 50 8WR TURN SIGNAL SWITCH (LIGHT L-H CHANGE SWITCH) HIGH-BEAM LOW-BEAM STARTER MOTOR BATTERY STARTER SWITCH RELAY 21 LgR 21 LgR STARTER SWITCH BATTERY 12V 115D31R R2-4-10005 10-048...

  • Page 209: Stop Lamp Does Not Light

    TROUBLESHOOTING 2-6-7. Stop lamp does not light Reference Fig.: 2-6-1 Check point Check/Cause Action 1. Each Bulb • Check that none of lamp bulbs is burned out or has a Replace each bulb. contact failure. • Bulb is faulty or poorly connected. 2.
  • Page 210 FUEL UNIT ALTERNATOR THERMO UNIT 8 Br 73 L 48 W STARTER RELAY SPEED PULSE STARTER MOTOR ON/OFF RELAY 21 LgR PARKING INTERLOCK RELAY STARTER PARKING BRAKE SWITCH SWITCH BATTERY STARTER SWITCH RELAY 21 LgR BATTERY 12V 115D31R R2-4-10006 10-050...

  • Page 211: Illumination Of Combination Meter Does Not Light

    TROUBLESHOOTING 2-6-8. Illumination of combination meter does not light Reference Fig.: 2-6-2 Check point Check/Cause Action 1. Harness • Measure resistance between lighting switch terminal 3 Repair or replace wire RL and combination meter connector terminal wire harness. No.45 wire RL. Standard resistance : 10 Ω...
  • Page 212 FUEL UNIT ALTERNATOR THERMO UNIT 8 Br 73 L 48 W STARTER RELAY SPEED PULSE STARTER MOTOR ON/OFF RELAY 21 LgR PARKING INTERLOCK RELAY STARTER PARKING BRAKE SWITCH SWITCH BATTERY STARTER SWITCH RELAY 21 LgR BATTERY 12V 115D31R R2-4-10006 10-052...

  • Page 213: Tachometer Reading Is Abnormal

    TROUBLESHOOTING 2-6-10. Tachometer reading is abnormal Reference Fig.: 2-6-2 Check point Check/Cause Action 1. Combination Meter (1) when starter switch is ON, measure voltage between Replace combination (Tachometer) combination meter terminal wires and ground terminal meter. wire. • Battery (12 V) terminal wire No.73 inlet wire L and ground terminal wire No.2 wire B •...
  • Page 214 FUEL UNIT ALTERNATOR THERMO UNIT 8 Br 73 L 48 W STARTER RELAY SPEED PULSE STARTER MOTOR ON/OFF RELAY 21 LgR PARKING INTERLOCK RELAY STARTER PARKING BRAKE SWITCH SWITCH BATTERY STARTER SWITCH RELAY 21 LgR BATTERY 12V 115D31R R2-4-10006 10-054...

  • Page 215: Temperature Meter Is Abnormal

    TROUBLESHOOTING 2-6-12. Temperature meter is abnormal Reference Fig.: 2-6-2 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) 26.44 Ω (at unit temperature of 103°C) •...
  • Page 216 FUEL UNIT ALTERNATOR THERMO UNIT 8 Br 73 L 48 W STARTER RELAY SPEED PULSE STARTER MOTOR ON/OFF RELAY 21 LgR PARKING INTERLOCK RELAY STARTER PARKING BRAKE SWITCH SWITCH BATTERY STARTER SWITCH RELAY 21 LgR BATTERY 12V 115D31R R2-4-10006 10-056...

  • Page 217: Charge Warning Lamp Remains On

    TROUBLESHOOTING 2-6-14. Charge warning lamp remains ON • Check with engine running. Reference Fig.: 2-6-2 Check point Check/Cause Action 1. Harness • Disconnect connectors between combination meter and Repair or replace alternator terminal L. harness. • Measure resistance between terminals and chassis ground.
  • Page 218 21 LgR 49 15B ALTERNATOR BRAKE RELAY STARTER 1.25GW RELAY 22 1.25WB 39 YL TURN SIGNAL SWITCH STARTER MOTOR PARKING PARKING BRAKE INTERLOCK SWITCH RELAY BATTERY RELAY 21 LgR 21 LgR STARTER SWITCH STARTER SWITCH BATTERY 12V 115D31R R2-4-10007 10-058...

  • Page 219: Flood Lamp Indicator Lamp Does Not Light

    TROUBLESHOOTING 2-6-16. Flood lamp indicator lamp does not light • Check that flood lamp lights. Reference Fig.: 2-6-3 Check point Check/Cause Action 1. Harness • Measure resistance between flood lamp relay terminal 5 Repair or replace wire RG and combination meter connector terminal wire harness.
  • Page 220 21 LgR 49 15B ALTERNATOR BRAKE RELAY STARTER 1.25GW RELAY 22 1.25WB 39 YL TURN SIGNAL SWITCH STARTER MOTOR PARKING PARKING BRAKE INTERLOCK SWITCH RELAY BATTERY RELAY 21 LgR 21 LgR STARTER SWITCH STARTER SWITCH BATTERY 12V 115D31R R2-4-10007 10-060...

  • Page 221: Parking Brake Indicator Lamp Does Not Light

    TROUBLESHOOTING 2-6-18. 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 4 wire YL and combination meter connector harness. terminal wire No.39 wire YL. Standard resistance : 10 Ω...
  • Page 222 21 LgR 49 15B ALTERNATOR BRAKE RELAY STARTER 1.25GW RELAY 22 1.25WB 39 YL TURN SIGNAL SWITCH STARTER MOTOR PARKING PARKING BRAKE INTERLOCK SWITCH RELAY BATTERY RELAY 21 LgR 21 LgR STARTER SWITCH STARTER SWITCH BATTERY 12V 115D31R R2-4-10007 10-062...

  • Page 223: Turn Signal Indicator Lamp Does Not Light

    TROUBLESHOOTING 2-6-19. Turn signal indicator lamp does not light • Check that turn signal lamp blinks. Reference Fig.: 2-6-3 Check point Check/Cause Action 1. Harness (1) Measure resistance between turn signal switch terminal Repair or replace wire GR (left-hand side) and combination meter harness.
  • Page 224 TROUBLESHOOTING Fig.: 2-6-4 BACKUP BUZZER SWITCH HORN 31 RY 11 Gr 13 GY 11 Gr 12 P HORN BACKUP RELAY BUZZER HORN SWICTH FUSE BOX R2-4-10008 10-064...

  • Page 225: Horn Does Not Sound

    TROUBLESHOOTING 2-6-20. Horn does not sound Reference Fig.: 2-6-4 Check point Check/Cause Action 1. Horn • Disconnect horn and directly connect battery positive Replace horn. terminal to horn terminal wire GY side and negative terminal to horn terminal chassis ground side. •...

  • Page 226: Hydraulic System Troubleshooting

    TROUBLESHOOTING 3. HYDRAULIC SYSTEM TROUBLESHOOTING 3-1. When Performing Hydraulic System Troubleshooting • The largest factor in the majority of failures of hydraulic devices operating under conditions of higher pressure and greater precision is the entry of dirt (foreign substances) into the hydraulic circuit. Particular caution is required when supplying hydraulic oil or when disassembling and assembling hydraulic devices.

  • Page 227: Propulsion System

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

  • Page 228: Machine Moves Neither Forward Nor Backward 2/2

    TROUBLESHOOTING 3-2-1. Machine moves neither forward nor backward 2/2 Check point Cause Check/Action 9. Propulsion Pump Discharge flow rate is insufficient due to • Measure discharge flow rate of propulsion efficiency degradation of propulsion pump. pump with flow meter. • If discharge flow rate is not within specified range, repair propulsion pump or replace it if necessary.

  • Page 229: Slow Machine Speed Or Small Drive Force 2/2

    TROUBLESHOOTING 3-2-3. Slow machine speed or small drive force 2/2 Check point Cause Check/Action 5. Propulsion Motor Propulsion motor inlet pressure is low. • Measure propulsion motor inlet pressure. • If low, check and adjust multifunction 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 230: Propulsion System Is Overheating

    TROUBLESHOOTING 3-2-6. Propulsion system is overheating Check point Cause Check/Action 1. Oil Level of Oil level in hydraulic oil tank is low. Fill tank until correct oil level is obtained. Hydraulic Oil Tank 2. Oil Cooler Cooling efficiency is reduced due to clogged Clean oil cooler fins.
  • Page 231 TROUBLESHOOTING 3-3. Steering System If a problem occurs in the steering systems such as the steering • charge 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 232 TROUBLESHOOTING 3-3-3. 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 234 SAkAI HEAVY INDUSTRIES, LTD. Head office: Seiwa Bldg., 4-8, Shibadaimon 1-chome, Minato-ku, Tokyo, Japan Telephone: +81-3-3434-3401 Global Service Division: 2500 Takayanagi, Kuki-shi, Saitama, Japan Telephone: +81-480-52-1111 Copyright © 2016 SAKAI HEAVY INDUSTRIES, LTD. All Rights Reserved. Printed in Japan 2016.3.50 ○ 0634-99373-0-31526-A...

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