Sakai TW354 Shop Manual

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SW/TW354

SW/TW504

SHOP MANUAL

3498-6446A-1

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Summary of Contents for Sakai TW354

Page 1 SW/TW354 SW/TW504 SHOP MANUAL 3498-6446A-1...
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   1-005 1-11. Transporting the Machine   1-007 2. SPECIFICATIONS 1. SPECIFICATION DATA 1-1. SW354  2-001 1-2. SW354 ROPS  2-003 1-3. TW354  2-005 1-4. TW354 ROPS  2-007 1-5. TW504  2-009 1-6. TW504 ROPS  2-011 1-7.
Page 6 SW/TW354,SW/TW504 ○ 5. SPECIFICATION DATA (SW504) 5-1. SW504  2-019 5-2. SW504 ROPS  2-021 5-3. Common Specifications  2-023 6. TABLE OF STANDARD VALUES (SW504) 6-1. Engine   2-024 6-2. Propulsion   2-024 ○ 6-3. Hydraulic System  2-024 6-4.
Page 7 SW/TW354,SW/TW504 ○ 1-2. Hydraulic Circuit Diagram 4-003 1-2-1. Hydraulic circuit diagram (SW354)   4-003 1-2-2. Hydraulic circuit diagram (TW354)   4-004 1-2-3. Hydraulic circuit diagram (TW504)   4-005 2. PROPULSION HYDRAULIC SYSTEM 2-1. Propulsion Hydraulic Piping   4-006 2-1-1.
Page 8 Electrical Circuit Diagram, Wiring Harness Layout and Wiring Harnesses  5-001 2. SYSTEM CIRCUIT DIAGRAM 2-1. Electrical Circuit Diagram (SW354)  5-003 2-2. Electrical Circuit Diagram (SW354 ROPS)  5-004 2-3. Electrical Circuit Diagram (TW354)   5-005 2-4. Electrical Circuit Diagram (TW354 ROPS)   5-006 2-5.
Page 9 4-8. Parking Brake Switch Harness   5-029 4-9. Vibration Lo-Hi Change Switch Harness  5-030 4-9-1. Short harness (SW/TW354 : except SW354 ROPS)  5-030 4-9-2. Vibration Lo-Hi change switch harness (TW504)  5-031 4-10. Vibrator Solenoid (R) Harness  5-032 4-10-1.
Page 10 SW/TW354,SW/TW504 ○ 6. SYSTEM CIRCUIT DIAGRAM (SW504) 6-1. Electrical Circuit Diagram (ROPS)   5-047 6-2. Electrical Circuit Diagram (except ROPS)  5-048 7. ELECTRICAL COMPONENTS (SW504) 7-1. Wiring Harness Layout (1)   5-049 7-2. Wiring Harness Layout (2)   5-050 8.
Page 11 2-2. Brake System (TW354, 504)  7-003 8. WATER SPRAY SYSTEM 1. WATER SPRAY PIPING 1-1. Water Spray Piping (SW354)   8-001 1-2. Water Spray Piping (TW354, 504)   8-002 2. LIQUID SPRAY SYSTEM 2-1. Liquid Spray Piping (TW354,504)   8-003...
Page 12 SW/TW354,SW/TW504 ○ 9. INSPECTION AND ADJUSTMENT 1. INSPECTION AND ADJUSTMENT 1-1. Safety Precautions for Inspection and Adjustment   9-001 1-2. Preparation for Inspection and Adjustment  9-001 1-3. Precautions for Inspection and Adjustment   9-001 1-4. Warm-up   9-001 1-5.
Page 13 SW/TW354,SW/TW504 ○ 13-2. Adjustment of Operating Force  9-020 14. PROCEDURE FOR MEASURING QUANTITY OF BRAKE PISTON STROKE (REPLACEMENT STANDARD) 14-1. Measurement  9-021 15. MEASUREMENT AND INSPECTION OF PROPULSION CIRCUIT PRESSURE (SW504) 15-1. Measurement  9-022 15-2. Inspection  9-023 16.
Page 14 2-4-2. Vibration mode cannot be switched (F-R lever vibration switch does not work)  1 0-034 2-4-3. Vibratory drum cannot be switched (SW354 ROPS)  1 0-036 2-4-4. Amplitude does not change (Remains either low or high) (TW504)  1 0-038 2-5.
Page 15 3-3-1. No vibration  1 0-078 3-3-2. Vibrator frequency is too low   1 0-079 3-3-3. Vibratory drum does not changeover vibrating (SW354 ROPS)  1 0-079 3-3-4. Vibration mode does not switch (TW504)  1 0-079 3-3-5. Vibrator does not stop   1 0-079 3-3-6.
Page 16 SW/TW354,SW/TW504 ○ 4. ELECTRICAL SYSTEM TROUBLESHOOTING (SW504) 4-1. Engine Diagnosis Trouble Code   1 0-084 4-1-1. Description of diagnostic trouble code (SPN, FMI)  1 0-084 4-1-2. Table of the diagnostic trouble code (DTC)   1 0-085 4-2. Engine   1 0-092 4-2-1.
Page 17: Safety
SAFETY...
Page 19: 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 20: 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 21: 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 22: 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 23: 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 24 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 25: 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 27: Specifications
SPECIFICATIONS...
Page 30: Specification Data
SPECIFICATIONS SPECIFICATIONS SW354 1. SPECIFICATION DATA 1-1. SW354 1200 2000 1200 2675 0446-99024-0-10967-0 Model SAKAI SW354 Model & Type Type VIBRATORY TANDEM ROLLER without ballast 2,900 kg 6,395 lbs. ) Operating weight with ballast N/A kg N/A lbs. ) Maximum weight 3,020 kg 6,660 lbs.
Page 31: Sw354
SW354 SPECIFICATIONS SPECIFICATIONS Centrifugal force 29.0 kN 6,520 lbf Front Frequency 66.7 Hz 4,000 vpm Amplitude 0.31 mm 0.012 in. Vibrator system Centrifugal force 29.0 kN 6,520 lbf Rear Frequency 66.7 Hz 4,000 vpm Amplitude 0.31 mm 0.012 in. Static linear...
Page 32: Sw354 Rops
SPECIFICATIONS SW354 ROPS SPECIFICATIONS 1-2. SW354 ROPS 1200 2000 1200 2675 0446-99026-0-11005-0 Model SAKAI SW354 with ROPS Model & Type Type VIBRATORY TANDEM ROLLER without ballast 2,960 kg 6,525 lbs. ) Operating weight with ballast N/A kg N/A lbs. ) Maximum weight 3,080 kg 6,790 lbs.
Page 33 SW354 ROPS SPECIFICATIONS SPECIFICATIONS Centrifugal force 29.0 kN 6,520 lbf Front Frequency 66.7 Hz 4,000 vpm Amplitude 0.31 mm 0.012 in. Vibrator system Centrifugal force 29.0 kN 6,520 lbf Rear Frequency 66.7 Hz 4,000 vpm Amplitude 0.31 mm 0.012 in. Static linear...
Page 34: Tw354
SPECIFICATIONS TW354 SPECIFICATIONS 1-3. TW354 1200 2000 2675 0447-99021-0-10193-A Model SAKAI TW354 Model & Type Type VIBRATORY COMBINED ROLLER without ballast 2,600 kg 5,730 lbs. ) Operating weight with ballast N/A kg N/A lbs. ) Maximum weight 2,720 kg 5,995 lbs. )
Page 35 TW354 SPECIFICATIONS SPECIFICATIONS Centrifugal force 20.6 kN 4,630 lbf Front Frequency 52.0 Hz 3,120 vpm Amplitude 0.36 mm 0.014 in. Vibrator system Centrifugal force N/A kN N/A lbf Rear Frequency N/A Hz N/A vpm Amplitude N/A mm N/A in. Static linear Front drum Operating weight 120 N/cm 70 lbf./in.
Page 36: Tw354 Rops
SPECIFICATIONS SPECIFICATIONS TW354 ROPS 1-4. TW354 ROPS 1200 2000 2675 0447-99023-0-10198-0 Model SAKAI TW354 with ROPS Model & Type Type VIBRATORY COMBINED ROLLER without ballast 2,660 kg 5,865 lbs. ) Operating weight with ballast N/A kg N/A lbs. ) Maximum weight 2,780 kg 6,130 lbs.
Page 37 SPECIFICATIONS SPECIFICATIONS TW354 ROPS Centrifugal force 20.6 kN 4,630 lbf Front Frequency 52.0 Hz 3,120 vpm Amplitude 0.36 mm 0.014 in. Vibrator system Centrifugal force N/A kN N/A lbf Rear Frequency N/A Hz N/A vpm Amplitude N/A mm N/A in. Static linear Front drum Operating weight 120 N/cm 70 lbf./in.
Page 38: Tw504
SPECIFICATIONS SPECIFICATIONS TW504 1-5. TW504 1300 2300 3105 0449-99014-0-10234-A Model SAKAI TW504 Model & Type Type VIBRATORY COMBINED ROLLER without ballast 3,440 kg 7,585 lbs. ) Operating weight with ballast N/A kg N/A lbs. ) Maximum weight 3,620 kg 7,980 lbs. )
Page 39 SPECIFICATIONS TW504 SPECIFICATIONS 26.5 kN 5,955 lbf Centrifugal amplitude High force 34.3 kN 7,710 lbf amplitude 52 Hz 3,100 vpm amplitude Front Frequency High 52 Hz 3,100 vpm amplitude 0.30 mm 0.012 in. amplitude Amplitude High 0.40 mm 0.016 in. amplitude Vibrator system N/A kN...
Page 40: Tw504 Rops
SPECIFICATIONS SPECIFICATIONS TW504 ROPS 1-6. TW504 ROPS 1300 2300 3105 0449-99020-0-10260-A Model SAKAI TW504 with ROPS Model & Type Type VIBRATORY COMBINED ROLLER without ballast 3,510 kg 7,740 lbs. ) Operating weight with ballast N/A kg N/A lbs. ) Maximum weight 3,680 kg 8,115 lbs.
Page 41 SPECIFICATIONS TW504 ROPS SPECIFICATIONS 26.5 kN 5,955 lbf Centrifugal amplitude High force 34.3 kN 7,710 lbf amplitude 52 Hz 3,100 vpm amplitude Front Frequency High 52 Hz 3,100 vpm amplitude 0.30 mm 0.012 in. amplitude Amplitude High 0.40 mm 0.016 in. amplitude Vibrator system N/A kN...
Page 42: Common Specifications
Power transmission type Hydraulic Steering system Steering type Articulated Front Steel drum / Vibrate and drive / 1pc. SW354 Steel drum / Vibrate and drive / 1pc. Rear TW354,504 Rubber tyre / Drive / 4pcs. Drums and tyres Front Rubber isolation...
Page 43: Table Of Standard Values
SPECIFICATIONS SPECIFICATIONS 2. TABLE OF STANDARD VALUES 2-1. Engine Item Standard value Remarks Engine model KUBOTA D1703-M-DI-E4B 17.7 kW 24 HP Rated output Max. rpm under no load 2,470 min or less Min. rpm under no load 1,050 to 1,150 min Cylinder head tightening torque 93.2 to 98.0 N·m 68.8 to 72.3 lbf·ft...
Page 44: Hydraulic System
SPECIFICATIONS SPECIFICATIONS 2-3. Hydraulic System Standard value Item Remarks SW354 TW354 TW504 High pressure relief valve pressure 34.5 MPa ( 5,003 psi ) setting Charge relief valve pressure setting MPa ( 276 psi ) ± 0.7 ± 100 Pump 0.25 MPa ( 36.3 psi ) or less...
Page 45: Brakes
Note 1: 119 mm (4.7 in.) floorboard (as released) Clearance between brake pedal and Note 2: 79 mm (3.1 in.) floorboard (when pressed down) SW354-02002 Brake lock condition Bolt More than 3.5 mm (0.14 in.) Brake releasing condition Replacement standard brake stroke length...
Page 46: Fuel And Lubricants Specification
SPECIFICATIONS SPECIFICATIONS 3. FUEL AND LUBRICANTS SPECIFICATION 3-1. Rating Ambient temp. and applicable viscosity rating Service Applicable -15 to 30°C 0 to 40°C 15 to 55°C Lubricant classification standards (5 to 86°F) (32 to 104°F) (59 to 131°F) Cold Moderate Tropical Engine oil API grade CF...
Page 47: Tightening Torque Chart
SPECIFICATIONS 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)
Page 48: Specification Data (Sw504)
SPECIFICATIONS SPECIFICATIONS SW504 5. SPECIFICATION DATA (SW504) 5-1. SW504 2300 1300 1300 3100 0448-99030-0-10639-0 Model SAKAI SW504 Model & Type Type VIBRATORY TANDEM ROLLER without ballast 3,990 kg 8,800 lbs. ) Operating weight with ballast N/A kg N/A lbs. ) Maximum weight 4,170 kg 9,195 lbs.
Page 49: Sw504
SW504 SPECIFICATIONS SPECIFICATIONS 26.5 kN 5,955 lbf Centrifugal amplitude force High 34.3 kN 7,710 lbf amplitude 55.0 Hz 3,300 vpm amplitude Front Frequency High 55.0 Hz 3,300 vpm amplitude 0.27 mm 0.011 in. amplitude Amplitude High 0.35 mm 0.014 in. amplitude Vibrator system 26.5 kN...
Page 50: Sw504 Rops
SPECIFICATIONS SPECIFICATIONS SW504 ROPS 5-2. SW504 ROPS 2300 1300 1300 3100 0448-99032-0-10746-0 Model SAKAI SW504 with ROPS Model & Type Type VIBRATORY TANDEM ROLLER without ballast 4,060 kg 8,955 lbs. ) Operating weight with ballast N/A kg N/A lbs. ) Maximum weight 4,240 kg 9,350 lbs.
Page 51 SW504 ROPS SPECIFICATIONS SPECIFICATIONS 26.5 kN 5,955 lbf Centrifugal amplitude High force 34.3 kN 7,710 lbf amplitude 55.0 Hz 3,300 vpm amplitude Front Frequency High 55.0 Hz 3,300 vpm amplitude 0.27 mm 0.011 in. amplitude Amplitude High 0.35 mm 0.014 in. amplitude Vibrator system 26.5 kN...
Page 52: Common Specifications
SPECIFICATIONS SPECIFICATIONS SW504 5-3. Common Specifications Model KUBOTA D1803-CR-T-EF02 (Diesel, EPA-Tier 4) 4-cycle, water-cooled, 3-cylinder in-line, vertical mounted, Type overhead valve, direct injection type, with turbo charger Bore × Stroke 87.0 mm × 102.4 mm (3.425 in. × 4.031 in.) Displacement 1.826 L ( 111.4 cu.in.
Page 53: Table Of Standard Values (Sw504)
SW504 SPECIFICATIONS SPECIFICATIONS 6. TABLE OF STANDARD VALUES (SW504) 6-1. Engine Item Standard value Remarks Engine model KUBOTA D1803-CR-T-EF02 32.8 kW 44 HP Rated output Max. rpm under no load 2,600 min or less Min. rpm under no load 1,000 ± 25 Cylinder head tightening torque 93.2 to 98.0 N·m 68.8 to 72.3 lbf·ft...
Page 54: Steering
Note 1: 119 mm (4.7 in.) floorboard (as released) Clearance between brake pedal and Note 2: 79 mm (3.1 in.) floorboard (when pressed down) SW354-02002 Brake lock condition Bolt More than 3.5 mm (0.14 in.) Brake releasing condition Replacement standard brake stroke length...
Page 55: Fuel And Lubricants Specification (Sw504)
SW504 SPECIFICATIONS SPECIFICATIONS 7. FUEL AND LUBRICANTS SPECIFICATION (SW504) 7-1. 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...
Page 57: Engine And Controls
ENGINE AND CONTROLS...
Page 59: Engine
ENGINE AND CONTROLS 1. ENGINE 1-1. Engine Mount VIEW B VIEW A 0446-01805-0-10913-0 (1) Bolt : M12×30 (8) Bolt : M12×30 P=1.25 (15) Bolt : M10×30 P=1.25 (2) Bracket (9) Spacer (16) Bracket (3) Nut : M12 (10) Bolt : M10×20 (17) Nut : M12 (4) Rubber isolator...
Page 60: Control System
ENGINE AND CONTROLS 2. CONTROL SYSTEM 2-1. Throttle Control IDLE FULL SECTION B-B VIEW C DETAIL A 0446-12806-0-10917-B (1) Control cable (10) Stopper bolt (FULL) : M8×35 (2) Throttle lever (11) Washer (Apply grease*) (3) ECO lamp switch 2 (Apply grease) (12) Nut : M14 (4) ECO lamp switch 1 (Apply grease)
Page 61: Forward-Reverse Control
ENGINE AND CONTROLS 2-2. Forward-reverse Control DETAIL C VIEW A-A SECTION B-B VIEW D 0446-12807-0-10939-B (1) Control cable (8) Friction plate (14) Lock nut : M12 (2) F-R lever (L) (9) Bush (15) Set screw : M12×22 (3) F-R lever (R) (10) Holder (Apply grease) (16) Rod end (4) Backup buzzer switch...
Page 62: Pump Mount
ENGINE AND CONTROLS 3. PUMP MOUNT 3-1. Pump Mount Weep hole VIEW A 0446-36804-0-20215-B (1) Cover (5) Coupling (2) Bolt : M10×35 P=1.25 (6) Bolt : M12×40 (3) Pin (7) Pump (4) Bolt : M 8×20 N•m (4) Bolt M 8×20 : 23 N·m ( 17 lbf·ft ) (6) Bolt M12×40 : 108 N·m ( 80 lbf·ft ) 3-004...
Page 63: Installation Of Pump
ENGINE AND CONTROLS 3-1-1. Installation of pump • When the pump assembly has been removed from the engine for repair or replacement, reinstall it in accordance with the following procedure. ① Apply adequate amount of grease to pump (7) and coupling (5) splines.
Page 65: Engine (Sw504)
SW504 ENGINE AND CONTROLS 4. ENGINE (SW504) 4-1. Engine Mount 15,16 19,20 15,16 19,20 VIEW B VIEW A 0448-01806-0-10620-A (1) Bolt : M12×30 (10) Bracket (19) Base (2) Bracket (11) Bolt : M12×30 (20) Bracket (3) Nut : M12 P=1.25 (12) Engine (21) Bolt : M10×25...
Page 66: Fuel System (Sw504)
ENGINE AND CONTROLS SW504 5. FUEL SYSTEM (SW504) DETAIL A 0448-02806-0-10621-A 3-007...
Page 67 SW504 ENGINE AND CONTROLS Engine Engine (suction) Engine (return) Fuel cooler Main filter VIEW B Fuel pump Check 29 15 valve Sedimenter Fuel tank (return) Fuel tank (suction) Fuel tank Fuel system diagram VIEW C 0448-02806-0-10621-A (1) Fuel gauge unit (18) Check valve (2) Cap (19) IN (check valve)
Page 68: Control System (Sw504)
ENGINE AND CONTROLS SW504 6. CONTROL SYSTEM (SW504) 6-1. Throttle Control IDLE FULL VIEW A 14 13 SECTION B-B 0448-12803-0-10627-0 (1) Throttle lever (9) Key (2) Lock nut : M8 (10) Nut : M14 (3) Stopper bolt (FULL) : M8×35 (11) Disc spring (4) Potentiometer (12) Bush (Apply grease*)
Page 69: Forward-Reverse Control
SW504 ENGINE AND CONTROLS 6-2. Forward-reverse Control DETAIL C SECTION A-A SECTION B-B VIEW D 0448-12804-0-10628-A (1) Control cable (8) Friction plate (14) Lock nut : M12 (2) F-R lever (L) (9) Bush (15) Set screw : M12×22 (3) F-R lever (R) (10) Holder (Apply grease) (16) Rod end (4) Backup buzzer switch...
Page 70: Pump Mount (Sw504)
ENGINE AND CONTROLS SW504 7. PUMP MOUNT (SW504) 7-1. Pump Mount Engine flywheel Weep hole VIEW A SECTION B-B 0448-36814-0-20631-0 (1) Bolt : M 8×16 (5) Cover (2) Bolt : M10×35 (6) Coupling (3) Pin (7) Bolt : M12×35 (4) Bolt : M 8×20 (8) Pump N•m...
Page 71: Installation Of Pump
SW504 ENGINE AND CONTROLS 7-1-1. Installation of pump • When the pump assembly has been removed from the engine for repair or replacement, reinstall it in accordance with the following procedure. ① Apply adequate amount of grease to pump (8) and coupling (6) splines.
Page 73: Hydraulic Systems
HYDRAULIC SYSTEMS...
Page 76: 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 77 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 79: Hydraulic Circuit Diagram
HYDRAULIC SYSTEMS 1-2. Hydraulic Circuit Diagram (1/2") 1-2-1. Hydraulic circuit diagram (SW354) (1/2") Vibrator motor (F) (1/2") Vibrator motor (R) 29.0kN/4000min (1/2") 29.0kN/4000min /rev 12.7MPa /rev 12.7MPa (3/8") (1/2") (1/2") (3/8") (1/2") Check valve 0.7MPa Vibrator solenoid valve (F) Check valve Vibrator solenoid (1/2")
Page 81: Hydraulic Circuit Diagram (Tw354)
HYDRAULIC SYSTEMS 1-2-2. Hydraulic circuit diagram (TW354) (1/2") Vibrator motor (1/2") 20.6kN/3120min 10.8 /rev 12.75MPa (3/8") (1/2") (1/2") Check valve 0.7MPa Vibrator solenoid valve Cooling (1/2") Steering cylinder (1/4") Propulsion motor (F) 50X 25X220 14.4 /rev (1/2") Oil cooler (3/8") (1/2") 1200 Cooling fan...
Page 83: Hydraulic Circuit Diagram (Tw504)
HYDRAULIC SYSTEMS 1-2-3. Hydraulic circuit diagram (TW504) (1/2") (1/2") Vibrator motor (1/2") LOW :26.5kN/3120min HIGH:34.3kN/3120min 10.8 /rev HIGH Cooling fan Steering cylinder drive motor 14.0MPa (1/2") (3/8") 63X 30X250 5.0MPa (1/4") Propulsion motor (F) (3/8") (3/8") Vibrator solenoid valve (1/2") (1/2") 14.4 1300...
Page 85: Propulsion Hydraulic System
HYDRAULIC SYSTEMS 2. PROPULSION HYDRAULIC SYSTEM 2-1. Propulsion Hydraulic Piping Hydraulic oil tank Oil cooler 2-1-1. Propulsion hydraulic piping (F) (SW/TW354) Speed change Parking brake solenoid valve solenoid valve SECTION C-C SECTION D-D Propulsion pump VIEW E Hose AFD) SECTION B-B Hydraulic oil filter Hose Hydraulic oil tank...
Page 87: Propulsion Hydraulic Piping (F) (Tw504)
HYDRAULIC SYSTEMS 2-1-2. Propulsion hydraulic piping (F) (TW504) Oil cooler Hydraulic oil tank Speed change Parking brake solenoid valve solenoid valve SECTION C-C SECTION B-B Hose VIEW D Propulsion pump Hose Hydraulic oil tank AFD) Hose (FMD Hose Hydraulic oil filter Hose FM4) Cooling fan drive motor...
Page 89: Propulsion Hydraulic Piping (R) (Sw354)
HYDRAULIC SYSTEMS 2-1-3. Propulsion hydraulic piping (R) (SW354) Hydraulic oil tank Bypass valve Hose SECTION B-B (TV1 BV1) SECTION A-A DETAIL C Hose Hose (TT6 (TR4 AP4) Hose (TR4 AP4) Propulsion pump Hose Hose TPB) (PRB (TT6 Hose Hose Hose...
Page 91: Propulsion Hydraulic Piping (R) (Tw354)
HYDRAULIC SYSTEMS 2-1-4. Propulsion hydraulic piping (R) (TW354) Differential lock valve Hose SECTION A-A SECTION B-B (ADC Bypass valve Hose Hose (TV2 BV2) (TV1 BV1) DETAIL D DETAIL C Hose (RM3 RRP) Differential lock valve Hose (TR4 Hose RRA) Hose Hose (OTK Hose...
Page 93: Propulsion Hydraulic Piping (R) (Tw504)
HYDRAULIC SYSTEMS 2-1-5. Propulsion hydraulic piping (R) (TW504) Differential lock valve Hydraulic oil tank Hose Hose (OTK (ADC SECTION A-A SECTION B-B Bypass valve Hose Hose Hose (TV2 BV2) (TV1 BV1) (TR4 DETAIL D DETAIL C Hose (RM3 RRP) Propulsion pump Differential lock valve Hose Hose...
Page 96: Hydraulic Component Specifications
HYDRAULIC SYSTEMS 2-2. Hydraulic Component Specifications 2-2-1. Propulsion hydraulic pump VIEW A VIEW B Hydraulic circuit diagram SW354-04001 4-011...
Page 97 HYDRAULIC SYSTEMS (1) Port B (Reverse) [PB] : 1 1/16-12UN (2) High pressure gauge port (For port B) 9/16-18UNF (3) Servo pressure gauge port 9/16-18UNF (4) Drain port [PD] : 1 1/16-12UN (5) High pressure gauge port (For port A) 9/16-18UNF (6) Port A (Forward) [PA] : 1 1/16-12UN...
Page 98: Propulsion Hydraulic Motor (F) (Sw/Tw354)
Flow of oil (Rotation direction is when viewed in direction of arrow A.) 4 1 Clockwise rotation 1 4 Counterclockwise rotation Motor circuit diagram SW354-04002 (1) Port B [FMB] : G1/2 (5) Parking brake pilot port [FM3] : G1/4 (2) Parking brake pilot port...
Page 99: Propulsion Hydraulic Motor (F) (Tw504)
HYDRAULIC SYSTEMS 2-2-3. Propulsion hydraulic motor (F) (TW504) Flow of oil (Rotation direction is when viewed in direction of arrow A.) 5 3 Clockwise rotation 3 5 Counterclockwise rotation Motor circuit diagram TW504-04001 (1) Charge relief valve (6) Parking brake pilot port [FM3] : G1/4 (2) Parking brake pilot port : G1/4...
Page 100: Propulsion Hydraulic Motor (R) (Sw354)
HYDRAULIC SYSTEMS 2-2-4. Propulsion hydraulic motor (R) (SW354) Flow of oil (Rotation direction is when viewed in direction of arrow A.) 4 1 Clockwise rotation 1 4 Counterclockwise rotation Motor circuit diagram SW354-04003 (1) Port B [RMB] : G1/2 (4) Port A...
Page 101: Propulsion Hydraulic Motor (R) (Tw354,504)
HYDRAULIC SYSTEMS 2-2-5. Propulsion hydraulic motor (R) (TW354,504) Flow of oil (Rotation direction is when viewed in direction of arrow A.) 4 1 Clockwise rotation 1 4 Counterclockwise rotation Motor circuit diagram TW504-04002 (1) Port B [RLB] [RRB] : G1/2 (4) Port A [RLA] [RRA] : G1/2 [RLP]...
Page 102: Differential Lock Valve (Tw354,504)
HYDRAULIC SYSTEMS 2-2-6. Differential lock valve (TW354,504) VIEW A Hydraulic diagram SW300-1-04004 (1) Body (6) Check valve (2) Port C [DC] : 9/16-18UNF (7) Port B1 [B1] : 3/4-16UNF (3) Port A [DA] : 3/ 4-16UNF (8) Port B2 [B2] : 3/4-16UNF (9) Flow control valve (4) Orifice...
Page 103: Vibrator Hydraulic System
HYDRAULIC SYSTEMS 3. VIBRATOR HYDRAULIC SYSTEM Hose (VPD VAR) 3-1. Vibrator Hydraulic Piping 3-1-1. Vibrator hydraulic piping (SW354) Vibrator solenoid valve (R) Hose Vibrator solenoid valve (F) (TT8 TVR) SECTION A-A Vibrator (F) + steering charge pump DETAIL B Check valve...
Page 105: Vibrator Hydraulic Piping (Tw354)
HYDRAULIC SYSTEMS 3-1-2. Vibrator hydraulic piping (TW354) Vibrator solenoid valve Hydraulic oil tank Check valve VIEW A Vibrator (F) + steering charge pump Hose (VFP VPF) Hose (TO8 Cooling fan drive motor Hose (VFB FVB) VIEW B Hose (FVD Hose (FVA TFA) Hose...
Page 107: Vibrator Hydraulic Piping (Tw504)
HYDRAULIC SYSTEMS 3-1-3. Vibrator hydraulic piping (TW504) Hydraulic oil tank Vibrator (F) + steering charge pump Hose TVT) DETAIL A Vibrator solenoid valve Hose Cooling fan drive motor Hose FVB) Hose (FVD Hose FVA) VIEW B Hose (TO8 Vibrator motor The letters and numbers in the figure such as “VA”...
Page 109: Hydraulic Component Specifications
HYDRAULIC SYSTEMS 3-2. Hydraulic Component Specifications 3-2-1. Hydraulic pump assembly (vibrator (F) + steering • charge) VIEW A Hydraulic circuit diagram SW354-04004 (1) Suction port [VVS] : G1 (2) Discharge port (steering) [SD] : G1/2 (3) Discharge port (vibration) [VD]...
Page 110: Vibrator Hydraulic Pump (R) (Sw354)
HYDRAULIC SYSTEMS 3-2-2. Vibrator hydraulic pump (R) (SW354) Hydraulic circuit diagram VIEW A SW354-04005 (1) Suction port [RVS] : G3/4 (2) Discharge port [RVD] : G1/2 Specifications • Displacement : 13.9 cm /rev ( 0.85 cu.in./rev ) • Rated pressure : 17.2 MPa...
Page 111: Vibrator Hydraulic Motor
/rev ( 0.66 cu.in./rev ) • Rated pressure 25 MPa ( 3,625 psi • Allowable motor case pressure 0.5 MPa ( 72.5 psi • Weight (SW354) 2.5 kg 5.5 lbs. (TW354,504) 2.7 kg 6.0 lbs. * [RVD], [RVA], [RVB] : SW354 only 4-023...
Page 112: Cooling Fan Drive Hydraulic Motor
HYDRAULIC SYSTEMS 3-2-4. Cooling fan drive hydraulic motor Motor circuit diagram VIEW A SW354-04007 [CMS] : (1) Suction port 7/ 8-14UNF (2) Discharge port [CMD] : 1 1/16-12UN (3) Relief valve Specifications • Displacement 14.4 cm /rev ( 0.88 cu.in./rev ) •...
Page 113: Vibrator Solenoid Valve (F), (R) (Sw/Tw354)
Maximum flow 75 L/min ( 19.8 gal./min • Maximum pressure : 21.0 MPa ( 3,045 psi • Relief valve pressure setting : 12.7 MPa ( 1,842 psi • Weight : 1.30 kg 2.9 lbs. * (R) : SW354 only 4-025...
Page 114: Vibrator Solenoid Valve (Tw504)
HYDRAULIC SYSTEMS 3-2-6. Vibrator solenoid valve (TW504) Hydraulic circuit diagram TW504-04003 (1) Port B [VB] : 3/4-16UNF (5) Port P [VP] : 3/ 4-16UNF (2) Port A [VA] : 3/4-16UNF (6) Port M : 7/16-20UNF (3) Relief valve (7) Solenoid valve a (4) Port T [VT] : 3/4-16UNF (8) Solenoid valve b...
Page 115: Steering System
HYDRAULIC SYSTEMS 4. STEERING SYSTEM Suction filter 4-1. Steering Hydraulic Piping 4-1-1. Steering hydraulic piping (SW/TW354) Hose Hose Hydraulic oil tank (SSP STF) Hose Hose SSP) (STF Steering cylinder Vibrator (F) + steering charge pump Orbitrol DETAIL A Hose Hose (TVS VSS) SSP)
Page 117: Steering Hydraulic Piping (Tw504)
HYDRAULIC SYSTEMS 4-1-2. Steering hydraulic piping (TW504) Suction filter Hose Hose Hydraulic oil tank (SSP STF) Hose Hose (STF SSP) Vibrator (F) + steering charge pump Steering cylinder Orbitrol DETAIL A Hose Hose VSS) SSP) Hydraulic oil filter Hose Coupling : STF) Charge pressure gauge port Hose...
Page 119: Steering Wheel
HYDRAULIC SYSTEMS 4-2. Steering Wheel 0446-32803-0-20620-A (1) Nut : M12 P=1.25 (2) Steering wheel (3) Column shaft (4) Bolt : M10×35 (5) Orbitrol N•m (1) Nut M12 P=1.25 : 64 N·m ( 47 lbf·ft ) (4) Bolt M10×35 39.2 N·m ( 29 lbf·ft ) 4-029...
Page 120: Hydraulic Circuit Diagram (Sw504)
HYDRAULIC SYSTEMS 4-3. Hydraulic Component Specifications 4-3-1. Orbitrol Hydraulic circuit diagram ORB-SD-04140 (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 121: Hydraulic Circuit Diagram
SW504 HYDRAULIC SYSTEMS 5. HYDRAULIC CIRCUIT DIAGRAM (SW504) 5-1. Hydraulic Circuit Diagram Vibrator solenoid valve (F) Vibrator solenoid valve (R) (1/2") Vibrator motor 14.4MPa (1/2") LOW :26.5kN/3300min Vibrator motor HIGH:34.3kN/3300min 14.4MPa LOW :26.5kN/3300min HIGH:34.3kN/3300min /rev HIGH /rev HIGH (1/2") (3/8") (1/2") (1/2") (1/2")
Page 123: Propulsion Hydraulic System (Sw504)
SW504 HYDRAULIC SYSTEMS 6. PROPULSION HYDRAULIC SYSTEM (SW504) 6-1. Propulsion Hydraulic Piping Oil cooler Hydraulic oil tank 6-1-1. Propulsion hydraulic piping (F) Speed change Parking brake solenoid valve solenoid valve SECTION C-C SECTION D-D Hose VIEW E SECTION B-B Hose Hydraulic oil tank Hose Hydraulic oil filter...
Page 125: Propulsion Hydraulic Piping (R)
SW504 HYDRAULIC SYSTEMS 6-1-2. Propulsion hydraulic piping (R) Hydraulic oil tank Bypass valve SECTION C-C SECTION B-B Hose (TV1 BV1) VIEW A Hose (TT6 D 詳細 Hose Hose Hose (TT6 (TR5 AP4) (TR5 AP4) Propulsion pump Hose TPA) Hose Hose (PRB (P.4-034) (PRA TPB)
Page 128: Hydraulic Component Specifications
HYDRAULIC SYSTEMS SW504 6-2. Hydraulic Component Specifications 6-2-1. Propulsion hydraulic pump VIEW A VIEW B Hydraulic circuit diagram SW354-04001 4-034...
Page 129 SW504 HYDRAULIC SYSTEMS (1) Port B (Forward) [PB] : 1 1/16-12UN (2) High pressure gauge port (For port B) 9/16-18UNF (3) Servo pressure gauge port 9/16-18UNF (4) Drain port [PD] : 1 1/16-12UN (5) High pressure gauge port (For port A) 9/16-18UNF (6) Port A (Reverse) [PA] : 1 1/16-12UN...
Page 130: Propulsion Hydraulic Motor (R)
HYDRAULIC SYSTEMS SW504 6-2-2. Propulsion hydraulic motor (R) Flow of oil (Rotation direction is when viewed in direction of arrow A.) 2 Clockwise rotation 4 Counterclockwise rotation Motor circuit diagram SW504-04001 (1) Parking brake pilot port : G1/4 (4) Port A [RMA] : G1/2 [RMB] : G1/2 [RM5] : G1/4...
Page 131: Vibrator Hydraulic System (Sw504)
SW504 HYDRAULIC SYSTEMS 7. VIBRATOR HYDRAULIC SYSTEM (SW504) 7-1. Vibrator Hydraulic Piping Hose (VTF TVT ) Vibrator solenoid valve (R) VIEW A (P.4-040) Pump assembly (vibrator + steering charge) (P.4-038) Hose Hose (VTF TVT ) (VRD VPR) Hose VPR) (VRD SECTION B-B Hose (VTR...
Page 133: Hydraulic Component Specifications
HYDRAULIC SYSTEMS SW504 7-2. Hydraulic Component Specifications 7-2-1. Hydraulic pump assembly (vibrator + steering • charge) VIEW A Hydraulic circuit diagram SW504-04002 (1) Vibrator pump (F) (5) Suction port (steering) [SPS] : G3/4 (2) Vibrator pump (R) (6) Discharge port (steering) [SD] : G1/2 (3) Steering •...
Page 134: Cooling Fan Drive Hydraulic Motor
HYDRAULIC SYSTEMS SW504 7-2-2. Cooling fan drive hydraulic motor Motor circuit diagram VIEW A SW354-04007 [CMS] : (1) Suction port 7/ 8-14UNF (2) Discharge port [CMD] : 1 1/16-12UN (3) Relief valve Specifications • Displacement 10.8 cm /rev ( 0.66 cu.in./rev ) •...
Page 135: Vibrator Solenoid Valve Assembly
HYDRAULIC SYSTEMS SW504 7-2-3. Vibrator solenoid valve assembly VIEW A sol.a sol.b Hydraulic circuit diagram SW504-04003 (1) Solenoid valve b (5) Port A [VAF] [VAR] : G1/2 (2) Solenoid valve a (6) Port T [VTF] [VTR] : G1/2 (3) Relief valve : G3/4 (7) Port P [VPF] [VPR]...
Page 137: Steering System (Sw504)
SW504 HYDRAULIC SYSTEMS 8. STEERING SYSTEM (SW504) Suction filter 8-1. Steering Hydraulic Piping Hose Hose Hydraulic oil tank (SSP STF) Hose Hose SSP) (STF Orbitrol DETAIL A (P.4-042) Pump assembly (vibrator + steering charge) (P.4-038) Steering cylinder Hose Hose SSP) (STF Hose SECTION B-B...
Page 139: Hydraulic Component Specifications
HYDRAULIC SYSTEMS SW504 8-2. Hydraulic Component Specifications 8-2-1. Orbitrol Hydraulic circuit diagram ORB-ET-04140 (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 141: Electrical System
ELECTRICAL SYSTEM...
Page 143: 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 144 ELECTRICAL SYSTEM • Wire color code chart Black/ Black/ Black/ Black/ Black/ Black White stripe Yellow stripe Red stripe Green stripe Blue stripe White/ White/ White/ White/ White/ W White Red stripe Black stripe Blue stripe Yellow stripe Green stripe Red/ Red/ Red/...
Page 145: System Circuit Diagram
ELECTRICAL SYSTEM 2. SYSTEM CIRCuIT DIAGRAM 37 GB 2-1. Electrical Circuit Diagram (SW354) 35 G 36 GR FLOOD LAMP HEAD LAMP (R) 55W COMBINATION LAMP (R) 35 G TURN SIGNAL LAMP (R) 21W 61 RG F-R LEVER VIBRATION STOP LAMP 21W...
Page 147: Electrical Circuit Diagram (Sw354 Rops)
ELECTRICAL SYSTEM 2-2. Electrical Circuit Diagram (SW354 ROPS) 37 GB 35 G 36 GR FLOOD LAMP HEAD LAMP (R) 55W COMBINATION LAMP (R) 35 G TURN SIGNAL LAMP (R) 21W 61 RG HEAD LAMP F-R LEVER VIBRATION STOP LAMP 21W...
Page 149: Electrical Circuit Diagram (Tw354)
ELECTRICAL SYSTEM 2-3. Electrical Circuit Diagram (TW354) 37 GB 35 G 36 GR FLOOD LAMP HEAD LAMP (R) 55W COMBINATION LAMP (R) 35 G TURN SIGNAL LAMP (R) 21W 61 RG HEAD LAMP STOP LAMP 21W (L) 55W 37 GB WATER SPRAY TAIL LAMP 5W 20 2BrR...
Page 151: Electrical Circuit Diagram (Tw354 Rops)
ELECTRICAL SYSTEM 2-4. Electrical Circuit Diagram (TW354 ROPS) 37 GB 35 G 36 GR FLOOD LAMP HEAD LAMP (R) 55W 9 BrW COMBINATION LAMP (R) 35 G TURN SIGNAL LAMP (R) 21W 61 RG HEAD LAMP STOP LAMP 21W (L) 55W 37 GB WATER SPRAY TAIL LAMP 5W...
Page 153: Electrical Circuit Diagram (Tw504)
ELECTRICAL SYSTEM 2-5. Electrical Circuit Diagram (TW504) 37 GB 35 G 36 GR FLOOD LAMP HEAD LAMP (R) 55W 9 BrW COMBINATION LAMP (R) 35 G TURN SIGNAL LAMP (R) 21W 61 RG HEAD LAMP STOP LAMP 21W (L) 55W 37 GB WATER SPRAY TAIL LAMP 5W...
Page 155: Electrical Circuit Diagram (Tw504 Rops)
ELECTRICAL SYSTEM 2-6. Electrical Circuit Diagram (TW504 ROPS) 37 GB 35 G 36 GR FLOOD LAMP HEAD LAMP (R) 55W 9 BrW COMBINATION LAMP (R) 35 G TURN SIGNAL LAMP (R) 21W 61 RG HEAD LAMP STOP LAMP 21W (L) 55W 37 GB WATER SPRAY 20 2BrR...
Page 157: Electrical Components
SW354 ELECTRICAL SYSTEM 3. ELECTRICAL CoMPonEnTS Battery relay 3-1. Wiring Harness Layout (SW354) GW(NO) 3-1-1. Wiring harness layout (1) WR(NO) W(COM) to Drum edge lamp (F,R) (option) Vibrator solenoid (F) Engine oil pressure switch VIEW A Turn signal lamp (R)
Page 159: Wiring Harness Layout (2)
Dashboard harness Dashboard harness (P.5-017) (P.5-017) Insulation protection VIEW G VIEW G ECO lamp switch 1 (SW354) (SW354 ROPS) DETAIL L Starter switch harness (P.5-025) Working switch harness Parking brake Starter switch (P.5-028) Parking brake switch harness Working switch harness...
Page 161: Wiring Harness Layout (Tw354)
TW354 ELECTRICAL SYSTEM 3-2. Wiring Harness Layout (TW354) Battery relay 3-2-1. Wiring harness layout (1) GW(NO) WR(NO) W(COM) to Drum edge lamp (F,R) (option) Vibrator solenoid Engine oil pressure switch VIEW A Fuel gauge unit Turn signal lamp (R) (B),(YG) (B),(G) to Mihaalu (option) Head lamp (R)
Page 163: Wiring Harness Layout (2)
TW354 ELECTRICAL SYSTEM 3-2-2. Wiring harness layout (2) Backup buzzer Dashboard harness F-R lever switch switch (P.5-017) Horn relay to Turn signal switch to Horn switch to Horn switch to Turn signal switch W(NO) (G),(GR),(GY) (LgW) (LgW) (G),(GR),(GY) B(COM) Flasher unit R(NC) J : to Working switch harness to Combination meter...
Page 165: Wiring Harness Layout (Tw504)
TW504 ELECTRICAL SYSTEM 3-3. Wiring Harness Layout (TW504) Battery relay 3-3-1. Wiring harness layout (1) GW(NO) WR(NO) W(COM) to Drum edge lamp (F,R) (option) Turn signal lamp (R) Fuel gauge unit VIEW A Engine oil pressure switch (B),(YG) (B),(G) to Mihaalu (option) Head lamp (R) Alternator K : to Liquid spray pump harness...
Page 167: Dashboard Harness
TW504 ELECTRICAL SYSTEM 3-3-2. Wiring harness layout (2) Backup buzzer Dashboard harness F-R lever switch switch (P.5-017) Horn relay to Turn signal switch to Horn switch to Horn switch to Turn signal switch W(NO) (G),(GR),(GY) (LgW) (LgW) (G),(GR),(GY) B(COM) Flasher unit R(NC) J : to Working switch harness to Combination meter...
Page 168 ELECTRICAL SYSTEM 4. wIRInG HARnESSES 4-1. Engine Harness 12015792 Speed change solenoid LgW B 40 X 12015792 Parking brake solenoid YB,50 Engine oil pressure switch PB104 Terminal cover LE104 Hydraulic oil filter switch 5WG,80 LCR RL-1B LA108 Ground 7283-1528-10 Engine stop solenoid SWP-4M Corrugate Corrugate...
Page 169 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS B × 3, Ground, Tachometer sensor B , Engine stop solenoid B , Glow plugs B × 2 B , Alternator B × 2 B , Alternator B , Hydraulic oil filter switch B , Engine stop solenoid, Tachometer sensor B ×...
Page 170 LgW,50 (P.5-028) CB104 Horn switch 58X-2M 2BrW GY,50 CB104 SW/TW354 Tape G,50 Turn signal CB104 (except SW354 ROPS) switch : Short harness Glow lamp timer RB6B-SL GR,50 CB104 (P.5-030) SWP-2M SW354 ROPS SWP-6F : Vibratory drum select 302 300 LgW LgB RL...
Page 171 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS A (6F), C , E , Brake lamp relay, Combination meter (16M) × 3, G × 2, Flasher unit, Turn signal switch ECO lamp, Flasher unit, F-R lever vibration switch (L) harness, A (8F), C , G , Combination meter (12F), Turn signal switch F-R lever vibration switch (R) harness, Glow lamp timer, Ground, B,2B...
Page 172: Frame (F) Harness
ELECTRICAL SYSTEM 4-3. Frame (F) Harness 4-3-1. Frame (F) harness (SW/TW354) Fuel gauge unit Vibrator solenoid (F) Turn signal lamp (R) CA104 CB104 CA104 CB104 CA104 CB104 Fuel pump RB2B-SL Head lamp (R) CB104 5WG,80 LCT RL-1A Horn Ground PB104 LA210 SWP-4M Drum edge lamp...
Page 173 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS A (6M), B , Battery relay-X, Fuel gauge unit, Fuel pump, Ground, A (3M), B B,2B Turn signal lamp (L), (R), Drum edge lamp (F,L) (option), (F,R) (option) A (4M), B Battery relay-COM, Fusible link 65A A (8M), Turn signal lamp (R)
Page 174: Frame (F) Harness (Tw504)
ELECTRICAL SYSTEM 4-3-2. Frame (F) harness (TW504) Fuel gauge unit Turn signal lamp (R) Vibrator solenoid CA104 CB104 CA104 CB104 DT06-2S DT06-2S Fuel pump 47 46 RB2B-SL LgY BrR Head lamp (R) CB104 5WG,80 LCT RL-1A Horn Ground PB104 LA210 SWP-4M SWP-6M Dashboard harness...
Page 175 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS A (6M), B , Battery relay-X, Fuel gauge unit, Fuel pump, Ground, A (3M), B B,2B Turn signal lamp (L), (R), Drum edge lamp (F,L) (option), (F,R) (option) A (4M), B Battery relay-COM, Fusible link 65A A (8M), Turn signal lamp (R)
Page 176: Frame (R) Harness
Combination lamp (L) Combination lamp (R) (option) (P.5-021) Water spray pump RB6B-SL Flood lamp RB6B-SL SWP-2F SWP-2M 58X-2F CB104 SWP-8F SW354 1500 2BrW,50 : Not in use LCR RL-1B Corrugate Corrugate Corrugate Corrugate Corrugate Corrugate Corrugate TW354,504 : Liquid spray pump...
Page 177 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS C , Backup buzzer, Combination lamp (L), (R), Ground, Mihaalu harness, C , Water spray relay-g B,3B Water spray pump, Water spray relay-e, Backup lamp (option), Water spray pump, Water spray relay-G Drum edge lamp (R,L) (option), (R,R) (option) C , J 2BrW...
Page 179: Stater Switch Harness
ELECTRICAL SYSTEM 4-5. Stater Switch Harness 5WR,100 LE305 5WG,100 LE305 (R1) BrB,100 LE105 (ACC) 2Y,100 RB6B-SL LE205 (ACC) Starter switch LgR,100 LE105 (BR) Dashboard WL,100 5WR,50 harness LCR RL-1B LE105 Tape (P.5-017) 3W,100 LE205 3BY,100 5WG,50 LCT RL-1A LE205 1446-09027-0-30316-0 CONTACT SIZE, COLOR CONNECTION...
Page 180 ELECTRICAL SYSTEM 4-6. Control Switch Harness RY,80 Speed change switch LgW,80 SWP-2M 3R,80 Dashboard harness (P.5-017) 3R,80 Tape Lighting switch 2GB 3R 58X-3M 2GB,80 2Or,80 1446-09028-0-30317-A CONTACT SIZE, COLOR CONNECTION POINTS 2R,3R F , Lighting swich-1, 4 F , Speed change swich-1 F , Speed change swich-2 F , Lighting swich-3 F , Lighting swich-5...
Page 181: Working Switch Harness (Except Rops)
ELECTRICAL SYSTEM 4-7. Working Switch Harness 4-7-1. Working switch harness (except ROPS) LY,80 LW,80 Water spray mode select switch GY,80 27 39 SWP-3F LW LY LW,80 Dashboard harness (P.5-017) Tape RL,80 SWP-3M RL,80 Vibration mode select switch RW,80 BrY,80 1446-09063-0-30837-0 CONTACT SIZE, COLOR CONNECTION...
Page 182: Working Switch Harness (Rops)
ELECTRICAL SYSTEM 4-7-2. Working switch harness (ROPS) X 70 RB4B-SL Water spray timer 39 70 SWP-3F LW LY Dashboard harness LY,80 (P.5-017) LY,80 SWP-3M Water spray mode Tape select switch LW,80 P,80 B,350 Ground LA108 RL,80 RL,80 Vibration mode select switch RW,80 BrY,80 1446-75052-0-30851-0...
Page 183: Parking Brake Switch Harness
ELECTRICAL SYSTEM 4-8. Parking Brake Switch Harness RW,100 WB,100 Dashboard harness YL,100 Parking brake switch SWP-6F (P.5-017) Tape B,100 Y,100 1446-09062-0-30834-0 CONTACT SIZE, COLOR CONNECTION POINTS Parking brake switch-4 Parking brake switch-5 Parking brake switch-3 Parking brake switch-1 Parking brake switch-2 5-029...
Page 184: Vibration Lo-Hi Change Switch Harness
ELECTRICAL SYSTEM 4-9. Vibration Lo-Hi Change Switch Harness 4-9-1. Short harness (SW/TW354 : except SW354 ROPS) Dashboard harness LgR LgR SWP-6M (P.5-017) 1446-09015-0-40121-0 CONTACT SIZE, COLOR CONNECTION POINTS Dashboard harness × 2 Dashboard harness × 2 5-030...
Page 185: Vibration Lo-Hi Change Switch Harness (Tw504)
ELECTRICAL SYSTEM 4-9-2. Vibration Lo-Hi change switch harness (TW504) RL,80 RL,80 LgR,80 Dashboard harness Vibration Lo-Hi change switch SWP-6M (P.5-017) LgY,80 Tape RL LgB LgW LgB,80 LgW,80 1448-09005-0-30064-A CONTACT SIZE, COLOR CONNECTION POINTS Vibration Lo-Hi change switch-1, 4 Vibration Lo-Hi change switch-3 Vibration Lo-Hi change switch-2 Vibration Lo-Hi change switch-6 Vibration Lo-Hi change switch-5...
Page 186: Vibrator Solenoid (R) Harness
ELECTRICAL SYSTEM 4-10. Vibrator Solenoid (R) Harness 4-10-1. Vibrator solenoid (R) harness (SW354) BrR,50 CA104 Vibrator solenoid (R) Frame (R) harness LgB,50 CB104 SWP-3M (P.5-023) Tape LgW,50 Not in use CB104 1446-09012-0-30118-0 CONTACT SIZE, COLOR CONNECTION POINTS Vibrator solenoid (R)
Page 187: Cap (Tw354,504)
ELECTRICAL SYSTEM 4-10-2. Cap (TW354,504) Frame (R) harness SWP-3M (P.5-023) 1447-09002-0-40043-0 5-033...
Page 188: Hazard Switch Harness
ELECTRICAL SYSTEM 4-11. Hazard Switch Harness 4-11-1. Cap (except ROPS) Dashboard harness SWP-4F (P.5-017) 1418-09044-0-40589-0 5-034...
Page 189: Hazard Switch Harness (Rops)
ELECTRICAL SYSTEM 4-11-2. Hazard switch harness (ROPS) GY,100 GB,100 Dashboard harness Hazard switch SWP-4F (P.5-017) GY,100 Corrugate GR,100 1634-09078-0-31116-0 CONTACT SIZE, COLOR CONNECTION POINTS Hazard switch-1, 4 G × 2, Hazard switch-5 Hazard switch-2 5-035...
Page 190: Mihaalu Harness
ELECTRICAL SYSTEM 4-12. Mihaalu Harness Super flex vinyl cabtyre cord S-VCTF 0.75mm ×4C 38 X Frame (R) harness Mihaalu (option) SWP-6F SWP-4M (P.5-023) * 308 1446-70015-0-30858-0 CONTACT SIZE, COLOR CONNECTION POINTS Frame (R) harness, Mihaalu (option) Frame (R) harness, Mihaalu (option) Frame (R) harness, Mihaalu (option) Frame (R) harness, Mihaalu (option) 5-036...
Page 191: Liquid Spray Switch Harness (Tw354,504)
ELECTRICAL SYSTEM 4-13. Liquid Spray Switch Harness (TW354,504) 2BrR,130 Dashboard harness Liquid spray switch 58X-2M (P.5-017) 2BrR 2BrW Tape 2BrW,130 1442-09001-0-30054-0 CONTACT SIZE, COLOR CONNECTION POINTS Liquid spray switch-2 2BrW Liquid spray switch-2 2BrR 5-037...
Page 192: Liquid Spray Pump Harness (Tw354,504)
ELECTRICAL SYSTEM 4-14. Liquid Spray Pump Harness (TW354,504) Frame (R) harness 2BrW,30 1350 2BrW,30 CB104 Liquid spray pump LCT RL-1A (P.5-023) Corrugate 1447-09003-1-30081-A CONTACT SIZE, COLOR CONNECTION POINTS Liquid spray pump 2BrW 5-038...
Page 193: Short Harness
ELECTRICAL SYSTEM 4-15. Short Harness Dashboard harness 29 29 SWP-2F BY BY (P.5-017) 1446-09080-0-40879-0 CONTACT SIZE, COLOR CONNECTION POINTS Dashboard harness × 2 5-039...
Page 194: Vibratory Drum Select Switch Harness (Sw354 Rops)
ELECTRICAL SYSTEM 4-16. Vibratory Drum Select Switch Harness (SW354 ROPS) RL,80 RL,80 Vibratory drum select switch LgR,80 Dashboard harness SWP-6M (P.5-017) LgB,80 Tape RL LgB LgW LgY,80 Not in use LgW,80 1448-09005-0-30064-A CONTACT SIZE, COLOR CONNECTION POINTS Vibratory drum select switch-1, 4...
Page 195: F-R Lever Vibration Switch (L) Harness
ELECTRICAL SYSTEM 4-17. F-R Lever Vibration Switch (L) Harness Br,55 Br,65 Dashboard harness G,55 G,65 F-R lever vibration switch (L) (P.5-017) PVC tube ( 6×0.5) W,55 W,65 See “Wiring Harness Layout (2), DETAIL P”. (P.5-010),(P.5-012),(P.5-014) 1539-12013-0-30226-0 CONTACT SIZE, COLOR CONNECTION POINTS Dashboard harness, F-R lever vibration switch (L)-1 –...
Page 196: F-R Lever Vibration Switch (R) Harness
ELECTRICAL SYSTEM 4-18. F-R Lever Vibration Switch (R) Harness Br,55 Br,65 Dashboard harness G,55 G,65 F-R lever vibration switch (R) (P.5-017) PVC tube ( 6×0.5) W,55 W,65 See “Wiring Harness Layout (2), DETAIL R”. (P.5-010),(P.5-012),(P.5-014) 1539-12013-0-30226-0 CONTACT SIZE, COLOR CONNECTION POINTS Dashboard harness, F-R lever vibration switch (R)-1 –...
Page 197: Electrical Component Specifications
ELECTRICAL SYSTEM 5. ELECTRICAL CoMPonEnT SPECIfICATIonS 5-1. Fuse Box (SW354) (RL) (RB) Fuel pump Vibrator lamp relay Engine stop solenoid Vibration mode select switch Vibrator solenoid (F) Tachometer sensor Vibrator solenoid (R) Vibratory drum select switch (ROPS) (RG) Backup buzzer switch...
Page 198: Fuse Box (Tw354)
ELECTRICAL SYSTEM 5-2. Fuse Box (TW354) (RB) Fuel pump Vibrator lamp relay (RL) Vibration mode select switch Engine stop solenoid Tachometer sensor Vibrator solenoid (RG) Backup buzzer switch Horn relay Flasher unit ECO lamp switch 1 (RY) (BrR) Liquid spray switch Brake lamp relay F-R lever switch Speed change switch...
Page 199: Fuse Box (Tw504)
ELECTRICAL SYSTEM 5-3. Fuse Box (TW504) (RB) Fuel pump Vibrator lamp relay (RL) Vibration mode select switch Engine stop solenoid Tachometer sensor Vibration Lo-Hi change switch (RG) Backup buzzer switch Horn relay Flasher unit ECO lamp switch 1 (RY) (BrR) Liquid spray switch Brake lamp relay F-R lever switch Speed change switch...
Page 200: Combination Meter
Engine charge Engine charge warning warning indicator Hydraulic filter indicator Engine oil pressure Glow plug indicator Hydraulic filter Lamp check Coolant temperature 1 Coolant temperature 2 System configuration diagram Note: The circuit in the dashed box is not mounted. SW354-05002 5-046...
Page 201: System Circuit Diagram (Sw504)
SW504 ELECTRICAL SYSTEM 6. SYSTEM CIRCUIT DIAGRAM (SW504) 6-1. Electrical Circuit Diagram (ROPS) FLOOD 38 Or LAMP HEAD LAMP 18 3LY (R) 55W COMBINATION METER COMBINATION LAMP (R) Battery 12V (+) Head lamp Water splay 35 G TURN SIGNAL Starter switch (ACC) Parking brake Flood lamp 42 3LB...
Page 203: Electrical Circuit Diagram (Except Rops)
SW504 ELECTRICAL SYSTEM 6-2. Electrical Circuit Diagram (except ROPS) 38 Or FLOOD LAMP HEAD LAMP 18 3LY (R) 55W COMBINATION METER COMBINATION LAMP (R) Battery 12V (+) Head lamp Water splay 35 G TURN SIGNAL Starter switch (ACC) Parking brake Flood lamp 42 3LB 18 3LY...
Page 205: Electrical Components (Sw504)
SW504 SW504 ELECTRICAL SYSTEM 7. ELECTRICAL COMPONENTS (SW504) Battery relay Engine Harness (P.5-051) 7-1. Wiring Harness Layout (1) GW(NO) Turn signal lamp (R) K : Not in use WR(NO) W(COM) (B),(G) to Drum edge lamp (F,R) (option) Insulation protection Fuel gauge unit (B),(YG) to Mihaalu (option) Alternator...
Page 207: Wiring Harness Layout (2)
SW504 SW504 ELECTRICAL SYSTEM 7-2. Wiring Harness Layout (2) Dashboard F-R lever switch to Turn signal switch harness (2) Potentiometer Starter relay to Horn switch (G),(GR),(GY) (P.5-055) to Combination meter Backup buzzer switch (LgW) W(NO) (P.5-089) J : to Working switch harness F : to Control switch harness B(COM) ROPS: (P.5-067)
Page 208: Wiring Harnesses (Sw504)
ELECTRICAL SYSTEM SW504 8. WIRING HARNESSES (SW504) 8-1. Engine Harness Starter motor 5WG, 50 LE304 Glow plugs LA308 RB1B-SL Corrugate (H-COT) 109 111 Air flow 6189-1046 Corrugate 0.5WL 0.5Gr 0.5L 0.5G 0.5Gr sensor (H-COT) AEX 0.85 Marking tape (Color:yellow) 33 X 12015792 Speed change solenoid LgW B...
Page 209 SW504 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS B , Parking brake solenoid, Speed change solenoid B , Speed change solenoid B , Glow plugs B , Parking brake solenoid B , Alternator 0.5WL, WL B , Air flow sensor B , Alternator 0.5Gr, Gr...
Page 210: Dashboard Harness (1)
ELECTRICAL SYSTEM SW504 8-2. Dashboard Harness (1) Mihaalu Mihaalu Combination meter OUT 1 ground Twist pair cable (option) (option) (P.5-089) Stater relay harness Glow relay Neutral relay (AVS 0.85 mm x 2C) CB104 CA104 776164-1 (P.5-083) 7123-9246 RB6B-SL SWP-2M 58Y-2M 25 26 OUT1 5BY G...
Page 211 SW504 ELECTRICAL SYSTEM CONNECTION CONNECTION CONNECTION SIZE, CONTACT SIZE, CONTACT SIZE, CONTACT COLOR POINTS COLOR POINTS COLOR POINTS Dashboard Harness (1) Dashboard Harness (1) Dashboard Harness (1) ECU-VD (8F), Neutral relay A (4F) , ( 8F) , C (8M), COMB , C (4M), Combination meter -25 DIA , Combination meter -3,...
Page 212: Dashboard Harness (2)
ELECTRICAL SYSTEM SW504 8-3. Dashboard Harness (2) LgR, 40 Fuse LgW, 40 7124-9681 3WR, 40 Fuse Y, 40 7124-9681 Fuse box 2G, 40 Fuse SWP-2M SWP-2M SWP-2M 2Br, 40 7124-9681 BrB, 40 Fuse Sub power DT04-2P-E005 BY, 40 Tape (12V/120W) 7124-9681 WL, 40 Fuse...
Page 213 SW504 ELECTRICAL SYSTEM CONNECTION CONNECTION CONNECTION SIZE, CONTACT SIZE, CONTACT SIZE, CONTACT COLOR POINTS COLOR POINTS COLOR POINTS Dashboard Harness (2) Dashboard Harness (2) Dashboard Harness (2) E , Brake lamp relay, F-R lever Vibrator lamp relay vibration switch (L) harness, Brake lamp relay J , F-R lever switch, B, 1.25B, 2B...
Page 214: Ecu Harness (Vihicle)
ELECTRICAL SYSTEM SW504 8-4. ECU Harness (Vihicle) Twist shield cable Twist shield cable Twist shield cable Twist cable Twist cable Shield drain(117) (122,126,134) (119,123,125) Twist shield cable Shield drain(114) 134 126 1000 Engine side connector ECU-VF SWP-16M Corrugate 1 928 404 881 112 113 Tape Tape...
Page 215 SW504 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS C2 -246, ECU-VD (8F) C1 -141, ECU-VF (16M) C2 -216, ECU-VD (8F) C1 -131, ECU-VF (16F) WL, 1.25WL C2 -239, 253, 255, 256, ECU-VD (8F) C1 -102, ECU-VF (16M) C2 -241, ECU-VD (8F) C1 -103, ECU-VF (16M) C1 -121, ECU-VD (8F)
Page 216: Ecu Harness (Engine)
ELECTRICAL SYSTEM SW504 8-5. ECU Harness (Engine) B RW YR Shield drain X WR LW Sb TYCO: 0-936421-2 Engine connector A BrY * Y LY 132 134 133 132 Twist cable Twist cable Twist cable KUBOTA engine harness 120 118 116 1000 MOLEX: 33472-1206 ECU-E...
Page 217 SW504 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS B, 1.25B ECA -2, ECU-E (12M) ECA -28, ECU-E (16F) ECA -6, ECU-E (12M) ECA -37, ECU-E (16F) ECA -36, ECU-E (16F) ECA -34, ECU-E (16F) ECA -31, ECU-E (16F) ECA -33, ECU-E (16F) ECA -4, ECU-E (16F) ECA -39, 42, ECC -11, ECU-E (16F)
Page 218: Frame (F) Harness
ELECTRICAL SYSTEM SW504 8-6. Frame (F) Harness Vibrator solenoid (F) Vibrator solenoid (F) harness (2) harness (1) (P.5-072) (P.5-071) Shield drain Twist shield cable CB104 CA104 CB104 CA104 Hydraulic SWP-8M oil filter switch 1.25B Twist cable LE104 58Y-2M Fuel pump Fuel gauge unit Turn signal lamp (R) Head lamp (R)
Page 219 SW504 ELECTRICAL SYSTEM CONTACT CONTACT SIZE, COLOR CONNECTION SIZE, COLOR CONNECTION POINTS POINTS ECU-E (16M), ECU-VF (16F) A (4M), (8M), B (8F), ECU-E (12F), Battery relay, Diode, B, 1.25B, 2B Fuel gauge unit, Fuel pump, Ground, Turn signal lamp (L), (R), ECU-E (16M), ECU-VF (16F) Drum edge lamp (F, L)(option), (F, R)(option) ECU-E (8M), ECU-VF (16F)
Page 220: Frame (R) Harness
ELECTRICAL SYSTEM SW504 8-7. Frame (R) Harness SWP-2M Drum edge lamp Frame (F) Harness (R,R) (P.5-061) Water spray pump Combination lamp (L) Combination lamp (R) (option) Flood lamp SWP-2M 58X-2F RB6B-SL RB6B-SL SWP-2F CB104 58X-2F 2BrW Marking tape (Color:yellow) SWP-8F 1500 2BrW,50 Dashboard harness (1)
Page 221 ELECTRICAL SYSTEM SW504 CONTACT SIZE, COLOR CONNECTION POINTS C (8F), Combination lamp (L), (R), Ground × 2, Mihaalu harness, Water spray pump, Water spray relay -e, B, 3B Backup lamp (option), Drum edge lamp (R, L)(option), (R, R)(option) 2BrW C (X-2F), K (not in use) C (X-2F), Water spray relay -B C (8F), Backup buzzer C (8F), Combination lamp (R)
Page 222: Stater Switch Harness
ELECTRICAL SYSTEM SW504 8-8. Stater Switch Harness 5WR,100 LE305 (B) 5WG,100 LE305 (R1) BrB,100 LE105 (ACC) 2Y,100 Dashboard LE205 (BR) RB6B-SL Starter harness (2) switch LgR,100 (P.5-055) LE105 (BR) 5WR,50 WL,100 LE105 (C) LCR RL-1B Tape 3W,100 LE205 (C) Not in use 3BY,100 5WG,50 Insulation...
Page 223: Control Switch Harness
ELECTRICAL SYSTEM SW504 8-9. Control Switch Harness RY,80 Speed change switch LgW,80 SWP-2M 3R,80 Dashboard harness (2) 3R,80 Tape (P.5-055) Lighting switch 58X-3M 2GB,80 2Or,80 1446-09028-0-30317-B CONTACT SIZE, COLOR CONNECTION POINTS F , Lighting swich -1, 4 F , Speed change swich -1 F , Speed change swich -2 F , Lighting swich -3 F , Lighting swich -5...
Page 224: Working Switch Harness
ELECTRICAL SYSTEM SW504 8-10. Working Switch Harness 8-10-1. Working switch harness (ROPS) X 70 RB4B-SL Water spray timer 39 70 SWP-3F LW LY Dashboard harness (2) LY,80 (P.5-055) LY,80 SWP-3M Water spray mode Tape select switch LW,80 P,80 B,350 Ground LA108 RL,80 RL,80...
Page 225: Working Switch Harness (Except Rops)
ELECTRICAL SYSTEM SW504 8-10-2. Working switch harness (except ROPS) LY,80 LW,80 Water spray mode select switch GY,80 27 39 SWP-3F LW LY LW,80 Dashboard harness (2) Tape RL,80 (P.5-055) SWP-3M RL,80 Vibration mode select switch RW,80 BrY,80 1446-09063-0-30837-0 CONTACT SIZE, COLOR CONNECTION POINTS J , Water spray mode select switch -1...
Page 226: Vibration Switch Harness
ELECTRICAL SYSTEM SW504 8-11. Vibration Switch Harness 8-11-1. Vibration switch harness (ROPS) Vibratory drum select switch (1) (4) (3) (6) BrB,80 BrW,80 LgR,80 Dashboard Vibration Lo-Hi harness (2) SWP-6M LgY,80 change switch Tape (P.5-055) RL LgB LgW LgB,80 LgW,80 1448-09015-0-30369-A CONTACT SIZE, COLOR CONNECTION...
Page 227: Vibration Lo-Hi Change Switch Harness (Except Rops)
ELECTRICAL SYSTEM SW504 8-11-2. Vibration Lo-Hi change switch harness (except ROPS) RL,80 RL,80 LgR,80 Dashboard Vibration Lo-Hi harness (2) SWP-6M change switch LgY,80 Tape (P.5-055) RL LgB LgW LgB,80 LgW,80 1448-09005-0-30064-B CONTACT SIZE, COLOR CONNECTION POINTS Vibration Lo-Hi change switch -1, 4 D ×...
Page 228: Vibrator Solenoid (F) Harness (1)
ELECTRICAL SYSTEM SW504 8-12. Vibrator Solenoid (F) Harness (1) CA104 (LgY) Frame (F) harness Vibrator solenoid (F) Hi (P.5-061) VCTF 0.75mm × 2C CB104 (BrR) ・ (LgY), (BrR) indicate the connection line color. 1448-09003-0-40062-0 CONTACT SIZE, COLOR CONNECTION POINTS Vibrator solenoid (F) Hi -1, Frame (F) harness -(LgY) Vibrator solenoid (F) Hi -2, Frame (F) harness -(BrR) 5-071...
Page 229: Vibrator Solenoid (F) Harness (2)
ELECTRICAL SYSTEM SW504 8-13. Vibrator Solenoid (F) Harness (2) CA104 (LgR) Frame (F) harness Vibrator solenoid (F) Lo (P.5-061) VCTF 0.75mm × 2C CB104 (BrR) ・ (LgR), (BrR) indicate the connection line color. 1448-09003-0-40062-0 CONTACT SIZE, COLOR CONNECTION POINTS Vibrator solenoid (F) Lo -1, Frame (F) harness -(LgR) Vibrator solenoid (F) Lo -2, Frame (F) harness -(BrR) 5-072...
Page 230: Vibrator Solenoid (R) Harness (1)
ELECTRICAL SYSTEM SW504 8-14. Vibrator Solenoid (R) Harness (1) Vibrator solenoid (R) CA104 (LgW) harness (3) (P.5-075) Vibrator solenoid (R) Hi VCTF 0.75mm × 2C Vibrator solenoid (R) CB104 (BrR) harness (4) (P.5-076) ・ (LgW), (BrR) indicate the connection line color. 1448-09003-0-40062-0 CONTACT SIZE, COLOR...
Page 231: Vibrator Solenoid (R) Harness (2)
ELECTRICAL SYSTEM SW504 8-15. Vibrator Solenoid (R) Harness (2) Vibrator solenoid (R) harness (3) CA104 (LgB) (P.5-075) Vibrator solenoid (R) Lo VCTF 0.75mm × 2C Vibrator solenoid (R) CB104 (BrR) harness (4) (P.5-076) ・ (LgB), (BrR) indicate the connection line color. 1448-09003-0-40062-0 CONTACT SIZE, COLOR...
Page 232 ELECTRICAL SYSTEM SW504 8-16. Vibrator Solenoid (R) Harness (3) Vibrator solenoid (R) BrR,50 CA104 (BrR) harness (4) (P.5-076) Vibrator solenoid (R) LgB,50 Frame (R) harness harness (2) SWP-3M CB104 (P.5-063) Tape (P.5-074) Vibrator solenoid (R) LgW,50 harness (1) CB104 (P.5-073) ・...
Page 233: Vibrator Solenoid (R) Harness (3)
ELECTRICAL SYSTEM SW504 8-17. Vibrator Solenoid (R) Harness (4) Vibrator solenoid (R) Vibrator solenoid (R) BrR,50 BrR,50 harness (1) (BrR) CA104 CB104 harness (3) Tape (P.5-073) (P.5-075) Vibrator solenoid (R) BrR,50 CA104 harness (2) (P.5-074) ・ (BrR), (W) indicate the connection line color. 1448-09004-0-40063-0 CONTACT SIZE, COLOR...
Page 234: Hazard Switch Harness
ELECTRICAL SYSTEM SW504 8-18. Hazard Switch Harness 8-18-1. Hazard switch harness (ROPS) GY,100 GB,100 Dashboard harness (2) Hazard switch SWP-4F (P.5-055) GY,100 Corrugate GR,100 1634-09078-0-31116-A CONTACT SIZE, COLOR CONNECTION POINTS Hazard switch -1, 4 G × 2, Hazard switch -5 Hazard switch -2 5-077...
Page 235: Cap (Except Rops)
ELECTRICAL SYSTEM SW504 8-18-2. Cap (except ROPS) Dashboard harness (2) SWP-4F (P.5-055) 1418-09044-0-40589-0 5-078...
Page 236: Dpf Switch Harness
ELECTRICAL SYSTEM SW504 8-19. DPF Switch Harness WL,100 Dashboard harness (2) 82 148 DPF switch SWP-2F (P.5-055) WL LgY Tape LgY,100 1448-09021-0-30554-A CONTACT SIZE, COLOR CONNECTION POINTS Q , DPF switch -1 Q , DPF switch -2 5-079...
Page 237: Diagnostic Switch Harness
ELECTRICAL SYSTEM SW504 8-20. Diagnostic Switch Harness B,50 LA104 Dashbord 315 X Diagnostic switch SWP-2M harness (1) Tape (P.5-053) GW,50 LA104 1448-09040-0-30777-0 CONTACT SIZE, COLOR CONNECTION POINTS DIA , Diagnostic switch -1 DIA , Diagnostic switch -2 5-080...
Page 238: Parking Brake Switch Harness
ELECTRICAL SYSTEM SW504 8-21. Parking Brake Switch Harness RW,100 WB,100 Dashboard harness (2) YL,100 Parking brake switch SWP-6F (P.5-055) Tape B,100 Y,100 1446-09062-0-30834-A CONTACT SIZE, COLOR CONNECTION POINTS Parking brake switch -4 Parking brake switch -5 Parking brake switch -3 Parking brake switch -1 Parking brake switch -2 5-081...
Page 239: Mihaalu Harness
ELECTRICAL SYSTEM SW504 8-22. Mihaalu Harness Super flex vinyl cabtyre cord S-VCTF 0.75mm ×4C 38 X Frame (R) harness Mihaalu (option) SWP-6F SWP-4M (P.5-063) * 308 1446-70015-0-30858-0 CONTACT SIZE, COLOR CONNECTION POINTS Frame (R) harness, Mihaalu (option) Frame (R) harness, Mihaalu (option) Frame (R) harness, Mihaalu (option) Frame (R) harness, Mihaalu (option) 5-082...
Page 240: Starter Relay Harness
ELECTRICAL SYSTEM SW504 8-23. Starter Relay Harness VCF4-1002 Starter relay 58Y-2F 5BR 3W Tape Dashboard harness (1) (P.5-053) SWP-2F 1448-09022-0-30555-A CONTACT SIZE, COLOR CONNECTION POINTS P , Starter relay P , Starter relay P , Starter relay P , Starter relay 5-083...
Page 241: F-R Lever Vibration Switch (L) Harness
ELECTRICAL SYSTEM SW504 8-24. F-R Lever Vibration Switch (L) Harness Br,55 Br,65 Dashboard harness (2) F-R lever vibration G,55 G,65 (P.5-055) switch (L) PVC tube ( 6×0.5) W,55 W,65 See “Wiring Harness Layout (2), DETAIL P”. (P.5-050) 1539-12013-0-30226-0 CONTACT SIZE, COLOR CONNECTION POINTS Dashboard harness (2), F-R lever vibration switch (L) -1...
Page 242: F-R Lever Vibration Switch (R) Harness
ELECTRICAL SYSTEM SW504 8-25. F-R Lever Vibration Switch (R) Harness Br,55 Br,65 Dashboard harness (1) F-R lever vibration G,55 G,65 (P.5-053) switch (R) PVC tube ( 6×0.5) W,55 W,65 See “Wiring Harness Layout (2), DETAIL R”. (P.5-050) 1539-12013-0-30226-0 CONTACT SIZE, COLOR CONNECTION POINTS Dashboard harness (1), F-R lever vibration switch (R) -1...
Page 243: Short Harness
ELECTRICAL SYSTEM SW504 8-26. Short Harness Dashboard harness (2) 29 29 SWP-2F BY BY (P.5-055) 1446-09080-0-40879-0 CONTACT SIZE, COLOR CONNECTION POINTS Dashboard harness (2) × 2 5-086...
Page 244: Cord
ELECTRICAL SYSTEM SW504 8-27. Cord LA208 LA208 Ground AV3,B 1745-33006-0-40486-0 CONTACT SIZE, COLOR CONNECTION POINTS – ECU, Ground 5-087...
Page 245: Electrical Component Specifications (Sw504)
ELECTRICAL SYSTEM SW504 9. ELECTRICAL COMPONENT SPECIFICATIONS (SW504) 9-1. Fuse Box (RL) (RG) Vibrator lamp relay Backup buzzer switch Vibration mode select switch Horn relay Vibratory drum select switch (ROPS) Flasher unit Vibration Lo-Hi change switch (except ROPS) Brake lamp relay (RY) F-R lever switch Speed change switch...
Page 246: Combination Meter
ELECTRICAL SYSTEM SW504 9-2. Combination Meter Harness side DETAIL A DESCRIPTION System configuration diagram Battery 24V (+) +BAT Starter switch (ACC) Battery 24V (+) DC/DC Converter TACHO Ground Ground Turn signal (R) MOTOR +BAT FUEL driver Starter switch Engine stop (ACC) Over heat TEMP...
Page 247: Vibratory Drum • Rear Wheel
VIBRATORY DRUM • REAR WHEEL...
Page 249: Precautions For Disassembly And Reassembly
VIBRATORY DRUM • REAR WHEEL 1. PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY • When removing, installing, disassembling or reassembling the unit, observe the general precautions described below. 1) Precautions for removal work • Coolant that contains antifreeze should be treated as a chemical, and must not be drained carelessly on the ground.
Page 250 VIBRATORY DRUM • REAR WHEEL 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 251: Vibratory Drum
Place support stands under frame when drum is slightly off ground to support machine body. Front axle Rear axle SW354 : 1,470 kg (3,240 lbs.) 1,430 kg (3,155 lbs.) TW354 : 1,470 kg (3,240 lbs.) TW504 : 3,510 kg (7,740 lbs.) Support stand...
Page 252 VIBRATORY DRUM • REAR WHEEL WARN ING The hydraulic oil in the machine is hot and compressed immediately after the machine is stopped. Disconnecting the hydraulic hoses in this condition can cause burns. Wait for the hydraulic oil to cool down before starting the work.
Page 253 Remove bolts (17) (left and right sides). • Remove drum assembly together with plates (15), (16) from frame. • Remove rear drum assembly in same way. (SW354) (NOTICE) 15,16 • Damper mounting bolts and nuts must not be stressed during the removal.
Page 254: Installation Of Vibratory Drum
VIBRATORY DRUM • REAR WHEEL 2-1-2. Installation of vibratory drum 1) Install vibratory drum in reverse order in which it was removed. • Tightening torque for bolts where particular care is required when installing vibratory drum. (17) Bolt M16×50 : 265 N·m ( 195 lbf·ft) N•m (19) Bolt M12×50 : 108 N·m ( 80 lbf·ft) (24) Nut M16...
Page 255: Vibratory Drum Assembly
VIBRATORY DRUM • REAR WHEEL 3. VIBRATORY DRUM ASSEMBLY (1) O-ring 3-1. Vibratory Drum Assembly (SW/TW354) (2) Holder (3) O-ring (4) Vibrator bearing (5) Eccentric shaft 12,13 (6) Drum 41,42 (7) Vibrator bearing (8) Boss (9) O-ring (10) Bolt : M16×40 (11) Plug (12) Bolt : M16×50...
Page 257: Vibratory Drum Assembly (Tw504)
VIBRATORY DRUM • REAR WHEEL 3-2. Vibratory Drum Assembly (TW504) (1) O-ring (2) Holder (3) O-ring (4) Vibrator bearing (5) Eccentric shaft 12,13 (6) Drum (7) Vibrator bearing 41,42 (8) Boss (9) O-ring (10) Bolt : M16×40 (11) Plug (12) Bolt : M16×50 (13) Plug (14) Plate...
Page 259: Disassembly And Reassembly Of Vibratory Drum
Hold with chocks. 11-2 Drum assembly 11-3 SW/TW354 : 590 kg (1,301 lbs.) TW504 : 890 kg (1,962 lbs.) Chock SW354-06045 2) Remove plugs (11-1) and (11-3). 11-1 Supply • Drain gear oil. port • Quantity of gear oil SW/TW354 : 5.0 L (1.3 gal.) TW504 : 6.0 L (1.6 gal.)
Page 260 VIBRATORY DRUM • REAR WHEEL 4) Remove adapters. Adapter SW300-1-06016 5) Remove bolts (44). • Remove vibrator motor (43). • Remove breather (16). (43) Vibrator motor : 5 kg (11 lbs.) SW300-1-06017 6) Remove sleeve (21). SW354-06040 6-010...
Page 261 VIBRATORY DRUM • REAR WHEEL 7) Remove bolts (25). SW354-06047 8) Lift cover (26) using two pulling bolts (M10×40). Pulling bolt • Remove cover. SW354-06048 9) Remove bolts (17). (17) Bolts SW/TW354 (four bolts) TW504 (eight bolts) • Remove dampers (20).
Page 262 VIBRATORY DRUM • REAR WHEEL 10) Remove bolts (23). • Remove cover (24). • Remove shim (28). SW354-06035 11) Put a piece of wooden board on end of boss (8). Wooden • Set a puller on disc (29). board Puller •...
Page 263 13) Lift disc subassembly with roller bearing from boss subassembly. Boss Disc subassembly subassembly Disc subassembly SW/TW354 : 35 kg (77 lbs.) TW504 : 45 kg (99 lbs.) SW354-06050 14) Remove bolts (10). SW354-06028 15) Lift boss subassembly using two pulling bolts (M16×40). Pulling bolt SW354-06051 6-013...
Page 264 VIBRATORY DRUM • REAR WHEEL 16) Install lifting bolts (M16) to boss subassembly. Lifting bolt SW354-06052 17) Remove boss subassembly. Boss subassembly Boss subassembly : 35 kg (77 lbs.) SW354-06077 WARN ING Drum subassembly Be careful because reversing the vibratory drum involves risk.
Page 265 VIBRATORY DRUM • REAR WHEEL 19) Remove dampers (36) and bolts (35). (35) Bolts SW/TW354 (six bolts) TW504 (twelve bolts) SW354-06019 20) Remove adapters. Adapter SW354-06018 21) Install lifting bolts (SW/TW354 : M16, TW504 : M12) to Lifting bolt disc (34).
Page 266 VIBRATORY DRUM • REAR WHEEL 22) Lift disc (34). • Remove bolts (38). SW354-06054 23) Remove disc (34). (34) Disc SW/TW354 : 15 kg (33 lbs.) TW504 : 20 kg (44 lbs.) SW354-06015 24) Install lifting bolts (SW/TW354 : M16, TW504 : M18) to Lifting bolt propulsion motor (39).
Page 267 VIBRATORY DRUM • REAR WHEEL 25) Remove propulsion motor (39). (39) Propulsion motor SW/TW354 : 45 kg ( 99 lbs.) TW504 : 85 kg (187 lbs.) SW354-06011 26) Remove bolts (31). SW354-06008 27) Lift holder subassembly using two pulling bolts (M16×40). Holder Pulling bolt...
Page 268 VIBRATORY DRUM • REAR WHEEL 28) Install lifting bolts (SW/TW354 : M16, TW504 : M18) to Holder holder subassembly. Lifting bolt subassembly SW354-06056 29) Remove holder subassembly. Holder subassembly Holder subassembly SW/TW354 : 50 kg (110 lbs.) TW504 : 60 kg (132 lbs.) SW354-06007 30) Remove snap ring (32) while supporting eccentric shaft (5).
Page 269 VIBRATORY DRUM • REAR WHEEL 31) Remove holder subassembly. Holder Holder subassembly : 30 kg (66 lbs.) subassembly SW354-06003 32) Put holder subassembly on wooden blocks. Wooden block Holder subassembly SW354-06057 33) Remove vibrator bearing (4). Holder subassembly SW354-06058 6-019...
Page 270: Reassembly Of Vibratory Drum
• Propulsion motor side dimension “a” SW/TW354 : 363.5 mm (14.3 in.) TW504 : 379.5 mm (14.9 in.) SW354-06006 2) Reassembly of holder subassembly • Apply a coat of gear oil to holder (2) at where bearing will be press-fitted.
Page 271 VIBRATORY DRUM • REAR WHEEL 3) Reverse holder subassembly. Holder subassembly : 30 kg (66 lbs.) Holder subassembly SW354-06061 W AR N ING When installing lifting bolts, screw in the threads fully Lifting bolt before using. 4) Install lifting bolts (SW/TW354 : M16, TW504 : M18) to holder subassembly.
Page 272 VIBRATORY DRUM • REAR WHEEL 6) Install eccentric shaft (5) to holder subassembly. Holder subassembly SW354-06063 7) Hold eccentric shaft (5) with snap ring (32). (NOTICE) • Make sure that the snap ring is fitted completely in its groove. SW354-06081 8) Apply grease to O-ring (3).
Page 273 Holder (6). subassembly Holder subassembly SW/TW354 : 50 kg (110 lbs.) TW504 : 60 kg (132 lbs.) SW354-06064 10) Secure holder subassembly with eight bolts (31) and Holder washers. subassembly (31) Bolts M16×40 : 265 N·m (195 lbf·ft) N•m SW354-06065 11) Install lifting bolts (SW/TW354 : M16, TW504 : M18) to propulsion motor (39).
Page 274 • Install O-ring to propulsion motor. SW300-1-06049 13) Lower propulsion motor (39) on mounting surface of holder subassembly. SW354-06066 14) Secure propulsion motor (39) with six bolts (33) and washers. (33) Bolts N•m SW/TW354 : M16×45 : 265 N·m (195 lbf·ft) TW504 : M18×50 : 343 N·m (253 lbf·ft)
Page 275 VIBRATORY DRUM • REAR WHEEL 15) Install lifting bolts (SW/TW354 : M16, TW504 : M12) to disc (34). Lifting bolt SW354-06013 16) Lift disc (34). (34) Disc SW/TW354 : 15 kg (33 lbs.) TW504 : 20 kg (44 lbs.) SW354-06014 17) Lower disc (34) on mounting surface of propulsion motor (39).
Page 276 A. Longer direction of disc Propulsion motor port A SW354-06016 18) Secure disc (34) with six bolts (38) and washers. (38) Bolts N•m SW/TW354 : M16×40 : 265 N·m (195 lbf·ft) TW504 : M18×40 : 343 N·m (253 lbf·ft) SW354-06017 19) Apply grease to O-rings for adapters.
Page 277 (35) and washers. (35) Bolts N•m SW/TW354 (six bolts) : M16×40 : 265 N·m (195 lbf·ft) TW504 (twelve bolts) : M12×30 : 108 N·m ( 80 lbf·ft) SW354-06019 W AR N ING Drum subassembly Be careful because reversing the vibratory drum involves risk.
Page 278 VIBRATORY DRUM • REAR WHEEL 22-2) Reverse boss subassembly. Boss Boss subassembly : 30 kg (66 lbs.) subassembly SW354-06022 WARN ING Wear heat resistant gloves when handling heated parts to avoid burns. 22-3) Heat up roller bearing (15) inner race by using a ring heater or the like.
Page 279 VIBRATORY DRUM • REAR WHEEL 23) Install lifting bolts (M16) to boss subassembly. Lifting bolt SW354-06025 24) Lift boss subassembly. Boss subassembly : 35 kg (77 lbs.) • Apply grease to O-ring (9). • Install O-ring to boss (8). SW300-1-06062 25) Lower boss subassembly on mounting surface of drum subassembly slowly.
Page 280 Boss washers. subassembly (10) Bolts M16×40 : 265 N·m (195 lbf·ft) N•m SW354-06068 27) Install lifting bolts (M5) to end of eccentric shaft (5). Lifting bolt SW354-06029 28) Slowly lift eccentric shaft (5) with a crane and check that there is an axial play of 2 to 4 mm (0.08 to 0.16 in.).
Page 281 Apply grease to lip of oil seal. SW300-1-06067 30) Install lifting bolts (SW/TW354 : M16, TW504 : M12) to Lifting bolt disc subassembly. Disc subassembly SW354-06032 31) Lower disc subassembly on mounting surface of boss Disc Boss subassembly. subassembly subassembly Disc subassembly : 35 kg (77 lbs.)
Page 282 Drive in roller bearing inner race until rollers come in Outer race contact with outer race. SW354-06034 33) Preload adjustment of roller bearing ① I nstall a shim of about 1 mm (0.04 in.) and secure cover (24) to boss subassembly with four bolts (23) and washers.
Page 283 • Remove shim. (NOTICE) • Do not turn the disc subassembly after the cover is Shim removed. SW354-06070 ④ W ithout inserting shim, install cover (24) to boss subassembly with four bolts (23) and washers. Boss subassembly SW354-06036 6-033...
Page 284 SW300-1-06075 ⑥ Remove bolts (23). • Remove cover (24). SW354-06071 ⑦ I nstall shim (28) of preload adjusting shim thickness = “A + 0.1 mm (0.004 in.)”. • Secure cover (24) to boss subassembly with four bolts (23) and washers.
Page 285 34) Apply grease to O-ring (27). • Install O-ring to cover (26). SW300-1-06077 35) Lower cover (26) on mounting surface of disc subassembly. Disc subassembly SW354-06037 (NOTICE) Breather Recess of • The recess of the disc must face the same direction mounting disc hole as the breather mounting hole in the cover.
Page 286 VIBRATORY DRUM • REAR WHEEL 36) Secure cover (26) to disc subassembly with six bolts (25) and washers SW354-06038 37) Secure two dampers (20) to disc subassembly with four / eight bolts (17) and washers. (17) Bolts N•m SW/TW354 (four bolts) : M16×40 : 265 N·m (195 lbf·ft) TW504 (eight bolts) : M12×30 : 108 N·m ( 80 lbf·ft)
Page 287 VIBRATORY DRUM • REAR WHEEL 39) Apply molybdenum-based grease to splined portion of sleeve (21). • Fit sleeve to splined portion on eccentric shaft end. SW354-06074 40) Apply grease to O-ring (18). • Install O-ring to vibrator motor (43). SW300-1-06082 41) Wind seal tape around threaded portion of breather (16).
Page 288 Drum assembly SW/TW354 : 585 kg (1,290 lbs.) TW504 : 885 kg (1,951 lbs.) 11-2 11-3 Chock SW354-06045 44) Remove plugs (11-1) and (11-2). Supply port 11-1 • Supply gear oil from oil supply port • Check that oil drips from gauge port.
Page 289: Rear Axle
VIBRATORY DRUM • REAR WHEEL 4. REAR AXLE 4-1. Rear Axle Assembly (TW types) 7, 8 21 20 15,16 SW300-1-06097 (1) Adapter (11) Adapter (21) Hose (2) Hose (12) Bolt : M14×50 (22) Bolt : M20×80 (3) Hose (13) Hose (23) Hose (4) Hose (14) Adapter...
Page 290: Removal And Installation Of Rear Axle (Tw Types)
VIBRATORY DRUM • REAR WHEEL 4-2. Removal and Installation of Rear Axle (TW types) 1) Hold drum with chocks. Chock TW354-06004 2) Lock front and rear frames with lock pin (1). SW354-06075 6-040...
Page 291: Removal Of Rear Axle
VIBRATORY DRUM • REAR WHEEL 4-2-1. Removal of rear axle • Lead line numbers shown in the illustrations for the following rear axle removal and installation procedures are constant with part numbers of rear axle assembly (TW types) shown on page 6-039. DA NGER When lifting the machine body, use an appropriate hoist of sufficient strength.
Page 292 VIBRATORY DRUM • REAR WHEEL 3) Remove wheel subassembly with forklift. Wheel subassembly TW354 : 110 kg (243 lbs.) TW504 : 145 kg (320 lbs.) • Wheel subassembly of right side is also removed in the same procedure. Wheel subassembly TW354-06003 WARN ING The hydraulic oil in the machine is hot and compressed...
Page 293 VIBRATORY DRUM • REAR WHEEL 4-2) Disconnect hydraulic hoses (2), (3), (4) and (5) connecting to rear propulsion motor. SW300-1-06100 5) Hold up propulsion motor subassembly with forklift. • Remove bolts (22). • Remove propulsion motor subassembly. Propulsion motor subassembly : 130 kg (287 lbs.) Propulsion motor subassembly TW354-06005...
Page 294: Installation Of Rear Axle
VIBRATORY DRUM • REAR WHEEL 4-2-2. Installation of rear axle 1) Install rear axle in reverse order in which it was removed. • Tightening torque for bolts where particular care is required when installing rear axle. (12) Bolt M14×50 : 167 N·m ( 123 lbf·ft) N•m (22) Bolt M20×80 : 539 N·m ( 398 lbf·ft) 2) Upon installing rear axle, pay particular attention to items...
Page 295: Vibratory Drum (Sw504)
SW504 VIBRATORY DRUM • REAR WHEEL 5. VIBRATORY DRUM (SW504) 5-1. Removal and Installation of Vibratory Drum • For removal and installation, refer to "2-1. Removal and Installation of Vibratory Drum" (P.6-003). • Each mass is same as TW 504 except for supporting frame. Front axle : 2,000 kg (4,410 lbs.) Rear axle : 2,090 kg (4,605 lbs.) 5-2.
Page 297: Brake
BRAKE...
Page 299: Brake Pedal
BRAKE 1. BRAKE PEDAL VIEW B SECTION A-A 0446-51802-0-10194-A (1) Washer (6) Rod end : M10 (11) Nut : M10 P=1.25 (2) Split pin (7) Rubber bolt : M10×25 P=1.25 (12) Rubber bolt : M10×25 P=1.25 (3) Rod (Apply grease to hole*) (8) Foot brake switch (13) Nut : M10...
Page 300: Brake System
BRAKE 2. BRAKE SYSTEM 2-1. Brake System (SW354) Foot brake switch (Condition in which brake pedal pressed) combination meter Parking brake switch (Brake OFF condition) Fuse Brake Propulsion Brake Propulsion (Brake ON condition) motor (F) (Brake ON condition) motor (R) Parking brake solenoid valve when brake is ON.
Page 301: Brake System (Tw354, 504)
BRAKE 2-2. Brake System (TW354, 504) Foot brake switch (Condition in which brake pedal pressed) combination meter Parking brake switch (Brake OFF condition) Fuse Brake Propulsion (Brake ON condition) motor (R,R) Brake Propulsion Brake Propulsion (Brake ON condition) motor (R,L) (Brake ON condition) motor (F) Parking brake solenoid valve...
Page 303: Water Spray System
WATER SPRAY SYSTEM...
Page 305: Water Spray Piping
WATER SPRAY SYSTEM 1. WATER SPRAY PIPING Water spray tank Water spray pump 1-1. Water Spray Piping (SW354) Tee 4 Tee 3 Filter Pipe (F) Hose Hose 3 way valve Tee 2 Tee 1 (Tee Pipe (F)) (Tank Filter (Water spray pipe (F))
Page 307: Water Spray Piping (Tw354,504)
WATER SPRAY SYSTEM 1-2. Water Spray Piping (TW354,504) Water spray tank Water spray pump Tee 4 Tee 3 Filter Pipe (F) Hose Hose 3 way valve Tee 2 Tee 1 (Water spray pipe (F)) (Tank Filter (Tee Pipe (F)) From Filter OUT Drain valve Check valve Drain valve...
Page 309: Liquid Spray System
WATER SPRAY SYSTEM 2. LIQUID SPRAY SYSTEM 2-1. Liquid Spray Piping (TW354,504) Drain valve Hose Liquid pipe Hose Ball valve (Pump OUT Liquid pipe) (Liquid pipe Liquid tank) (Liquid spray pipe) Liquid spray pump Pump OUT Pump (Liquid spray pump) Drain valve Ball valve Filter...
Page 311: Inspection And Adjustment
INSPECTION AND ADJUSTMENT...
Page 313: 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 314: Measurement And Inspection Of Propulsion Circuit Pressure
④ Set propulsion speed change switch to “ ”. ⑤ Start the engine and set throttle lever to “Full”. ⑥ Establish a condition in which machine propulsion load SW354-09001 becomes maximum. (Pressure does not build up unless propulsion load is applied.) ⑦...
Page 315: Inspection
④ If pressure still deviates from maximum circuit pressure range after valve is disassembled and cleaned, replace SW354-09002 high pressure relief valve. ⑤ After inspection, measure pressure again and check that pressure reaches maximum circuit pressure range.
Page 316: Measurement And Adjustment Of Propulsion Charge Circuit Pressure
• Pressure gauge : 0 to 50 MPa (0 to 7,250 psi) ② C onfirm that F-R lever is “N”. SW354-09027 ③ A pply parking brake by pressing parking brake switch button. ④ S tart the engine and set throttle lever to “Full”.
Page 317: Adjustment
: Pressure drop Pressure change rate : 0.19 MPa/turn (27.6 psi/turn) ③ If there is no evidence of nut having loosened, remove SW354-09004 charge relief valve. ④ Check removed charge relief valve for trapped dirt and scratches on its seat.
Page 318: Measurement Of Machine High/Low Speed Change Circuit Pressure
”. ⑤ S tart the engine and set throttle lever to “Full”. ⑥ R ead pressure indicated by pressure gauge. Standard charge relief valve setting ★ : 1.9 MPa (276 psi) ± 0.7 ± 100 SW354-09005 PG002002 9-006...
Page 319: Measurement Of Parking Brake Release Pressure
④ S tart the engine and set throttle lever to “Full”. ⑤ R elease parking brake by pressing parking brake switch button. ⑥ R ead brake release pressure indicated by pressure Front gauge. SW354-09006 Brake release pressure : 1.5 MPa (218 psi) ★ Rear SW354-09026 PG002002...
Page 320: Tw Types: Rear
INSPECTION AND ADJUSTMENT 5-1-2. TW types: rear • Oil temperature during measurement : 50 °C (122 °F) ± 5 ± 9 ① D isconnect hose (3) and (4) from propulsion motor. Attach pressure gauge through adapter ⓜ . • Adapter ⓜ : G1/4 •...
Page 321: Measurement Of Vibrator Circuit Pressure
② C onfirm that F-R lever is “N”. ③ A pply parking brake by pressing parking brake switch button. ④ SW354 ROPS : Set vibratory drum select switch to “ ”. ⑤ S et vibration mode change switch to “...
Page 322: Measurement And Inspection Of Steering Circuit Pressure
④ S tart the engine and set throttle lever to “Full”. ⑤ T urn steering wheel to operate relief valve. Hydraulic oil filter ⑥ R ead pressure indicated by pressure gauge. SW354-09003 Standard maximum circuit pressure ★ (orbitroll relief pressure) : 13.5 MPa (1,958 psi)
Page 323: 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 C heck removed relief valve for trapped dirt, scratches on its seat and other abnormalities.
Page 324: Measurement Of Hydraulic Pump Case Pressure
(Pressure does not build up unless propulsion load is applied.) ⑦ With propulsion load at maximum, measure pressure SW354-09011 when speed change switch is “ ” and “ ” and F-R lever is “N”, “F”, and “R”, respectively.
Page 325: Measurement Of Propulsion Motor Case Pressure
(Pressure does not build up unless propulsion load is applied.) Front ⑦ W ith propulsion load at maximum, measure pressure SW354-09012 when speed change switch is “ ” and “ ” and F-R lever is “N”, “F”, and “R”, respectively.
Page 326: Tw Types: Rear
INSPECTION AND ADJUSTMENT 9-1-2. TW types: rear • Oil temperature during measurement : 50 °C (122 °F) ± 5 ± 9 ① Disconnect hose (3) and (4) from propulsion motor. Attach pressure gauge with adapter ⓝ . • Adapter ⓝ : G3/8 •...
Page 327: Measurement Of Vibrator Motor Case Pressure (Except Tw504)
② C onfirm that F-R lever is “N”. ③ Apply parking brake by pressing parking brake switch button. ④ SW354 ROPS : Set vibratory drum select switch to “ ”. ⑤ Set vibration mode change switch to “ ”.
Page 328: Measurement Of Vibrator Motor Case Pressure (Tw504)
INSPECTION AND ADJUSTMENT 11. MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE (TW504) 11-1. Measurement • Oil temperature during measurement : 50 °C (122 °F) ± 5 ± 9 ① Disconnect hose (1) from vibrator motor. Attach pressure gauge with adapter ⓝ . •...
Page 329: Adjustment Of Throttle Lever
Standard minimum no-load rotational speed ★ : 1,050 ± 50 ⑦ Using lock nut (3), firmly secure stopper bolt (2). SW354-09016 ⑧ Set throttle lever (1) to “FULL”. ⑨ Loosen lock nut (6). FULL ⑩ Using stopper bolt (5), adjust so that standard maximum no-load rotational speed is achieved.
Page 330: Adjustment Of Operating Force
(1) knob to standard operating force. Do not turn nut to the loosening direction. Standard operating force : 44.1 N (9.9 lbf) ★ ± 6.86 ± 1.5 (NOTICE) • In case of loosen nut (7), replace it with a new one. SW354-09031 SECTION A-A SW354-09017 9-018...
Page 331: Adjustment Of F-R Lever
① Set F-R lever in “N”. ② Attach control cable (2) to F-R lever. Specified dimension a: 208 mm (8.19 in.) ★ SW354-09018 ③ Attach control cable to propulsion pump control lever (3). Specified dimension b: 208 mm (8.19 in.) ★...
Page 332: Adjustment Of Operating Force
F-R lever knob. Operating force to move lever over notch ★ : 49 N (11 lbf) ± 4.9 ± 1.1 SW354-09020 • After adjustment, fix set screw (4) with lock nut (5). VIEW A-A SW354-09021 SECTION B-B SW354-09022 9-020...
Page 333 14. PROCEDURE FOR MEASURING QUANTITY OF BRAKE PISTON STROKE (REPLACEMENT STANDARD) 14-1. Measurement ① Remove cap plug (1) from manual brake release port. SW354-09023 ② Attach bolt (3) for forced brake releaseing. Allow bolt to be out of contact with seating surface without tightening bolt completely.
Page 334: Measurement And Inspection Of Propulsion Circuit Pressure (Sw504)
④ Set propulsion speed change switch to “ ”. ⑤ Start the engine and set throttle lever to “Full”. ⑥ Establish a condition in which machine propulsion load SW354-09001 becomes maximum. (Pressure does not build up unless propulsion load is applied.) ⑦...
Page 335: Inspection
④ If pressure still deviates from maximum circuit pressure range after valve is disassembled and cleaned, replace SW354-09002 high pressure relief valve. ⑤ After inspection, measure pressure again and check that pressure reaches maximum circuit pressure range.
Page 336: Measurement And Adjustment Of Propulsion Charge Circuit Pressure (Sw504)
• Pressure gauge : 0 to 50 MPa (0 to 7,250 psi) ② C onfirm that F-R lever is “N”. SW354-09027 ③ A pply parking brake by pressing parking brake switch button. ④ S tart the engine and set throttle lever to “Full”.
Page 337: Adjustment
: Pressure drop Pressure change rate : 0.19 MPa/turn (27.6 psi/turn) ③ If there is no evidence of nut having loosened, remove SW354-09004 charge relief valve. ④ Check removed charge relief valve for trapped dirt and scratches on its seat.
Page 338: Measurement Of Machine High/Low Speed Change Circuit
”. ⑤ S tart the engine and set throttle lever to “Full”. ⑥ R ead pressure indicated by pressure gauge. Standard charge relief valve setting ★ : 1.8 MPa (261 psi) ± 0.7 ± 100 SW354-09005 PG002002 9-026...
Page 339: Measurement Of Vibrator Circuit Pressure (Sw504)
”. ⑤ S et vibration mode change switch to “ ”. SW354-09009 ⑥ Start the engine and set throttle lever to “Full”. ⑦ P ress F-R lever vibration switch ON. ⑧ Slowly move F-R lever to forward or reverse side.
Page 340: Measurement And Inspection Of Steering Circuit Pressure
INSPECTION AND ADJUSTMENT SW504 19. MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE (SW504) 19-1. Measurement WARN ING Make sure that there is no person around the articulated portion of the machine before operating the steering wheel. • Oil temperature during measurement : 50 °C (122 °F) ±...
Page 341: Inspection
INSPECTION AND ADJUSTMENT SW504 19-2. Inspection • If measurement results indicate the pressure deviating from standard maximum circuit pressure range, make an adjustment in accordance with procedure described below. ① Remove relief valve (2) from orbitrol. ② C heck removed relief valve for trapped dirt, scratches on its seat and other abnormalities.
Page 342: Measurement Of Hydraulic Pump Case Pressure (Sw504)
INSPECTION AND ADJUSTMENT SW504 20. MEASUREMENT OF HYDRAULIC PUMP CASE PRESSURE (SW504) 20-1. Measurement of Propulsion Pump Case Pressure • Oil temperature during measurement : 50 °C (122 °F) ± 5 ± 9 ① Disconnect hose (1) from propulsion pump. Attach pressure gauge through adapter ⓠ...
Page 343: Adjustment Of Throttle Lever (Sw504)
INSPECTION AND ADJUSTMENT SW504 21. ADJUSTMENT OF THROTTLE LEVER (SW504) 21-1. Adjustment of Potentiometer • If potentiometer (1) is replaced, make following adjustments. • Make adjustments after amply warmed engine. • Oil temperature during measurement : 50 ± °C (122 ± °F) ①...
Page 344: Adjustment Of Operating Force
INSPECTION AND ADJUSTMENT SW504 21-2. Adjustment of Operating Force ① Tighten nut (9) and set operating force at center of throttle lever (6) knob to standard operating force. Do not turn nut to the loosening direction. Standard operating force : 45 N (10 lbf) ★...
Page 345: Adjustment Of F-R Lever (Sw504)
① Set F-R lever in “N”. ② Attach control cable (2) to F-R lever. Specified dimension a: 210 mm (8.27 in.) ★ SW354-09018 ③ Attach control cable (2) to propulsion pump control lever (3). Specified dimension b: 198 mm (7.80 in.) ★...
Page 346 INSPECTION AND ADJUSTMENT SW504 • MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE Refer to (P.9-007). • MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE Refer to (P.9-013). • MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE Refer to (P.9-016). • PROCEDURE FOR MEASURING QUANTITY OF BRAKE PISTON STROKE (REPLACEMENT STANDARD) Refer to (P.9-021).
Page 347: Troubleshooting
TROUBLESHOOTING...
Page 349: 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 350: 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 351: 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 352: Inspection Procedures Using A Tester
TROUBLESHOOTING 2-1-2. Inspection procedures using a tester Some of the various inspection procedures are presented here for reference, using a sample circuit below. Equipment A Main power source Ground of Signal from Power to of equipment B equipment A equipment A equipment A Battery Equipment B...
Page 353 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 354 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 355 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 356 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 357: 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 358 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 360 COMBINATION METER STARTER SWITCH HEAT FUSE BOX GLOW LAMP TIMER COMBINATION METER FUSE TACHO METER SENSOR STARTER SWITCH COMBINATION METER FUEL PUMP ALTERNATOR ENGINE STOP SOLENOID AV60 AV60 AV60 12V 80AH 95D31R BATTERY RELAY BATTERY STARTER MOTOR FUSE F.L. SW354-10001 10-011...
Page 361: Engine
TROUBLESHOOTING 2-2. Engine Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. • Check any ground circuit which belongs to components to be checked. 2-2-1. Engine will not start (Starter motor does not run) 1/3 •...
Page 362 COMBINATION METER STARTER SWITCH HEAT FUSE BOX GLOW LAMP TIMER COMBINATION METER FUSE TACHO METER SENSOR STARTER SWITCH COMBINATION METER FUEL PUMP ALTERNATOR ENGINE STOP SOLENOID AV60 AV60 AV60 12V 80AH 95D31R BATTERY RELAY BATTERY STARTER MOTOR FUSE F.L. SW354-10001 10-013...
Page 363 TROUBLESHOOTING 2-2-1. Engine will not start (Starter motor does not run) 2/3 • F-R lever must be in “N”. • Parking brake switch must be applied. • Brake pedal is not depressed. Reference Fig.: 2-2-1 Check point Check/Cause Action 5. Interlock Relay (1) When starter switch is ON, measure voltage between Replace interlock relay.
Page 364 COMBINATION METER STARTER SWITCH HEAT FUSE BOX GLOW LAMP TIMER COMBINATION METER FUSE TACHO METER SENSOR STARTER SWITCH COMBINATION METER FUEL PUMP ALTERNATOR ENGINE STOP SOLENOID AV60 AV60 AV60 12V 80AH 95D31R BATTERY RELAY BATTERY STARTER MOTOR FUSE F.L. SW354-10001 10-015...
Page 365: Engine Will Not Start (Starter Motor Does Not Run) 1/3
TROUBLESHOOTING 2-2-1. Engine will not start (Starter motor does not run) 3/3 • F-R lever must be in “N”. • Parking brake switch must be applied. • Brake pedal is not depressed. Reference Fig.: 2-2-1 Check point Check/Cause Action 9. Parking Brake Switch (1) When starter switch is ON, measure voltage between Replace parking brake parking brake switch terminal 1 inlet wire RW and...
Page 366 COMBINATION METER STARTER SWITCH HEAT FUSE BOX GLOW LAMP TIMER COMBINATION METER FUSE TACHO METER SENSOR STARTER SWITCH COMBINATION METER FUEL PUMP ALTERNATOR ENGINE STOP SOLENOID AV60 AV60 AV60 12V 80AH 95D31R BATTERY RELAY BATTERY STARTER MOTOR FUSE F.L. SW354-10001 10-017...
Page 367: Engine Does Not Stop Running
TROUBLESHOOTING 2-2-3. Engine does not stop running Reference Fig. : 2-2-1 Check point Check/Cause Action 1. Engine Stop Solenoid (1) When starter switch is OFF, measure voltage between Replace engine stop engine stop solenoid terminal inlet wire RB and chassis solenoid.
Page 368 COMBINATION METER STARTER SWITCH HEAT FUSE BOX GLOW LAMP TIMER COMBINATION METER FUSE TACHO METER SENSOR STARTER SWITCH COMBINATION METER FUEL PUMP ALTERNATOR ENGINE STOP SOLENOID AV60 AV60 AV60 12V 80AH 95D31R BATTERY RELAY BATTERY STARTER MOTOR FUSE F.L. SW354-10001 10-019...
Page 369: Starter Motor Runs Even When F-R Lever Is Not At "N
TROUBLESHOOTING 2-2-6. Starter motor runs even when F-R lever is not at “N” Reference Fig. : 2-2-1 Check point Check/Cause Action 1. F-R Lever Switch • When starter switch is OFF and F-R lever is “F” or “R”, Replace F-R lever check continuity between F-R lever switch terminal wire switch.
Page 370 PARKING INTERLOCK RELAY 301 Y BRAKE LAMP RELAY COMBINATION METER PARKING BRAKE SWITCH SPEED CHANGE SWITCH SPEED CHANGE SWITCH SPEED CONNECTION FUSE BOX STARTER SWITCH HEAT 3 LgR AV60 AV60 STARTER SWITCH 12V 80AH 95D31R BATTERY RELAY BATTERY FUSE F.L. SW354-10002 10-021...
Page 371: Propulsion
TROUBLESHOOTING 2-3. Propulsion Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. • When measuring voltage and current without disconnecting connectors, refer to “Measuring voltage and current flowing using tester” (P.10-006 to P.10-008). •...
Page 372 PARKING INTERLOCK RELAY 301 Y BRAKE LAMP RELAY COMBINATION METER PARKING BRAKE SWITCH SPEED CHANGE SWITCH SPEED CHANGE SWITCH SPEED CONNECTION FUSE BOX STARTER SWITCH HEAT 3 LgR AV60 AV60 STARTER SWITCH 12V 80AH 95D31R BATTERY RELAY BATTERY FUSE F.L. SW354-10002 10-023...
Page 373: Machine Speed Cannot Be Changed
TROUBLESHOOTING 2-3-2. Machine speed cannot be changed • Speed change switch must be “ ”. Reference Fig.: 2-3-1 Check point Check/Cause Action 1. Speed Change • Disconnect harness and measure resistance of coil. Replace speed change Solenoid Standard resistance : 9.0 Ω solenoid.
Page 374 PARKING INTERLOCK RELAY 301 Y BRAKE LAMP RELAY COMBINATION METER PARKING BRAKE SWITCH SPEED CHANGE SWITCH SPEED CHANGE SWITCH SPEED CONNECTION FUSE BOX STARTER SWITCH HEAT 3 LgR AV60 AV60 STARTER SWITCH 12V 80AH 95D31R BATTERY RELAY BATTERY FUSE F.L. SW354-10002 10-025...
Page 375: Brake Cannot Be Released
TROUBLESHOOTING 2-3-3. Brake cannot be released • Parking brake switch must be released. • Brake pedal is not depressed. Reference Fig.: 2-3-1 Check point Check/Cause Action 1. Parking Brake Solenoid • Disconnect harness and measure resistance of coil. Replace parking brake Standard resistance : 9.0 Ω...
Page 376 PARKING INTERLOCK RELAY 301 Y BRAKE LAMP RELAY COMBINATION METER PARKING BRAKE SWITCH SPEED CHANGE SWITCH SPEED CHANGE SWITCH SPEED CONNECTION FUSE BOX STARTER SWITCH HEAT 3 LgR AV60 AV60 STARTER SWITCH 12V 80AH 95D31R BATTERY RELAY BATTERY FUSE F.L. SW354-10002 10-027...
Page 377: Brake Does Not Work
TROUBLESHOOTING 2-3-4. Brake does not work • Parking brake switch must be applied. • Brake pedal is depressed. Reference Fig.: 2-3-1 Check point Check/Cause Action 1. Parking Brake Solenoid • Disconnect harness and measure resistance of coil. Replace parking brake Standard resistance : 9.0 Ω...
Page 378: Vibration
VIBRATION MODE SELECT SWITCH 49 LgB 46 BrR VIBRATION CONNECTION 1-2,4-6 1-3,4-6 AUTO 1-3,4-5 VIBRATOR SOLENOID (R) SW354 (Except ROPS type) F-R LEVER VIBRATION 49 LgB SWITCH (R) 23 RL 47 LgR 47 LgR F-R LEVER VIBRATION VIBRATORY DRUM SWITCH (L) SELECT SWITCH...
Page 379: No Vibration Occurs 1/2
Replace vibratory drum Switch vibratory drum select switch terminal 1 inlet wire RL, select switch. (SW354 ROPS) terminal 4 inlet wire RL and chassis ground. Standard voltage : 12 V or more (2) When starter switch is ON and vibratory drum select switch is in “...
Page 380 VIBRATION MODE SELECT SWITCH 49 LgB 46 BrR VIBRATION CONNECTION 1-2,4-6 1-3,4-6 AUTO 1-3,4-5 VIBRATOR SOLENOID (R) SW354 (Except ROPS type) F-R LEVER VIBRATION 49 LgB SWITCH (R) 23 RL 47 LgR 47 LgR F-R LEVER VIBRATION VIBRATORY DRUM SWITCH (L) SELECT SWITCH...
Page 381: No Vibration Occurs 2/2
TROUBLESHOOTING 2-4-1. No vibration occurs 2/2 • F-R lever must be “F” or “R”. • Vibration mode select switch must be “AUTO” (automatic mode). Reference Fig.: 2-4-1 Check point Check/Cause Action 4. Vibration Lo-Hi Change (1) When starter switch is ON, measure voltage between Replace vibration Lo-Hi Switch change switch.
Page 382 VIBRATION MODE SELECT SWITCH 49 LgB 46 BrR VIBRATION CONNECTION 1-2,4-6 1-3,4-6 AUTO 1-3,4-5 VIBRATOR SOLENOID (R) SW354 (Except ROPS type) F-R LEVER VIBRATION 49 LgB SWITCH (R) 23 RL 47 LgR 47 LgR F-R LEVER VIBRATION VIBRATORY DRUM SWITCH (L) SELECT SWITCH...
Page 383: Vibration Mode Cannot Be Switched
TROUBLESHOOTING 2-4-2. Vibration mode cannot be switched (F-R lever vibration switch does not work) • Vibration mode select switch must be “ ” (manual mode). Reference Fig.: 2-4-1 Check point Check/Cause Action 1. Vibration Mode Select (1) When starter switch is ON, measure voltage between Replace vibration mode Switch vibration mode select switch terminal 1 inlet wire RL...
Page 384 VIBRATION MODE SELECT SWITCH 49 LgB 46 BrR VIBRATION CONNECTION 1-2,4-6 1-3,4-6 AUTO 1-3,4-5 VIBRATOR SOLENOID (R) SW354 (Except ROPS type) F-R LEVER VIBRATION 49 LgB SWITCH (R) 23 RL 47 LgR 47 LgR F-R LEVER VIBRATION VIBRATORY DRUM SWITCH (L) SELECT SWITCH...
Page 385: Vibratory Drum Cannot Be Switched (Sw354 Rops)
TROUBLESHOOTING 2-4-3. Vibratory drum cannot be switched (SW354 ROPS) Reference Fig.: 2-4-1 Check point Check/Cause Action 1. Vibratory Drum Select (1) When starter switch is ON, measure voltage between Replace vibratory drum Switch vibratory drum select switch terminal 1 inlet wire RL, select switch.
Page 386 VIBRATION MODE SELECT SWITCH 49 LgB 46 BrR VIBRATION CONNECTION 1-2,4-6 1-3,4-6 AUTO 1-3,4-5 VIBRATOR SOLENOID (R) SW354 (Except ROPS type) F-R LEVER VIBRATION 49 LgB SWITCH (R) 23 RL 47 LgR 47 LgR F-R LEVER VIBRATION VIBRATORY DRUM SWITCH (L) SELECT SWITCH...
Page 387: Amplitude Does Not Change (Remains Either Low Or High) (Tw504)
TROUBLESHOOTING 2-4-4. Amplitude does not change (Remains either low or high) (TW504) • Vibration mode change switch must be “AUTO” (automatic mode). Reference Fig.: 2-4-1 Check point Check/Cause Action 1. Vibrator Solenoid • Disconnect harness and measure resistance of coil. Replace amplitude Standard resistance : 5.42 Ω...
Page 388 70 P 39 LW 70 P ROPS type INTERLOCK RELAY 2BrW 20 2BrR COMBINATION METER LIQUID SPRAY SWITCH FUSE BOX LIQUID SPRAY PUMP TW354,504 STARTER SWITCH HEAT AV60 AV60 STARTER SWITCH 12V 80AH 95D31R BATTERY RELAY BATTERY FUSE F.L. SW354-10004 10-039...
Page 389: 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 “CONT”.
Page 390 70 P 39 LW 70 P ROPS type INTERLOCK RELAY 2BrW 20 2BrR COMBINATION METER LIQUID SPRAY SWITCH FUSE BOX LIQUID SPRAY PUMP TW354,504 STARTER SWITCH HEAT AV60 AV60 STARTER SWITCH 12V 80AH 95D31R BATTERY RELAY BATTERY FUSE F.L. SW354-10004 10-041...
Page 391: Continuous Water Spray Works, But Auto Water Spray Does Not Operate
TROUBLESHOOTING 2-5-2. Continuous water spray works, but auto water spray does not operate • Water spray mode select switch must be “AUTO”. • F-R lever must be “F” or “R”. Reference Fig.: 2-5-1 Check point Check/Cause Action 1. Water Spray Mode (1) When starter switch is ON, measure voltage between Replace water spray Select Switch...
Page 392 70 P 39 LW 70 P ROPS type INTERLOCK RELAY 2BrW 20 2BrR COMBINATION METER LIQUID SPRAY SWITCH FUSE BOX LIQUID SPRAY PUMP TW354,504 STARTER SWITCH HEAT AV60 AV60 STARTER SWITCH 12V 80AH 95D31R BATTERY RELAY BATTERY FUSE F.L. SW354-10004 10-043...
Page 393: Liquid Cannot Be Sprayed (Tw354, 504)
TROUBLESHOOTING 2-5-3. Liquid cannot be sprayed (TW354, 504) Reference Fig. : 2-5-1 Check point Check/Cause Action 1. Liquid Spray Pump (1) When starter switch is ON and liquid spray switch Replace liquid spray pressed, measure voltage between liquid spray pump pump.
Page 394: Lighting
LAMP (L) 21W PARKING BRAKE SWITCH 24 RY 61 RG 60 BrY BRAKE LAMP RELAY HAZARD SWITCH COMBINATION ROPS type FUSE BOX METER FLASHER UNIT STARTER SWITCH HEAT AV60 AV60 STARTER 12V 80AH SWITCH 95D31R BATTERY RELAY BATTERY FUSE F.L. SW354-10005 10-045...
Page 395: Head Lamp And Tail Lamp Do Not Light
TROUBLESHOOTING 2-6. Lighting Check following items before troubleshooting. • No blown fuse and power is applied up to fuses. 2-6-1. Head lamp and tail lamp do not light Reference Fig. : 2-6-1 Check point Check/Cause Action 1. Battery • Measure battery voltage or specific gravity. Charge or replace Standard voltage : 12 V or more battery.
Page 396 LAMP (L) 21W PARKING BRAKE SWITCH 24 RY 61 RG 60 BrY BRAKE LAMP RELAY HAZARD SWITCH COMBINATION ROPS type FUSE BOX METER FLASHER UNIT STARTER SWITCH HEAT AV60 AV60 STARTER 12V 80AH SWITCH 95D31R BATTERY RELAY BATTERY FUSE F.L. SW354-10005 10-047...
Page 397: Turn Signal Lamp Does Not Blink
TROUBLESHOOTING 2-6-3. 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 398 LAMP (L) 21W PARKING BRAKE SWITCH 24 RY 61 RG 60 BrY BRAKE LAMP RELAY HAZARD SWITCH COMBINATION ROPS type FUSE BOX METER FLASHER UNIT STARTER SWITCH HEAT AV60 AV60 STARTER 12V 80AH SWITCH 95D31R BATTERY RELAY BATTERY FUSE F.L. SW354-10005 10-049...
Page 399: Hazard Lamp Does Not Light (Turn Signal Blinks) (Rops Type)
TROUBLESHOOTING 2-6-4. Hazard lamp does not light (Turn signal blinks) (ROPS type) • 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.
Page 400 LAMP (L) 21W PARKING BRAKE SWITCH 24 RY 61 RG 60 BrY BRAKE LAMP RELAY HAZARD SWITCH COMBINATION ROPS type FUSE BOX METER FLASHER UNIT STARTER SWITCH HEAT AV60 AV60 STARTER 12V 80AH SWITCH 95D31R BATTERY RELAY BATTERY FUSE F.L. SW354-10005 10-051...
Page 401: Stop Lamp Does Not Light
TROUBLESHOOTING 2-6-5. 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 402 SET(NO.0) REV RATIO SEL. COOLANT TEMP. SEL. GND GND OPEN OPEN OPEN OPEN 2 WR 12 Y FUSE STARTER SWITCH FUSE BOX HEAT STARTER SWITCH AV60 AV60 STARTER MOTOR ALTERNATOR 12V 80AH 95D31R BATTERY RELAY BATTERY FUSE F.L. SW354-10006 10-053...
Page 403: Illumination Of Combination Meter Does Not Light
TROUBLESHOOTING 2-6-6. 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 GB and combination meter connector terminal wire harness. No.37 wire GB. Standard resistance : 10 Ω...
Page 404 SET(NO.0) REV RATIO SEL. COOLANT TEMP. SEL. GND GND OPEN OPEN OPEN OPEN 2 WR 12 Y FUSE STARTER SWITCH FUSE BOX HEAT STARTER SWITCH AV60 AV60 STARTER MOTOR ALTERNATOR 12V 80AH 95D31R BATTERY RELAY BATTERY FUSE F.L. SW354-10006 10-055...
Page 405: Tachometer Reading Is Abnormal
TROUBLESHOOTING 2-6-8. 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 tachometer (Tachometer) combination meter terminal wires and ground terminal sensor or combination wire. meter.
Page 406 SET(NO.0) REV RATIO SEL. COOLANT TEMP. SEL. GND GND OPEN OPEN OPEN OPEN 2 WR 12 Y FUSE STARTER SWITCH FUSE BOX HEAT STARTER SWITCH AV60 AV60 STARTER MOTOR ALTERNATOR 12V 80AH 95D31R BATTERY RELAY BATTERY FUSE F.L. SW354-10006 10-057...
Page 407: Temperature Meter Is Abnormal
TROUBLESHOOTING 2-6-10. 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℃) 26.44 Ω (at unit temperature of 103℃) •...
Page 408 SET(NO.0) REV RATIO SEL. COOLANT TEMP. SEL. GND GND OPEN OPEN OPEN OPEN 2 WR 12 Y FUSE STARTER SWITCH FUSE BOX HEAT STARTER SWITCH AV60 AV60 STARTER MOTOR ALTERNATOR 12V 80AH 95D31R BATTERY RELAY BATTERY FUSE F.L. SW354-10006 10-059...
Page 409: Hydraulic Oil Filter Warning Lamp Remains On
TROUBLESHOOTING 2-6-12. Hydraulic oil filter warning lamp remains ON Reference Fig. : 2-6-2 Check point Check/Cause Action 1. Harness • Disconnect connectors between combination meter and Repair or replace hydraulic oil filter switch. harness. • Measure resistance between terminals and chassis ground.
Page 410 SET(NO.0) REV RATIO SEL. COOLANT TEMP. SEL. GND GND OPEN OPEN OPEN OPEN 2 WR 12 Y FUSE STARTER SWITCH FUSE BOX HEAT STARTER SWITCH AV60 AV60 STARTER MOTOR ALTERNATOR 12V 80AH 95D31R BATTERY RELAY BATTERY FUSE F.L. SW354-10006 10-061...
Page 411: Engine Oil Pressure Warning Lamp Remains On
TROUBLESHOOTING 2-6-14. Engine oil pressure warning lamp remains ON Reference Fig. : 2-6-2 Check point Check/Cause Action 1. Harness • Disconnect connectors between combination meter and Repair or replace engine oil pressure switch. harness. • Measure resistance between terminals and chassis ground.
Page 412 The circuit in the dashed box is not mounted. COMBINATION METER LEVER SWITCH NO COM WR GL LR INTERLOCK RELAY 51 Br FUSE BOX STARTER SWITCH 11 BrB HEAT F.L. FUSE AV60 AV60 STARTER SWITCH 12V 80AH 95D31R BATTERY RELAY BATTERY FUSE F.L. SW354-10007 10-063...
Page 413: Vibration Indicator Lamp Does Not Light
TROUBLESHOOTING 2-6-15. Vibration indicator lamp does not light • Check that vibrator can be operated. Reference Fig. : 2-6-3 Check point Check/Cause Action 1. Harness • Measure resistance between vibrator lamp relay terminal Repair or replace 5 wire Br and combination meter connector terminal wire harness.
Page 414 NO COM 27 GY INTERLOCK RELAY WR GL LR FUSE BOX 2BrW 20 2BrR LIQUID SPRAY SWITCH LIQUID SPRAY PUMP TW354,504 11 BrB STARTER SWITCH HEAT FUSE AV60 AV60 STARTER SWITCH 12V 80AH 95D31R BATTERY RELAY BATTERY FUSE F.L. SW354-10008 10-065...
Page 415: Water Spray Indicator Lamp Does Not Light
TROUBLESHOOTING 2-6-16. Water spray indicator lamp does not light • Check that water spray pump can be activated. Reference Fig. : 2-6-4 Check point Check/Cause Action 1. Harness • Measure resistance between water spray mode select Repair or replace switch terminal 2 wire LW and combination meter harness.
Page 416 38 Or 35 G FUSE BOX FLASHER UNIT 38 Or FLOOD LAMP 35 G TURN SIGNAL LAMP(R) TURN SIGNAL LAMP(L) STARTER SWITCH 11 BrB HEAT FUSE AV60 AV60 STARTER SWITCH 12V 80AH 95D31R BATTERY RELAY BATTERY FUSE F.L. SW354-10009 10-067...
Page 417: Flood Lamp Indicator Lamp Does Not Light
TROUBLESHOOTING 2-6-18. Flood lamp indicator lamp does not light • Check that flood lamp lights. Reference Fig. : 2-6-5 Check point Check/Cause Action 1. Harness • Measure resistance between lighting switch terminal 5 Repair or replace wire Or and combination meter connector terminal wire harness.
Page 418 38 Or 35 G FUSE BOX FLASHER UNIT 38 Or FLOOD LAMP 35 G TURN SIGNAL LAMP(R) TURN SIGNAL LAMP(L) STARTER SWITCH 11 BrB HEAT FUSE AV60 AV60 STARTER SWITCH 12V 80AH 95D31R BATTERY RELAY BATTERY FUSE F.L. SW354-10009 10-069...
Page 419: Turn Signal Indicator Lamp Does Not Light
TROUBLESHOOTING 2-6-20. Turn signal indicator lamp does not light • Check that turn signal lamp blinks. Reference Fig. : 2-6-5 Check point Check/Cause Action 1. Harness (1) Measure resistance between turn signal switch terminal Repair or replace wire No.36 wire GR and combination meter connector harness.
Page 420 TROUBLESHOOTING Fig.: 2-6-6 BACKUP BUZZER BACKUP BUZZER SWITCH HORN HORN RELAY FUSE BOX STARTER SWITCH HEAT STARTER SWITCH AV60 AV60 12V 80AH 95D31R BATTERY RELAY BATTERY FUSE F.L. SW354-10010 10-071...
Page 421: Horn Does Not Sound
TROUBLESHOOTING 2-6-21. Horn does not sound Reference Fig. : 2-6-6 Check point Check/Cause Action 1. Horn • Disconnect horn and directly connect battery positive Replace horn. terminal to horn terminal wire Lg side and negative terminal to horn terminal chassis ground side. •...
Page 422: 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 423: 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 424: 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 8. 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 425: 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 high pressure relief valve or replace it if necessary. Propulsion circuit pressure is not held in •...
Page 426: Driving Not Possible With Differential Locked (Tw354, 504)
TROUBLESHOOTING 3-2-6. Driving not possible with differential locked (TW354, 504) Check point Cause Check/Action 1. Differential Lock Flow control valve is clogged or check valve Inspect flow control valve and check valve Valve is faulty. or replace it if necessary. 3-2-7.
Page 427: Vibrator System
TROUBLESHOOTING 3-3. Vibrator System If a problem occurs in the vibrator systems such as the vibrator pump, vibrator motor and vibrator solenoid valve, determine the cause and carry out action as required, according to the following general troubleshooting items. (NOTICE) •...
Page 428: Vibrator Frequency Is Too Low
Insufficient pump discharge due to wear of Replace vibrator pump. vibrator pump drive shaft spline. 3-3-3. Vibratory drum does not changeover vibrating (SW354 ROPS) Check point Cause Check/Action 1. Vibrator Solenoid...
Page 429: Vibrator System Is Overheating
TROUBLESHOOTING 3-3-6. Vibrator system is overheating Check point Cause Check/Action 1. Oil Level of Oil level in hydraulic oil tank is low. Fill tank until correct oil level is obtained. Hydraulic Oil Tank 2. Oil Cooler Cooling efficiency is reduced due to clogged Clean oil cooler fins.
Page 430: Steering System
TROUBLESHOOTING 3-4. 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 431: Steering Wheel Backlash Or Play Is Large
TROUBLESHOOTING 3-4-3. Steering wheel backlash or play is large Check point Cause Check/Action 1. Steering Column Spline of column shaft or orbitrol is worn. Replace column shaft or orbitrol. Column shaft bearings are worn. Replace column shaft bearings. 2. Steering Wheel Serration (spline) of wheel or column shaft Replace wheel or column shaft.
Page 432: Cooling System
TROUBLESHOOTING 3-5. Cooling System If a problem occurs in the cooling systems such as the vibrator pump and cooling fan drive motor, 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 433: Electrical System Troubleshooting (Sw504)
SW504 TROUBLESHOOTING 4. ELECTRICAL SYSTEM TROUBLESHOOTING (SW504) 4-1. Engine Diagnosis Trouble Code 4-1-1. Description of diagnostic trouble code (SPN, FMI) Display monitor SV544-09001 • Fault codes can be accessed in at least two different ways; using the electronic service tool or a method of displaying it on a display monitor in a combination meter.
Page 434: Table Of The Diagnostic Trouble Code (Dtc)
SW504 TROUBLESHOOTING 4-1-2. Table of the diagnostic trouble code (DTC) Behaviour During J1939-73 DTC Name Detection Item Malfunction Accelerator position sensor 2: • Battery short circuit out of sensor High / harness Accelerator position sensor 2: • Ground short circuit or open circuit of sensor / harness Accelerator position sensor •...
Page 435 SW504 TROUBLESHOOTING Behaviour During J1939-73 DTC Name Detection Item Malfunction • Faulty starting • Open circuit, short circuit or • Insufficient output Battery voltage: High damage of harness • Worsening exhaust gas • Failure of battery performance • Faulty starting •...
Page 436 SW504 TROUBLESHOOTING Behaviour During J1939-73 DTC Name Detection Item Malfunction • Rail pressure value is sticking Pressure limiter not open or too low engine power not to open PL valve forcibility • Engine stops • Rail pressure value is too high Rail pressure failure after or low despite the existence pressure limiter open...
Page 437 SW504 TROUBLESHOOTING Behaviour During J1939-73 DTC Name Detection Item Malfunction Differential pressure sensor 1: • Open circuit or +B short circuit of High sensor / harness 3251 • None Differential pressure sensor 1: • Ground short circuit of sensor / harness •...
Page 438 SW504 TROUBLESHOOTING Behaviour During J1939-73 DTC Name Detection Item Malfunction QR (IQA) data error • QR data read error 523538 No QR (IQA) data • QR data is unwritten • Accelerator position sensor • Insufficient output Accelerator position sensor signal error (sensor / harness 523543 error (CAN) open circuit, ground short circuit...
Page 439 SW504 TROUBLESHOOTING Behaviour During J1939-73 DTC Name Detection Item Malfunction High exhaust gas temperature • Exhaust gas temperature sensor 523601 after emergency high • None 0, 1, 2 output temperature DTC • Time interval from the end 523602 High frequency of regeneration time to the start time of the •...
Page 440 SW504 TROUBLESHOOTING Fig.: 4-2-1 FOOT F-R LEVER BRAKE SWITCH SWITCH NO COM PARKING BRAKE SOLENOID 301 Y COMBINATION METER PARKING BRAKE SWITCH TO BRAKE LAMP RELAY 25 3W 26 5BR 86 L 85 LY 87 LR 87 LR STARTER RELAY 301 Y INTERLOCK RELAY PARKING...
Page 441: Engine
SW504 TROUBLESHOOTING 4-2. Engine Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. • Check any ground circuit which belongs to components to be checked. 4-2-1. Engine will not start (Starter motor does not run) 1/3 •...
Page 442 SW504 TROUBLESHOOTING Fig.: 4-2-1 FOOT F-R LEVER BRAKE SWITCH SWITCH NO COM PARKING BRAKE SOLENOID 301 Y COMBINATION METER PARKING BRAKE SWITCH TO BRAKE LAMP RELAY 25 3W 26 5BR 86 L 85 LY 87 LR 87 LR STARTER RELAY 301 Y INTERLOCK RELAY PARKING...
Page 443: Engine Will Not Start (Starter Motor Does Not Run) 2/3
SW504 TROUBLESHOOTING 4-2-1. Engine will not start (Starter motor does not run) 2/3 • F-R lever must be in “N”. • Parking brake switch must be applied. • Brake pedal is not depressed. Reference Fig.: 4-2-1 Check point Check/Cause Action 6.
Page 444 SW504 TROUBLESHOOTING Fig.: 4-2-1 FOOT F-R LEVER BRAKE SWITCH SWITCH NO COM PARKING BRAKE SOLENOID 301 Y COMBINATION METER PARKING BRAKE SWITCH TO BRAKE LAMP RELAY 25 3W 26 5BR 86 L 85 LY 87 LR 87 LR STARTER RELAY 301 Y INTERLOCK RELAY PARKING...
Page 445: Engine Will Not Start (Starter Motor Does Not Run) 3/3
SW504 TROUBLESHOOTING 4-2-1. Engine will not start (Starter motor does not run) 3/3 • F-R lever must be in “N”. • Parking brake switch must be applied. • Brake pedal is not depressed. Reference Fig.: 4-2-1 Check point Check/Cause Action 11.
Page 446 SW504 TROUBLESHOOTING Fig.: 4-2-1 FOOT F-R LEVER BRAKE SWITCH SWITCH NO COM PARKING BRAKE SOLENOID 301 Y COMBINATION METER PARKING BRAKE SWITCH TO BRAKE LAMP RELAY 25 3W 26 5BR 86 L 85 LY 87 LR 87 LR STARTER RELAY 301 Y INTERLOCK RELAY PARKING...
Page 447: Glow Plugs Is Not Heated
SW504 TROUBLESHOOTING 4-2-3. Glow plug is not heated (Engine starting performance is bad in cold weather) Reference Fig. : 4-2-1 Check point Check/Cause Action 1. Glow Plug • When starter switch is ON, measure voltage between Replace glow plug. glow plug terminal inlet wire WG and chassis ground. Standard voltage : 12 V or more •...
Page 448 SW504 TROUBLESHOOTING Fig.: 4-2-1 FOOT F-R LEVER BRAKE SWITCH SWITCH NO COM PARKING BRAKE SOLENOID 301 Y COMBINATION METER PARKING BRAKE SWITCH TO BRAKE LAMP RELAY 25 3W 26 5BR 86 L 85 LY 87 LR 87 LR STARTER RELAY 301 Y INTERLOCK RELAY PARKING...
Page 449: Engine Speed Does Not Change When Operating Throttle Lever
SW504 TROUBLESHOOTING 4-2-4. 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. : 4-2-1 Check point Check/Cause Action 1.
Page 451: Propulsion
SW504 TROUBLESHOOTING 4-3. Propulsion Refer to (P.10-022). 10-101...
Page 452: Vibration
SW504 TROUBLESHOOTING Fig.: 4-4-1 VIBRATION MODE SELECT SWITCH VIBRATION MODE SELECT SWITCH POSITION CONNECTION 1-2,4-6 1-3,4-6 AUTO 1-3,4-5 F-R LEVER VIBRATION SWITCH (R) VIBRATION Lo-Hi CHANGE SWITCH POSITION CONNECTION 1-3,4-6 F-R LEVER VIBRATION SWITCH (L) 1-2,4-5 COMBINATION METER 46 BrR VIBRATOR LAMP 63 BrB 50 LgW...
Page 453: No Vibration Occurs 1/3
SW504 TROUBLESHOOTING 4-4. Vibration Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. • Throttle lever must be “FULL”. • Check any ground circuit which belongs to components to be checked. 4-4-1. No vibration occurs 1/3 •...
Page 454 SW504 TROUBLESHOOTING Fig.: 4-4-1 VIBRATION MODE SELECT SWITCH VIBRATION MODE SELECT SWITCH POSITION CONNECTION 1-2,4-6 1-3,4-6 AUTO 1-3,4-5 F-R LEVER VIBRATION SWITCH (R) VIBRATION Lo-Hi CHANGE SWITCH POSITION CONNECTION 1-3,4-6 F-R LEVER VIBRATION SWITCH (L) 1-2,4-5 COMBINATION METER 46 BrR VIBRATOR LAMP 63 BrB 50 LgW...
Page 455: No Vibration Occurs 2/3
SW504 TROUBLESHOOTING 4-4-1. No vibration occurs 2/3 • F-R lever must be “F” or “R”. • Vibration mode select switch must be “AUTO” (automatic mode). Reference Fig.: 4-4-1 Check point Check/Cause Action 4. Vibration Lo-Hi Change (1) When starter switch is ON and vibratory drum select Replace vibration Lo-Hi Switch change switch.
Page 456 SW504 TROUBLESHOOTING Fig.: 4-4-1 VIBRATION MODE SELECT SWITCH VIBRATION MODE SELECT SWITCH POSITION CONNECTION 1-2,4-6 1-3,4-6 AUTO 1-3,4-5 F-R LEVER VIBRATION SWITCH (R) VIBRATION Lo-Hi CHANGE SWITCH POSITION CONNECTION 1-3,4-6 F-R LEVER VIBRATION SWITCH (L) 1-2,4-5 COMBINATION METER 46 BrR VIBRATOR LAMP 63 BrB 50 LgW...
Page 457: No Vibration Occurs 3/3
SW504 TROUBLESHOOTING 4-4-1. No vibration occurs 3/3 • F-R lever must be “F” or “R”. • Vibration mode select switch must be “AUTO” (automatic mode). Reference Fig.: 4-4-1 Check point Check/Cause Action 7. F-R Lever Switch (1) When starter switch is ON, measure voltage between Replace F-R lever F-R lever switch terminal inlet wire RY and chassis switch.
Page 458 SW504 TROUBLESHOOTING Fig.: 4-4-1 VIBRATION MODE SELECT SWITCH VIBRATION MODE SELECT SWITCH POSITION CONNECTION 1-2,4-6 1-3,4-6 AUTO 1-3,4-5 F-R LEVER VIBRATION SWITCH (R) VIBRATION Lo-Hi CHANGE SWITCH POSITION CONNECTION 1-3,4-6 F-R LEVER VIBRATION SWITCH (L) 1-2,4-5 COMBINATION METER 46 BrR VIBRATOR LAMP 63 BrB 50 LgW...
Page 459: Vibratory Drum Cannot Be Switched (Rops)
SW504 TROUBLESHOOTING 4-4-2. Vibratory drum cannot be switched (ROPS) Reference Fig.: 4-4-1 Check point Check/Cause Action 1. Vibratory Drum Select (1) When starter switch is ON, measure voltage between Replace vibratory drum Switch vibratory drum select switch terminal 1, 4 inlet wire RL select switch.
Page 461: Water Spray
SW504 TROUBLESHOOTING 4-5. Water Spray Refer to (P.10-040). • Refer to ROPS type for water spray timer. 10-110...
Page 462: Lighting
SW504 TROUBLESHOOTING Fig.: 4-6-1 System configuration diagram HEAD LAMP +BAT TAIL LAMP Battery 12V (+) DC/DC Converter TACHO Ground MOTOR FLOOD LAMP +BAT FUEL Starter switch driver LIGHTING SWITCH LIGHTING (ACC) SWITCH POSITION CONNECTION TEMP CAN (+) CAN (-) 1-2,4-6 Transceiver Fuel meter 7 Segments...
Page 463: Illumination Of Combination Meter Does Not Light
SW504 TROUBLESHOOTING 4-6. Lighting Check following items before troubleshooting. • No blown fuse and power is applied up to fuses. • Head lamp and tail lamp do not light Refer to (P.10-046). • Flood lamp does not light Refer to (P.10-046). •...
Page 464 SW504 TROUBLESHOOTING Fig.: 4-6-1 System configuration diagram HEAD LAMP +BAT TAIL LAMP Battery 12V (+) DC/DC Converter TACHO Ground MOTOR FLOOD LAMP +BAT FUEL Starter switch driver LIGHTING SWITCH LIGHTING (ACC) SWITCH POSITION CONNECTION TEMP CAN (+) CAN (-) 1-2,4-6 Transceiver Fuel meter 7 Segments...
Page 465: Combination Meter Warning Lamp Or Indicator Lamp Is Abnormal
SW504 TROUBLESHOOTING 4-6-2. Combination meter warning lamp or indicator lamp is abnormal Reference Fig. : 4-6-1 Check point Check/Cause Action 1. Combination Meter (1) When starter switch is ON, measure voltage between Replace combination (Lamp check) combination meter terminal wires and ground terminal meter.
Page 466 SW504 TROUBLESHOOTING Fig.: 4-6-1 System configuration diagram HEAD LAMP +BAT TAIL LAMP Battery 12V (+) DC/DC Converter TACHO Ground MOTOR FLOOD LAMP +BAT FUEL Starter switch driver LIGHTING SWITCH LIGHTING (ACC) SWITCH POSITION CONNECTION TEMP CAN (+) CAN (-) 1-2,4-6 Transceiver Fuel meter 7 Segments...
Page 467: Hour Meter Is Abnormal
SW504 TROUBLESHOOTING 4-6-4. Hour meter is abnormal Reference Fig. : 4-6-1 Check point Check/Cause Action 1. Combination Meter • When starter switch is ON, measure voltage between Replace combination (Hour meter) combination meter terminal wires and ground terminal meter. wire. •...
Page 468 SW504 TROUBLESHOOTING Fig.: 4-6-1 System configuration diagram HEAD LAMP +BAT TAIL LAMP Battery 12V (+) DC/DC Converter TACHO Ground MOTOR FLOOD LAMP +BAT FUEL Starter switch driver LIGHTING SWITCH LIGHTING (ACC) SWITCH POSITION CONNECTION TEMP CAN (+) CAN (-) 1-2,4-6 Transceiver Fuel meter 7 Segments...
Page 469: Hydraulic Oil Filter Warning Lamp Remains On
SW504 TROUBLESHOOTING 4-6-6. Hydraulic oil filter warning lamp remains ON Reference Fig. : 4-6-1 Check point Check/Cause Action 1. Harness • Disconnect connectors between combination meter and Repair or replace hydraulic oil filter switch. harness. • Measure resistance between terminals and chassis ground.
Page 470 SW504 TROUBLESHOOTING Fig.: 4-6-2 System configuration diagram VIBRATOR SOLENOID (F), +BAT Battery 12V (+) DC/DC VIBRATOR Converter TACHO SOLENOID (R) Ground ROPS: MOTOR +BAT FUEL Starter switch driver TO VIBRATORY (ACC) DRUM SELECT TEMP SWITCH CAN (+) CAN (-) Transceiver Except ROPS: Fuel meter TO VIBRATION...
Page 471: Vibration Indicator Lamp Does Not Light
SW504 TROUBLESHOOTING 4-6-8. Vibration indicator lamp does not light • Check that vibrator can be operated. Reference Fig. : 4-6-2 Check point Check/Cause Action 1. Harness • Measure resistance between vibrator lamp relay terminal Repair or replace 5 wire Br and combination meter connector terminal wire harness.
Page 472 SW504 TROUBLESHOOTING Fig.: 4-6-3 System configuration diagram +BAT Battery 12V (+) DC/DC Converter TACHO Ground MOTOR +BAT FUEL driver Starter switch (ACC) TEMP CAN (+) CAN (-) Transceiver Fuel meter 7 Segments driver Pull up Pull up Resistor Resistor REV. ratio SEL.1 31KΩ x4 3.6KΩ x3 Dot Matrix...
Page 473: Water Spray Indicator Lamp Does Not Light
SW504 TROUBLESHOOTING 4-6-9. Water spray indicator lamp does not light • Check that water spray pump can be activated. Reference Fig. : 4-6-3 Check point Check/Cause Action 1. Harness • Measure resistance between water spray mode select Repair or replace switch terminal 2 wire LW and combination meter harness.
Page 474 SW504 TROUBLESHOOTING Fig.: 4-6-4 System configuration diagram +BAT Battery 12V (+) DC/DC Converter TACHO Ground MOTOR +BAT FUEL driver Starter switch (ACC) HEAD LAMP, TAIL LAMP, TEMP CAN (+) CAN (-) COMBINATION METER Transceiver Fuel meter 7 Segments driver 38 Or Pull up Pull up Resistor...
Page 475: Flood Lamp Indicator Lamp Does Not Light
SW504 TROUBLESHOOTING 4-6-10. Flood lamp indicator lamp does not light • Check that flood lamp lights. Reference Fig. : 4-6-4 Check point Check/Cause Action 1. Harness • Measure resistance between lighting switch terminal 5 Repair or replace wire Or and combination meter connector terminal wire harness.
Page 476 SW504 TROUBLESHOOTING Fig.: 4-6-4 System configuration diagram +BAT Battery 12V (+) DC/DC Converter TACHO Ground MOTOR +BAT FUEL driver Starter switch (ACC) HEAD LAMP, TAIL LAMP, TEMP CAN (+) CAN (-) COMBINATION METER Transceiver Fuel meter 7 Segments driver 38 Or Pull up Pull up Resistor...
Page 477: Turn Signal Indicator Lamp Does Not Light
SW504 TROUBLESHOOTING 4-6-12. Turn signal indicator lamp does not light • Check that turn signal lamp blinks. Reference Fig. : 4-6-4 Check point Check/Cause Action 1. Harness (1) Measure resistance between turn signal switch terminal Repair or replace wire No.36 wire GR and combination meter connector harness.
Page 478: Hydraulic System Troubleshooting (Sw504)
SW504 TROUBLESHOOTING 5. HYDRAULIC SYSTEM TROUBLESHOOTING (SW504) Refer to (P.10-073). 10-127...
Page 480 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 2016.11.50 ○ Printed in Japan 2016.11.10 ○ 0446-99019-0-30912-D 0449-99017-0-30245-C Printed in Japan 2019.07.10...

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