Sakai CR271 Shop Manual Download Page 68 | Manualshive

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5-007

ELECTRICAL SYSTEM

1.25B,100

1.25R,100

ACR6

ACR6

CB104

1.25R,160

1.25R,160

F-R lever

Vibration switch

CB104

1.25R,410

CB104

CA104

CB104

Marking

R1.25-5

Hour meter

Engine oil

pressure

pilot lamp

Horn switch

Starter switch-30

1.25B,60

60

1.25B,310

R1.25-5

3R,310

1.25R,310

1.25R,310

1.25B,360

1.25R,360

1.25B,410

1.25B,410

410

1.25R,410

1.25R,410

15

30

30

15

CN8PML

J100 J102

J101

3B

1.25B 3R 1.25R 1.25R

1.25B

3R

1.25R

J100 J102 J101

90

B2B4

⑭

ST-SW-30

Marking

B1B3

⑮

Starter switch-17

ST-SW-17

Starter switch-AC

⑯

B1B3

Marking

ST-SW-AC

㊳

B1B3

Starter switch-AC

Marking

ST-SW-AC2

③

B1B3

Marking

⑰

B2B4

Marking

OIL-ALM

OIL-ALM

Marking

HORN-SW

⑱

⑲

HORN-SW

Marking

Marking

HOUR

⑳

㉑

Marking

VIB-SW1-1

㉒

Marking

VIB-SW1-2

㉓

㉔

2-1

Marking

VIB-SW2-1

Marking

VIB-SW2-2

Marking

VIB-SW2-3

㉒

2-2

㉕

2-3

CorrugateΦ15

B2B4

㊳

③

⑱ ⑭ ⑮ ⑯

Harness (1)

(5-005)

CR271-0502

1-1

1-2

No. connection

VIB-SW2-1

VIB-SW2-2

4-2. Harness (2)

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Summary of Contents for CR271

Page 1: ...CR271 SHOP MANUAL 3498 65634 0 ...

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Page 3: ...he machine Improper operation is dangerous and can result in injury or death Sakai Heavy Industries cannot foresee all possible circumstances or varying conditions to which the operator serviceman or machine may be exposed to that might lead to a potential hazard Therefore the warnings and cautions listed in this manual and those placed on the machine are not intended to be all inclusive and liabi...

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Page 5: ...1 6 Safety Instructions 1 003 1 7 Starting 1 004 1 8 Operating 1 004 1 9 Stopping 1 004 1 10 Maintenance 1 005 1 11 Transporting the Machine 1 007 2 SPECIFICATIONS 1 SPECIFICATION DATA 1 1 CR271 2 001 2 TABLE OF STANDARD VALUES 2 1 Engine 2 003 2 2 Propulsion 2 003 2 3 Hydraulic Systems 2 003 2 4 Steering 2 004 2 5 Capacities 2 004 3 FUEL AND LUBRICANTS SPECIFICATION 3 1 Rating 2 005 3 2 Recommend...

Page 6: ...raulic Piping 4 004 2 1 1 Propulsion hydraulic piping 1 4 004 2 1 2 Propulsion hydraulic piping 2 4 005 2 2 Hydraulic Component Specifications 4 006 2 2 1 Hydraulic pump assembly propulsion vibrator steering 4 006 2 2 2 Propulsion hydraulic motor 4 008 2 2 3 Valve block 4 009 2 2 4 Valve 4 010 3 VIBRATOR HYDRAULIC SYSTEM 3 1 Vibrator Hydraulic Piping 4 011 3 2 Hydraulic Component Specification 4 0...

Page 7: ...s 2 5 007 6 DRUMS 1 PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY 6 001 2 REMOVAL AND INSTALLATION OF DRUMS 2 1 Removal of Drums 6 003 2 1 1 Front drum 6 003 2 1 2 Rear drum 6 006 2 2 Installation of Drums 6 008 3 DRUM ASSEMBLY 3 1 Front Drum 6 009 3 2 Rear Drum 6 010 4 DISASSEMBLY AND REASSEMBLY OF DRUMS 4 1 Disassembly of Drums 6 011 4 1 1 Front drum 6 011 4 1 2 Rear drum 6 018 4 2 Reassembly of Dr...

Page 8: ... 1 Measurement 9 006 4 2 Adjustment 9 007 5 MEASUREMENT OF HYDRAULIC PUMP CASE PRESSURE 5 1 Measurement 9 008 6 MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE 6 1 Measurement 9 009 7 ADJUSTMENT OF THROTTLE LEVER LINKAGE 7 1 Adjustment 9 010 8 ADJUSTMENT OF F R LEVER LINKAGE 8 1 Adjustment 9 012 10 TROUBLESHOOTING 1 TROUBLESHOOTING 1 1 Safety Precautions for Troubleshooting 10 001 1 2 Important Info...

Page 9: ...ubleshooting 10 021 3 2 Propulsion System 10 022 3 2 1 Machine moves neither forward nor backward 10 022 3 2 2 Machine moves in one direction only forward or backward 10 023 3 2 3 Slow machine speed or small drive force 10 023 3 2 4 Machine does not stop completely with F R lever in N 10 024 3 2 5 Propulsion system is overheating 10 024 3 2 6 Abnormal noise from propulsion system 10 024 3 3 Steeri...

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Page 11: ...SAFETY ...

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Page 13: ...machine if you fail to observe or important point to maintain of quality in maintenance works Indicates standard value to judge whether measured value is good or not Items that indicate the weight of a part or equipment and require attention in wire selection and operating posture for slinging operation N m In the assembly operation tightening torque in locations that require particular attention ...

Page 14: ... guidance of a skilled electrician and according to electrical engineering rules and regulations Work on the frame brakes hydraulic and steering systems must be performed by skilled personnel with special knowledge and training for such work 1 4 Safety Practices and Policies Keep the manuals in the container provided on the machine Manuals must always be available at the site where the machine is ...

Page 15: ...readable Never fill the fuel tank with the engine running or while near an open flame or while smoking Always clean up any spilled fuel Check for any warning tags placed on the machine do not operate the machine until all repairs have been made and warning tags have been removed by authorized personnel Check the seat belt for wear or damage inspect the belt hardware and fabric Replace if hardware ...

Page 16: ...to slide or roll over Avoid any areas that may be a risk to machine stability Avoid side hill travel Always operate up and down the slope Always keep the propulsion travel control lever in low speed range when climbing or descending hills or steep grades Make sure there is sufficient clearance when crossing underpasses bridges and tunnels or when passing under overhead power lines Never allow anyo...

Page 17: ... to avoid the risk of accident Use lifting devices that are in perfect condition and of sufficient lifting capacity Never stand under suspended loads Always use the proper tools and workshop equipment in good condition when performing maintenance or repairs on the machine Always use specially designed safety ladders and working platforms when working above floor level Never use machine parts as a ...

Page 18: ...g or grinding operations Inspect hydraulic hoses at regular intervals and immediately replace if they show signs of chafing cracking brittleness deformation blistering fitting separation leakage corrosion or other damage which may affect their function or strength Do not work on hydraulic system while the engine is running and the system is under pressure The hydraulic system remains pressurized e...

Page 19: ...ake sure that the compactor does not slide off the edge of the ramp Keep the deck clear of mud oil ice or snow or other materials that can make the deck slippery Position the compactor on the trailer or transport vehicle centered from side to side and apply the brake Shut off the engine and lock all lockable compartments Block the drums or tires and lock the articulation lock bar Chain the machine...

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Page 21: ...SPECIFICATIONS ...

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Page 24: ... 1 300 mm 51 in Compaction width 900 mm 35 5 in Minimum height above ground 280 mm 11 in Curb clearance 325 mm 13 in Speeds Forward and reverse 0 to 7 5 km h 0 to 4 6 mile h Vibration performance Frequency 66 7 Hz Centrifugal force 13 2 kN 2 975 lbs Amplitude 0 35 mm 0 014 in Minimum turning radius outer 2 8 m 110 in Gradability 1 25 14 Roll ber 2275 ROPS 2440 2000 325 1010 280 Φ560 Φ560 900 900 3...

Page 25: ...ical system Alternator 12 V 17 A Battery 12 V 36 Ah x 1 pcs 12 V Dry weight 44 4 kg 97 9 lbs Power line Transmission Type Hydrostatic transmission Reverser Switching the direction of flow delivered from the variable pump Vibrating system Transmission Hydrostatic transmission Vibrator Eccentric shaft type Braking device Service brake Hydrostatic type Parking brake Mechanical disc type Steering syst...

Page 26: ...on Item Standard value Remarks Travel speed Forward and reverse 0 to 7 5 km h 0 to 4 6 mile h 2 3 Hydraulic Systems Item Standard value Remarks Propulsion High pressure relief valve setting 17 2 MPa 2 49 psi Cut off valve setting Charge relief valve setting 0 5 MPa 0 07 psi Case pressure Pump 0 1 MPa 0 01 psi Front motor 5 0 MPa 0 73 psi Rear motor 5 0 MPa 0 73 psi Brake release pressure Front mot...

Page 27: ...mm 0 2 to 0 4 in Steering wheel circumference 5 mm 0 02 in or less Steering column shaft direction 2 5 Capacities Item Standard value Remarks Engine oil pan 1 9 L 0 5 gal Engine oil Fuel tank 30 L 7 9 gal Gasoline Hydraulic oil tank 30 L 7 9 gal Hydraulic oil Water spray tank 150 L 40 gal Water ...

Page 28: ... Grease Lithium type extreme pressure NLGI 2 Fuel Gasoline JIS K2202 2 3 2 Recommended Lubricants Lubricant Oil company Engine oil API CH 4 Gear oil API GL 4 Hydraulic oil VG 46 Grease NLGI II CALTEX PRM DELO 300 oil Universal Thuban 90 Rando Oil HD 46 Martifack EP 2 BP BP Vanellus C3 30 BP Gear Oil EP 90 BP Energol HLP 46 BP Energrease LS EP 2 ESSO Esso Lube D3 30 Esso Gear Oil GP 90 Nuto H 46 Be...

Page 29: ...43 253 20 2 5 294 217 392 289 539 398 539 398 22 2 5 441 325 539 398 686 506 686 506 24 3 0 539 398 637 470 883 651 883 651 27 3 0 785 579 981 724 1324 977 1324 977 30 3 5 1079 796 1324 977 1765 1302 1765 1302 Metric fine screw 10 1 25 39 29 49 36 69 51 69 51 12 1 25 69 51 88 65 118 87 118 87 14 1 5 108 80 137 101 186 137 186 137 16 1 5 167 123 206 152 284 209 284 209 18 1 5 245 181 294 217 392 28...

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Page 31: ...ENGINE AND CONTROLS ...

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Page 33: ...3 001 ENGINE AND CONTROLS 1 ENGINE 1 1 Engine Mount 0563 01802 0 10281 B 2 3 4 1 1 Engine 2 Key 3 Muffler 4 Bolt M10 50 N m 4 Bolt M10 50 49 N m 36 lbf ft ...

Page 34: ...EW D D 13 14 15 12 A A IDLE 16 17 Throttle 18 19 Choke 1 Choke cable 8 Bush Apply grease 15 Stopper bolt FULL 2 Control cable Throttle Cable 9 Coned disc spring 16 Throttle lever 3 Nut 10 Throttle lever pin Apply grease 17 Holder 4 Throttle lever 11 Key 18 Choke lever 5 Washer 12 Lock nut 19 Joint 6 Split pin 13 Stopper bolt IDLE 7 Pin 14 Lock nut ...

Page 35: ...15 16 13 14 17 19 18 20 8 7 10 9 Apply grease 22 1 F R lever 9 Plate 17 Steel ball 2 Control cable F R cable 10 Safety switch 18 Set screw 3 Lock nut 11 Nut 19 Spring Fill grease 4 Stopper bolt Forward 12 Key 20 Nut 5 Stopper bolt Reverse 13 Coned disc spring 21 Rod end 6 Lock nut 14 Bush Apply grease 22 Nut 7 Rod end 15 Pin 8 Nut 16 Washer ...

Page 36: ...NE AND CONTROLS 3 PUMP MOUNT 3 1 Pump Mount 1 Set screw 6 Key 8 Key 2 Set screw 7 Coupling 3 Bolt 7 1 Hub 4 Nut 7 2 Insert 5 Pump 7 3 Hub N m 4 Nut 49 N m 36 lbf ft a B A 8 2 7 3 7 2 7 1 6 1 5 4 3 2 1 CR271 03001 ...

Page 37: ...ush with hub 7 1 surface A Tighten set screws 1 Install insert 7 2 Secure pump to bracket with bolts 3 washers and nuts 4 Measure gap at dimension a between pump side hub 7 1 and engine side hub 7 3 Standard dimension a 1 9 0 7mm 0 07 0 03 in If measurement result deviates from standard dimension range loosen pump side set screw 1 in hub 7 1 and adjust the gap After completed adjustment tighten se...

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Page 39: ...HYDRAULIC SYSTEMS ...

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Page 42: ...eservoir vented Filter or strainer Heat exchanger lines in dicate flow of coolant Quick disconnect Connected with mechan ically opened checks Disconnected Sloping arrow through a symbol at 45 indicates that a component can be adjusted or varied Pump Motors and Cylinders DESCRIPTION SYMBOL Hydraulic pumps Fixed displacement Unidirectional Bidirectional Variable displacement Unidirectional Bidirecti...

Page 43: ...s providing various flow path options for the fluid The multiple square moves to represent how flow paths change when the valving element is shifted within the compo nent Valves with infinite posi tioning between certain limits are symbolized with lines parallel to the squares Methods of Operation DESCRIPTION SYMBOL Spring Manual Pressure compensated Reversing motor Pilot pressure Internal supply ...

Page 44: ...5st L T P R 1 4 1 4 3 8 Durm Front Propulsion motor Front FMA cc rev 500 FMB FMD cc rev 6 0 1 4 1 4 3 8 3 8 Vibrator motor PA PB X X 0 5 MPa 10cc rev 3 8 Valve 1 2 PF EF 3 8 LO LS Hydraulic oil filter Valve block X VBP VBB VBA 14 4 MPa 3 8 3 8 3 8 1 HONDA GX630R 12 kW 3600 min 1 VCD PC PD VCS 10 97 cc rev Proprlsion pump Steering vibrator charge pump Suction filter Hydraulic oil tank TD5 TD2 TD4 T...

Page 45: ...oil tank SECTION D D VIEW A A D D C B DETAIL B VCS TVS Hose TVS VCS VCO TD2 IN PF EF Hose VCO IN Hose LO PC PC VBP VBB TD2 Hose VBB TD4 Hydraulic oil tank TD4 TVS TD4 The letters and figures such as TVS and VCS show each port and the arrow symbols show the hose connection and the direction of the flow of the oil DETAIL C Hose EF VBP Hose PD TD2 LO PD VBB LO Hydraulic oil filter ...

Page 46: ... A B B TD3 Hose RMD PD Hose FMD TD3 PD PA PB Hose FMD TD3 Hose PA FMA FMA FMB Propulsion motor front Hose PB RMB RMB Propulsion motor rear Hose FMB RMA RMA 0563 36803 0 10462 0 The letters and figures such as FMD and TD3 show each port and the arrow symbols show the hose connection and the direction of the flow of the oil ...

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Page 48: ...aulic Component Specifications 2 2 1 Hydraulic pump assembly propulsion vibrator steering 1 9 2 1 10 1 4 1 3 1 11 1 5 1 1 1 1 2 1 8 1 7 1 6 1 13 CR271 04001 1 12 Pump circuit diagram 2 1 2 2 2 2 1 8 1 7 1 3 1 4 2 1 1 13 1 12 1 1 1 2 ...

Page 49: ...rt 7 16 20UNF 1 9 Charge supply port 1 10 Bypass valve 1 11 Forward reverse control lever 1 12 Drain port PD G3 8 1 13 Drain port G3 8 Specifications Displacement 10 0 cm3 rev 0 61 cu in rev High pressure relief valve pressure setting 17 2 MPa 2 494 psi Charge relief valve pressure setting 0 5 MPa 72 5 psi 2 Vibrator steering charge pump 2 1 Suction port VSC G3 4 2 2 Discharge port VCO G1 2 Specif...

Page 50: ... 䞉㻝䊻㻞䠖Counterclockwise rotation 䞉㻞䊻㻝䠖Clockwise rotation 3 2 Motor circuit didgram 1 Port B FMB RMB 7 8 14UNF 2 Port A FMA RMA 7 8 14UNF 3 Drain port FMD RMD 7 16 20UNF Specifications Displacement 488 cm3 rev 30 cu in rev Allowable pump case pressure 14 MPa 2 030 psi Weight 14 5 kg 32 lbs ...

Page 51: ...t P VBP 3 4 16UNF 3 Solenoid valve 4 Manifold block 5 Relief valve 6 Port B VBB 3 4 16UNF 7 Port A VBA 3 4 16UNF Specifications Maximum pressure 17 9 MPa 2 596 psi 4 5 32 MPa 4 640 psi 3 Maximum flow 35 L min 9 2 gal min 4 5 42 L min 11 gal min 3 Relief valve pressure setting 14 4 MPa 2 088 psi Weight 3 5 kg 7 7 lbs ...

Page 52: ... SYSTEM 2 2 4 Valve CR271 04004 1 2 3 1 2 3 Circuit diagram 1 Port IN IN G1 2 2 Port EF EF G1 2 3 Port PF PF G3 8 Specifications Maximum pressure 17 2 MPa 2 494 psi Rated flow 40 L min 10 6 gal min Weight 1 8 kg 1 lbs ...

Page 53: ...lic Piping SECTION A A A A VMA Hose VBA VMA TD5 VBA TD1 VMD Hose VMB TD5 Hose VMD TD1 VMB Vibrator motor 0563 49801 0 10186 C The letters and figures such as VMB and TD5 show each port and the arrow symbols show the hose connection and the direction of the flow of the oil ...

Page 54: ...1 04005 3 2 1 1 2 3 Flow of oil 䞉㻝䊻㻟䠖Counterclockwise rotation 䞉㻟䊻㻝䠖Clockwise rotation VIEW A A Motor circuit didgram 1 Port A VMA 7 8 14UNF 2 Drain port VMD 9 16 18UNF 3 Port B VMB 7 8 14UNF Specifications Displacement 6 cm3 rev 0 37 cu in rev Rated pressure 25 MPa 3 625 psi Weight 2 4 kg 5 3 lbs ...

Page 55: ... R T VIEW A A CL Steering wheel Hose T PC 0563 32801 0 10183 D Orbitrol P T L R PF Hose PF P PC Power cylinder CR Hose R CL Hose L CR The letters and figures such as L and CR show each port and the arrow symbols show the hose connection and the direction of the flow of the oil ...

Page 56: ...itrol 1 Relief valve 2 Port L L G1 4 3 Port R R G1 4 4 Port P P G1 4 5 Port T T G1 4 Specifications Displacement 50 cm3 rev 3 cu in rev Relief valve pressure setting 8 to 8 5 MPa 1160 to 1233 psi Weight 2 5 kg 5 5 lbs 1 CR271 04006 A VIEW A 2 3 4 5 2 3 4 5 Circuit diagram ...

Page 57: ...2 Adapter 3 Bolt M10x30 4 Washer 5 Bolt M12x45 6 Bracket 7 Bolt M12x35 8 Bracket 9 Bolt M12x30 10 Bracket 11 Bolt M12x35 12 Bearing unit 13 Bolt M12x45 14 Bolt M4x30 N m 3 Bolt M10x30 49 N m 36 lbf ft 5 Bolt M12x45 78 N m 58 lbf ft 7 Bolt M12x35 98 N m 72 lbf ft 9 Bolt M12x30 98 N m 72 lbf ft 13 Bolt M12x45 78 N m 58 lbf ft ...

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Page 59: ...ELECTRICAL SYSTEM ...

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Page 61: ...50 Corrugate Ǟ70 GB 100 CB104 58X 2F 200 Ǟ13 770 63 CorrugateǞ10 Brw 9 GB 63 LY 38 SWP 4㧲 Mark S Starter relay harness P 5 017 J P 5 005 BrR GL Fuel sensor Wire color Reference page Marking Reference page 24 1 25 BR Wire color AVS wire size Wire number 7 28 LgW R2 BR R1 C B ACC 24 1 25BR 4 26 Lg STARTER SWITCH 26 Lg 5G 5BY The pin or socket layout of mating connectors are symmetrical either vertic...

Page 62: ...stripe GY Green Yellow stripe GB Green Black stripe GL Green Blue stripe Gy Gray GyR Gray Red stripe Y Yellow YR Yellow Red stripe YB Yellow Black stripe YG Yellow Green stripe YL Yellow Blue stripe YW Yellow White stripe GyL Gray Blue stripe Br Brown BrW Brown White stripe BrR Brown Red stripe BrY Brown Yellow stripe BrB Brown Black stripe BrG Brown Green stripe BrL Brown Blue stripe Sb Sky blue ...

Page 63: ...R MOTOR PL CHARGE COIL 17A S B REGULATOR RECTIFIER G 25A 15A NC NO f e a c b 15A AC 30 17 NC NO f e a c b 2 E E E E 12 6 4 HOUR METER HORN HORN BUTTON HORN RELAY VIBRATOR SOLENOID F R LEVER VIBRATION SWITCH NO 5 1 3 2 SOL 3 2 START 1 ON 0 OFF E AV20 B AV20 R BATTERY 12V45AH BUCKUP BUZZER 55B24R SPARK PLUG IGNITION COIL ENGINE ACCESSORY ENGINE OIL PRESSURE PILOT LAMP INTERLOCK RELAY ENGINE ACCESSOR...

Page 64: ...t solenoid To engine alternator Starter motor B and S Fuel pump Engine oil pressure switch Interlock switch Engine oil pressure pilot lamp Starter switch Horn Switch Harness 2 5 007 R VIB SW2 1 R VIB SW2 3 R VIB SW2 2 No connection Insulate with insulating tape F R lever vibration switch harness Br COM W NC G NO R VIB SW1 1 R VIB SW1 2 VIEW A A 0563 09803 0 10286 C 1 2 3 4 10 7 9 6 5 8 DETAIL C C ...

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Page 66: ...25R 3R 1 25B 1 25R J101 J102 J100 1 25R 60 1 25B 60 60 3R 60 190 1 25R 80 150 100 1 25R 230 3 3 0 1 25B 100 1 25R 60 1 25B 60 1 25R 40 1 25B 40 1 25B 40 7 0 0 1 4 0 2 3 0 6 0 0 50 150 FL PUMP IL RY HORN RY FUL CUT E G DOD 15A Fuse2 Fuse3 25A 15A Fuse1 B1B3 B2B4 Marking B1B3 Harnesse 2 5 007 Marking B1B3 Marking B2B4 CorrugateΦ10 C o rr u g a te Φ 1 5 CorrugateΦ22 C o r r u g a t e Φ 2 2 Marking Ma...

Page 67: ...int 105 E 1 25R 2 IL SW Joint 106 4 1 25R 2 IL SW IL RY 8 3R 2 REG UNT Joint 107 13 3R 2 Connecter CN8PFL to Harness 2 Joint 107 13 1 25R 2 Connecter CN8PFL to Harness 2 Fuse 1 15A 1 1 25R 2 Connecter CN8PFL to Harness 2 Fuse 2 15A 3 1 25B 2 HORN RY Connecter CN8PFL to Harness 2 6 1 25B 2 E G DOD STOP RY 5 1 25R 2 FUL CUT Joint 106 4 1 25R 2 HORN RY Joint 106 4 1 25R 2 HORN RY Joint 106 4 1 25B 2 ...

Page 68: ...25R 410 1 25R 410 15 30 30 15 CN8PML J100 J102 J101 3B 1 25B 3R 1 25R 1 25R 1 25B 3R 1 25R J100 J102 J101 90 B2B4 ST SW 30 Marking B1B3 Starter switch 17 ST SW 17 Starter switch AC B1B3 Marking ST SW AC B1B3 Starter switch AC Marking ST SW AC2 B1B3 Marking B2B4 Marking OIL ALM OIL ALM Marking HORN SW HORN SW Marking Marking HOUR Marking VIB SW1 1 Marking VIB SW1 2 2 1 Marking VIB SW2 1 Marking VIB...

Page 69: ...ALM Engine oil pressure pilot lamp Joint 101 4 1 25B 2 HORN SW Horn switch Connecter CN8PFL to Harness 1 6 1 25B 2 HORN SW Horn switch Joint 100 E 1 25R 2 HOUR Hour meter Joint 101 4 1 25B 2 HOUR Hour meter Joint 100 E 1 25R 2 VIB SW1 1 VIB SW2 2 9 1 25R 2 VIB SW1 2 Joint 102 12 1 25R 2 VIB SW2 1 Joint 101 4 1 25R 2 VIB SW2 3 Joint 102 12 1 25B 2 ST SW AC2 to Harness 1 15 J100 3B 2 Joint 100 Conne...

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Page 71: ...DRUMS ...

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Page 73: ...ances from getting in Before removing piping for hydraulic oil or coolant or removing related parts satisfactorily release internal pressure 2 Precautions for installation work Tighten bolts and nuts sleeve nuts to the specified torque screw tightening torque table When installing hoses do not twist them or allow them to interfere with other parts Replace gaskets O rings split cotter pins and lock...

Page 74: ...olant to the specified level Start the engine and allow the coolant to circulate through the piping Then add coolant again to the specified level If hydraulic equipment has been removed and reinstalled fill with hydraulic oil to the specified level Start the engine and allow the oil to circulate through the piping Then add oil again to the specified level ...

Page 75: ...ly 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 2 Disconnect hydraulic hose connecting to vibrator motor NOTE Plug both ends of the disconnected hoses or implement other actions to prevent entry of foreign matter CR271 06002 3 Disconnect hydraulic hose connecting to propulsion motor...

Page 76: ...raper blade Loosen both side bracket fastening bolts CR271 06004 Scraper blade 5 Lift frame with a crane Front axle 650 kg 1 435 lbs Remove bolts Remove side plate CR271 06005 6 Flip up scraper blade CR271 06006 Scraper blade ...

Page 77: ...6 005 DRUMS 7 Remove drum assembly together with bracket from frame CR271 06007 ...

Page 78: ...6 006 DRUMS 2 1 2 Rear drum 1 Remove bolts 1 Remove cover 2 CR271 06009 2 1 2 Remove clevis 3 CR271 06010 3 3 Remove parking brake cable 4 CR271 06011 4 ...

Page 79: ...6 007 DRUMS 4 See step 5 and subsequent steps under 2 1 1 Front drum Rear axle 680 kg 1 500 lbs ...

Page 80: ... particular attention to items mentioned below Fill hydraulic oil tank to specified level to make for any oil leakage Start engine and circulate oil through piping Then check oil level again ensuring that the oil is at specified level NOTE If the engine is run at high speed or the cylinder is operated to full stroke when the engine is started for the first time after the work is completed the pist...

Page 81: ...nut 1 20UNF 25 Cover 8 Split pin 26 Bolt M10x25 9 Sunk key 27 Bolt M10x35 10 Disc 28 Vibrator motor 11 Damper 29 Coupling 12 Bolt M12x35 30 Retaining ring 13 Nut M12 31 Bracket 14 Nut M16 32 Nut M16 15 Bracket 33 Bolt M12x35 16 Propulsion motor 34 Nut M12 17 Bolt M12x45 35 Damper 18 Nut M12 35 33 34 32 31 30 29 28 27 26 25 24 23 22 21 20 19 17 18 16 15 14 12 13 11 10 9 7 8 6 5 4 3 2 1 0563 43801 0...

Page 82: ...x25 24 Side plate 8 Spacer 25 Damper 9 Washer 26 Bolt M12x35 10 Castle nut M16 27 Nut M12 11 Split pin 28 Nut M16 12 Ball bearing 29 Bolt M12x45 13 Bolt M12x100 30 Bolt M12x45 14 Nut M16 31 Nut M12 15 Bolt M12x35 32 Propulsion motor 16 Nut M12 33 Bracket 17 Damper 0563 27803 0 10289 0 17 22 18 33 32 30 31 29 28 26 27 25 24 23 21 20 19 15 16 14 13 12 10 11 9 8 7 6 5 3 4 2 1 ...

Page 83: ... 14 32 Remove bracket 15 31 15 31 Bracket 25 kg 55 lbs CR271 06012 14 32 15 31 When standing the vibratory drum use wooden blocks of sufficient strength to securely support the drum Carry out the work in an unstrained posture using a work stool or the like 2 Stand vibratory drum ASSY with its vibrator motor 28 side facing up Vibratory drum ASSY 330 kg 728 lbs CR271 06013 28 Vibratory drum ASSY 3 R...

Page 84: ...6 012 DRUMS 4 Remove coupling 29 CR271 06015 29 5 Remove bolts 24 CR271 06016 24 Remove eight bolts 24 CR271 06017 24 Disc SUB ASSY ...

Page 85: ...ccentric shaft 5 5 Eccentric shaft 10 kg 22 lbs CR271 06019 5 Be careful because reversing the vibratory drum involves Risk Confirm that the surrounding area is safe and work in a natural unstained posture 8 Lift drum with a crane and reverse it Drum SUB ASSY 275 kg 606 lbs CR271 06020 Drum SUB ASSY ...

Page 86: ...6 014 DRUMS 9 Remove bolts 19 CR271 06021 19 Remove four bolts 19 CR271 06022 19 Propulsion motor SUB ASSY Remove two bolts 19 CR271 06023 19 Propulsion motor SUB ASSY ...

Page 87: ...6 015 DRUMS 10 Remove propulsion motor SUB ASSY Propulsion motor SUB ASSY 40 kg 88 lbs CR271 06024 11 Remove bolts 21 CR271 06025 21 12 Remove hub 22 22 Hub 10 kg 22 lbs CR271 06026 22 Durm ...

Page 88: ...er 25 CR271 06027 25 26 Wooden block Wooden block 14 Remove retaining ring 30 CR271 06028 30 15 Put a piece of steel plate on end of boss 23 Set a puller on disc 2 Remove disc SUB ASSY with bearing 3 from boss 23 Disc SUB ASSY 25 kg 55 lbs CR271 06029 2 23 Plate Puller 3 ...

Page 89: ... Remove propulsion motor Remove split pin 8 Remove castle nut 7 Remove flange 20 20 Flange 5 kg 11 lbs CR271 06030 20 7 8 17 Remove bolt 17 nut 18 CR271 06031 18 17 18 Remove propulsion motor 16 16 Propulsion motor 15 kg 33 lbs CR271 06032 16 Disc SUB ASSY ...

Page 90: ... 33 Bracket 30 kg 66 lbs CR271 06033 28 14 33 6 When standing the vibratory drum use wooden blocks of sufficient strength to securely support the drum Carry out the work in an unstrained posture using a work stool or the like 2 Stand drum ASSY with its disc brake side facing up Vibratory drum ASSY 310 kg 683 lbs CR271 06034 ...

Page 91: ...Disc brake SUB ASSY 50 kg 110 lbs CR271 06037 Disc brake SUB ASSY Be careful because reversing the drum involves Risk Confirm that the surrounding area is safe and work in a natural unstained posture 5 Reverse drum SUB ASSY Drum SUB ASSY 260 kg 573 lbs CR271 06038 Drum SUB ASSY ...

Page 92: ...6 020 DRUMS 6 Remove bolts 29 CR271 06039 29 Remove four bolts 29 CR271 06040 29 Propulsion motor SUB ASSY 7 Remove propulsion motor SUB ASSY Propulsion motor SUB ASSY 35 kg 77 lbs CR271 06041 ...

Page 93: ...t pin 4 Remove castle nut 3 Remove flange 23 23 Flange 10 kg 22 lbs CR271 06042 23 4 3 9 Remove bolt 30 nut 31 CR271 06043 31 30 10 Remove propulsion motor 32 32 Propulsion motor 15 kg 33 lbs CR271 06044 32 Side plate SUB ASSY ...

Page 94: ...6 022 DRUMS 11 Remove bolt 7 CR271 06045 7 19 Remove three bolts 7 CR271 06046 7 12 Remove split pin 11 Remove castle nut 10 Remove washer 9 CR271 06047 9 10 11 ...

Page 95: ...6 023 DRUMS 13 Remove side plate SUB ASSY Side plate SUB ASSY 20 kg 44 lbs CR271 06048 ...

Page 96: ...ure using a work stool or the like 1 Stand drum 1 with its propulsion motor side facing up Drum 225 kg 496 lbs NOTE Propulsion motor side dimension a 320m 12 5 in CR271 06049 1 a 2 Apply a coat of gear oil to hub 22 at where bearing will be press fitted Drive in vibrator bearing 6 NOTE Take care not to damage the bearing when installing it CR271 06050 22 6 3 Reverse hub SUB ASSY and lower hub SUB ...

Page 97: ...olt 108 N m 80 lbf ft CR271 06052 Hub SUB ASSY 21 5 Install propulsion motor 16 to disc SUB ASSY 16 Propulsion motor 15 kg 33 lbs CR271 06053 16 Disc SUB ASSY 6 Secure propulsion motor 16 with fore bolts 17 nut 18 and washers 18 Nut 108 N m 80 lbf ft CR271 06054 18 17 16 ...

Page 98: ...6 026 DRUMS 7 Install sunk key 9 Install flange 20 Flange 5 kg 11 lbs CR271 06055 20 9 8 Secure flange 20 with castle nut 7 7 Nut 200 N m 147 5 lbf ft CR271 06056 20 7 Install split pin 8 CR271 06057 8 ...

Page 99: ...nting surface of hub Propulsion motor SUB ASSY 40 kg 88 lbs CR271 06058 10 Secure propulsion motor SUB ASSY with bolts 19 and washers CR271 06059 19 Secure propulsion motor SUB ASSY with four bolts 19 and washers CR271 06060 19 Propulsion motor SUB ASSY ...

Page 100: ...opulsion motor SUB ASSY Be careful because reversing the vibratory drum involves Risk Confirm that the surrounding area is safe and work in a natural unstained posture 11 Reverse drum SUB ASSY Drum SUB ASSY 275 kg 606 lbs CR271 06062 Drum SUB ASSY 12 Install eccentric shaft 5 Eccentric shaft 10 kg 22 lbs CR271 06063 5 ...

Page 101: ...71 06064 23 4 14 Apply a coat of gear oil to disc SUB ASSY at where bearing will be press fitted Drive in bearing 3 CR271 06065 Disc SUB ASSY 3 15 Reverse disc SUB ASSY Drum SUB ASSY 25 kg 55 lbs Apply a coat of gear oil to disc SUB ASSY at where bearing will be press fitted Drive in bearing 3 CR271 06066 Disc SUB ASSY 3 ...

Page 102: ...will be press fitted Lower disc SUB ASSY to boss SUB ASSY Disc SUB ASSY 30 kg 66 lbs CR271 06067 Disc SUB ASSY 23 17 Install retaining ring 30 NOTE Make sure that the retaining ring is fitted completely in its groove CR271 06068 30 18 Install cover hub 25 CR271 06069 25 ...

Page 103: ...our bolts 26 and spring washers 26 Bolt 59 N m 44 lbf ft CR271 06070 26 25 20 Lower disc SUB ASSY on mounting surface of vibratory drum slowly Disc SUB ASSY 40 kg 88 lbs CR271 06071 Disc SUB ASSY 21 Secure disc SUB ASSY with bolts 24 and washers CR271 06016 24 ...

Page 104: ...hers 24 Bolt 108 N m 80 lbf ft CR271 06017 24 Disc SUB ASSY 22 Drive spring pin into coupling 29 CR271 06072 Spring pin 29 23 Apply molybdenum based grease to splined portion of coupling 29 Fit coupling 29 to splined portion on eccentric shaft end CR271 06073 29 ...

Page 105: ...11 lbs CR271 06074 28 25 Secure vibrator motor 28 to cover with two bolts 27 spring washers and washers 27 Bolt 62 N m 46 lbf ft CR271 06075 27 26 Secure bracket 15 31 with nuts 14 32 spring washers and washers 15 31 Bracket 25 kg 55 lbs 14 32 Nut 157 N m 116 lbf ft CR271 06012 14 32 15 31 ...

Page 106: ...ork in an unstrained posture using a work stool or the like 1 Stand drum 1 with its propulsion motor side facing up Drum 225 kg 496 lbs NOTE Propulsion motor side dimension b 298 mm 11 7 in CR271 06076 1 b 2 Install propulsion motor 32 to side plate SUB ASSY Propulsion motor 15 kg 33 lbs CR271 06077 32 Side plate SUB ASSY 3 Secure propulsion motor 32 with four bolts 30 nuts 31 and washers 31 Nut 1...

Page 107: ... 4 Install sunk key 2 Install flange 23 23 Flange 10 kg 22 lbs CR271 06079 23 2 5 Secure flange 23 with castle nut 3 and washer 3 Castle Nut 200 N m 147 5 lbf ft CR271 06080 23 3 Install split pin 4 CR271 06081 4 ...

Page 108: ...e of drum Propulsion motor SUB ASSY 35 kg 77 lbs CR271 06082 7 Secure propulsion motor SUB ASSY with bolts 29 and washers CR271 06039 29 Secure propulsion motor SUB ASSY with six bolts 29 and washers 29 Bolt 108 N m 80 lbf ft CR271 06040 29 Propulsion motor SUB ASSY ...

Page 109: ...ASSY 9 Apply a coat of gear oil to side plate 18 at where bearing will be press fitted Drive in bearing 12 NOTE Take care not to damage the bearing when installing it CR271 06084 12 18 10 Reverse side plate SUB ASSY Side plate SUB ASSY 20 kg 44 lbs Install disc plate 19 Apply a coat of gear oil to side plate SUB ASSY at where bearing will be press fitted Drive in flange SUB ASSY CR271 06085 Flange...

Page 110: ... spacer 8 CR271 06086 Side plate SUB ASSY 8 12 Fill the grease Apply a coat of gear oil to side plate SUB ASSY at where bearing will be press fitted Drive in bearing 12 CR271 06087 12 Grease 13 Install washer 9 CR271 06088 9 ...

Page 111: ...ure washer with castle nut 10 and washers 10 Castle nut 106 N m 78 lbf ft CR271 06089 10 Washer Install split pin 11 CR271 06090 11 15 Install disc plate 19 Secure disc plate 19 with bolts 7 and washers CR271 06045 7 19 ...

Page 112: ...three bolts 7 and washers 7 Bolt 49 N m 36 lbf ft CR271 06091 7 19 16 Install control cable CR271 06092 Control cable 17 Lower disc brake SUB ASSY on mounting surface of drum Disc brake SUB ASSY 50 kg 110 lbs CR271 06093 Disc brake SUB ASSY ...

Page 113: ... 06094 13 Secure side plate SUB ASSY with six bolts 13 and washers 13 Bolt 108 N m 80 lbf ft CR271 06035 13 18 Secure bracket 6 33 with nuts 14 28 spring washers and washers 6 Bracket 30 kg 66 lbs 33 Bracket 20 kg 44 lbs 14 28 Nut 157 N m 116 lbf ft CR271 06033 28 14 33 6 ...

Page 114: ......

Page 115: ...PARKING BRAKE ...

Page 116: ......

Page 117: ...KE 1 1 Brake CR271 07001 2 1 3 4 5 6 7 8 9 11 12 13 10 14 1 Cover 8 Split pin 2 Bolt M8x20 9 Control cable 3 Parking brake 10 Brake ASSY 4 Bolt M8x20 11 Pin 5 Parking brake base ASSY 12 R pin 6 Bolt M8x20 13 Washer 7 Pin 14 Disc plate ...

Page 118: ......

Page 119: ...WATER SPRAY SYSTEM ...

Page 120: ......

Page 121: ......

Page 122: ...8 001 WATER SPRAY SYSTEM 1 WATER SPRAY SYSTEM 1 1 Water spray B B A A 1 2 3 4 5 6 7 8 9 10 Water spray tank 0563 75801 0 10190 F ...

Page 123: ...r spray pipe F Water spray pipe R Water spray diagram Cock R Tee CR271 08001 1 Cap 11 Cock R 2 Pipe F 12 Cock F 3 Hose Cock F Pipe F 13 Wing knob 4 Hose Tee Cock F 14 Bolt M6x16 5 Tee 15 Nut 6 Cap 16 Control lever ASSY 7 Hose Tee Cock R 17 Stand ASSY 8 Hose Tank Tee 18 Valve stand ASSY 9 Pipe R 19 Bolt M6x12 10 Hose Cock R Pipe R ...

Page 124: ......

Page 125: ...INSPECTION AND ADJUSTMENT ...

Page 126: ......

Page 127: ...an V belt or exhaust system parts while the engine is running may cause serious injury 1 2 Preparation for Inspection and Adjustment Prepare the necessary measuring instruments In addition particularly when measuring pressure values make sure to prepare the appropriate hoses adapters and a plug removal tool for the pressure reading port Make sure that the instruments to be used operate normally Wh...

Page 128: ...3 625 psi Start the engine and set throttle lever to Full Establish a condition in which machine propulsion load becomes maximum Pressure does not build up unless propulsion load is applied With propulsion load at maximum slowly move F R lever to the side to be measured Then read pressure indicated by pressure gauge After measuring promptly return F R lever to N Maximum circuit pressure high press...

Page 129: ...pped dirt is present disassemble and clean high pressure relief valve If pressure still deviates from maximum circuit pressure range after valve is disassembled and cleaned replace high pressure relief valve After inspection measure pressure again and check that pressure reaches maximum circuit pressure range N m Plug 78 N m 57 5 lbf ft NOTICE Carefully disassemble and reassemble after taking step...

Page 130: ... charge pressure gauge port 1 8 Attach pressure gauge with adapter ⓨ Adapter for ⓨ 7 16 20UNF Pressure gauge 0 to 5 MPa 0 to 725 psi Apply brake by parking brake lever Start the engine and set throttle lever to Full Then read pressure indicated by pressure gauge Standard charge relief valve setting 0 5 MPa 72 5 psi The number 1 8 appearing in above illustrations is consistent with lead line number...

Page 131: ...d other abnormalities If trapped dirt is present disassemble and clean charge pressure relief valve If pressure still deviates from standard charge relief valve setting range after valve is disassembled and cleaned replace charge pressure relief valve After inspection measure pressure again and check that pressure reaches standard charge relief valve setting range N m Plug 78 N m 57 5 lbf ft NOTIC...

Page 132: ...ent 50 5 C 122 9 F Disconnect hose 1 from line filter Attach pressure gauge through adapter ⓜ Adapter ⓜ G1 4 Pressure gauge 0 to 10 MPa 0 to 1 450 psi Confirm that F R lever is in N properly Start the engine and set throttle lever to Full Turn steering wheel to operate relief valve Then read pressure indicated by pressure gauge Standard maximum circuit pressure Orbitroll relief pressure charge rel...

Page 133: ...djustment plug 3 Adjustment plug turned clockwise Pressure rise Adjustment plug turned counterclockwise Pressure drop Pressure change rate 1 8 MPa turn 261 psi turn If there is no evidence of having loosened remove relief valve Check removed relief valve for trapped dirt and scratches on its seat If trapped dirt is present disassemble and clean relief valve If a scratch is found on seat replace re...

Page 134: ... through adapter ⓝ Adapter ⓝ G3 8 Pressure gauge 0 to 5 MPa 0 to 725 psi Start the engine and set throttle lever to FULL Establish a condition in which machine propulsion load becomes maximum Pressure does not build up unless propulsion load is applied With propulsion load at maximum measure pressure when F R lever is in N F and R respectively Pump case pressure 0 1 MPa 14 5 psi CR271 09008 1 n PG...

Page 135: ...through adapter ⓜ Adapter ⓜ G1 4 Pressure gauge 0 to 25 MPa 0 to 3 625 psi Start the engine and set throttle lever to FULL Establish a condition in which machine propulsion load becomes maximum Pressure does not build up unless propulsion load is applied With propulsion load at maximum measure pressure when F R lever is in N F and R respectively Motor case pressure 14 MPa 2 030 psi CR271 09009 1 m...

Page 136: ... below Make the adjustment after amply warming up engine Oil temperature during measurement 50 5 C 122 9 F Set throttle lever 1 to IDLE Attach control cable 2 to throttle lever 1 Attach control cable 2 to control lever 5 of control ASSY on the engine side Start the engine Loosen lock nut 3 Using stopper bolt IDLE 4 adjust so that standard minimum no load rotational speed is achieved Standard minim...

Page 137: ...firm that the engine speed is within standard range Standard minimum no load rotational speed 3 850 150 rpm Using lock nut 7 firmly secure stopper bolt 6 NOTICE If maximum no load rotational speed is not in standard range even when control lever 8 is against stopper 9 adjust control linkage or repair or replace them CR271 09012 1 2 6 7 FULL CR271 09013 2 8 9 ...

Page 138: ...lever does not move smoothly make an adjustment in accordance with procedure described below N positions of F R lever 1 are positioned by notches Set F R lever 1 N Attach control cable 2 to F R lever Specified dimension a 170 mm 6 7 in Attach control cable 2 to propulsion pump control lever 3 Specified dimension b 170 mm 6 7 in CR271 09014 1 2 N a CR271 09015 3 rc fc b ...

Page 139: ... to F R lever Using lock nut 4 firmly secure stopper bolt 5 Specified dimension fc 14 mm 0 55 in Loosen lock nut 7 Shift F R lever to R direction until propulsion pump control lever 3 moves specified dimension rc in reverse direction Contact stopper bolt 6 to F R lever Using lock nut 7 firmly secure stopper bolt 6 Specified dimension rc 14 mm 0 55 in CR271 09016 1 4 F 5 CR271 09017 1 6 R 7 ...

Page 140: ......

Page 141: ...TROUBLESHOOTING ...

Page 142: ......

Page 143: ...ay cause a serious accident When inspecting the engine make sure to exchange the appropriate cues and hand signal with the person at the operator station to avoid any accidents CAUTION Before inspecting inside of the engine compartment always stop the engine Contact with the fan V belt or exhaust system parts while the engine is running may cause serious injury 1 2 Important Information for Troubl...

Page 144: ...erating it Check the problem yourself 4 Identify the problem with either a mechanical hydraulic or electrical system source 5 Isolate the problem to a particular component or circuit 6 Eliminate the simplest or easiest to check possibilities first to prevent unnecessary disassembly of components 7 Following repair or replacement of any parts perform operational tests to verify that the problem has...

Page 145: ... internally Since connectors are not numbered be sure to affix alignment marks so that you can restore them to their original condition Before making a diagnosis check related connectors for faulty connections Check by disconnecting and reconnecting related connectors several times Before proceeding to the next step be sure to return the disconnected connectors to their original condition When dia...

Page 146: ... equipment A measuring resistance between terminals 1 and 3 1 2 3 3 4 2 5 1 2 3 1 2 3 1 GW750 2 10004 Equipment A Connector Harness Equipment A Ohmmeter tester Equipment B Main power source of equipment B Signal from equipment A Power to equipment A Ground of equipment A Inspection procedure Disconnect the connector of equipment A Connect the test probe to connector terminal 1 of equipment A and t...

Page 147: ...rness such as broken wire 10 Ω or higher measured value 1 3 Measuring resistance of grounding wire measuring resistance between terminal 5 of equipment B and ground 1 2 3 4 5 5 1 GW750 2 10006 Connector A Harness Ohmmeter tester Main power source of equipment B Equipment B Battery Equipment B Inspection procedure Disconnect the connector of equipment B Connect the test probe to connector terminal ...

Page 148: ...Power to equipment A Equipment B Equipment B Equipment A GW750 2 10007 Inspection procedure Connect the connectors of equipment A and that of equipment B Connect the test probe to connector terminal 3 of equipment A and the test probe to connector terminal 1 of equipment A and measure the voltage Note that reversing the connector terminals between the probes and changes the result of the measureme...

Page 149: ...s connected in position contact the tester probes to the terminals without disconnecting the connector The following methods are available Measurement using a test harness Prepare the test harness for the measurement Measurement from the backside of connector Insert a wire from the backside of the connector Measurement on a lead cable Remove the bundling tape from the harness to separate each cabl...

Page 150: ...on procedure Disconnect the connector of equipment A and connect the test harness Connect the test probe to connector terminal 1 harness side of equipment A and the test probe to connector terminal 1 equipment side of equipment A and measure the current Note that reversing the connector terminals between the probes and changes the result of the measurement Be sure to connect the probe to the power...

Page 151: ...of burning or of an odor investigate as described follows 2 3 How to find cause of failure when fuse blown is reproduced Turn the starter switch OFF and remove the connector from the load valve pump Referring to the circuit diagram remove electrical parts that are connected to the circuit such as relays timers and diodes Turn the starter switch ON and see whether the conditions can be reproduced f...

Page 152: ...dentify the location section to which 24 V or 12 V reaches Then replace the harness or take other action 5 Solenoid valve inspection Check ON OFF operation by sound Conduct without running the engine If you run the engine you cannot hear the sound of operation Sound heard The electrical system is normal No sound heard Check with a tester Continuity Turn the starter switch OFF temporarily disconnec...

Page 153: ......

Page 154: ...17A S B REGULATOR RECTIFIER G 25A 15A NC NO f e a c b 15A AC 30 17 NC NO f e a c b 2 E E E E 12 6 4 HOUR METER HORN HORN BUTTON HORN RELAY VIBRATOR SOLENOID F R LEVER VIBRATION SWITCH NO 5 1 3 2 SOL 3 2 START 1 ON 0 OFF E AV20 B AV20 R BATTERY 12V45AH BUCKUP BUZZER 55B24R SPARK PLUG IGNITION COIL ENGINE ACCESSORY ENGINE OIL PRESSURE PILOT LAMP INTERLOCK RELAY ENGINE ACCESSORY 9 BUCKUP BUZZER SWITC...

Page 155: ...START measure voltage between starter motor terminal S and chassis ground Standard voltage 12 V or more If starter motor does not run even though above items 1 and 2 are OK starter motor is faulty Replace starter motor 4 Interlock Switch When starter switch is ON measure voltage between interlock switch terminal 2 and chassis ground There is no electricity in normal condition If electricity flows ...

Page 156: ...17A S B REGULATOR RECTIFIER G 25A 15A NC NO f e a c b 15A AC 30 17 NC NO f e a c b 2 E E E E 12 6 4 HOUR METER HORN HORN BUTTON HORN RELAY VIBRATOR SOLENOID F R LEVER VIBRATION SWITCH NO 5 1 3 2 SOL 3 2 START 1 ON 0 OFF E AV20 B AV20 R BATTERY 12V45AH BUCKUP BUZZER 55B24R SPARK PLUG IGNITION COIL ENGINE ACCESSORY ENGINE OIL PRESSURE PILOT LAMP INTERLOCK RELAY ENGINE ACCESSORY 9 BUCKUP BUZZER SWITC...

Page 157: ...arter switch is ON measure voltage between fuel cut solenoid terminal wire marked FUL CUT and chassis ground Standard voltage 12 V or more If voltage is OK and engine will not start fuel cut solenoid is faulty Replace fuel cut solenoid 3 Engine Stop Relay 1 When starter switch is ON measure voltage between engine stop relay terminal b and chassis ground Standard voltage 12 V or more 2 When starter...

Page 158: ...17A S B REGULATOR RECTIFIER G 25A 15A NC NO f e a c b 15A AC 30 17 NC NO f e a c b 2 E E E E 12 6 4 HOUR METER HORN HORN BUTTON HORN RELAY VIBRATOR SOLENOID F R LEVER VIBRATION SWITCH NO 5 1 3 2 SOL 3 2 START 1 ON 0 OFF E AV20 B AV20 R BATTERY 12V45AH BUCKUP BUZZER 55B24R SPARK PLUG IGNITION COIL ENGINE ACCESSORY ENGINE OIL PRESSURE PILOT LAMP INTERLOCK RELAY ENGINE ACCESSORY 9 BUCKUP BUZZER SWITC...

Page 159: ...s not at N applied Reference Fig 2 2 1 Check point Check Cause Action 1 Interlock Switch When starter switch is OFF and F R lever is N check continuity between interlock switch terminal 1 and terminal 2 There is no continuity in normal condition If there is continuity interlock switch is faulty Replace interlock switch 2 Interlock Relay 1 When starter switch is ON and F R lever is F or R measure v...

Page 160: ...17A S B REGULATOR RECTIFIER G 25A 15A NC NO f e a c b 15A AC 30 17 NC NO f e a c b 2 E E E E 12 6 4 HOUR METER HORN HORN BUTTON HORN RELAY VIBRATOR SOLENOID F R LEVER VIBRATION SWITCH NO 5 1 3 2 SOL 3 2 START 1 ON 0 OFF E AV20 B AV20 R BATTERY 12V45AH BUCKUP BUZZER 55B24R SPARK PLUG IGNITION COIL ENGINE ACCESSORY ENGINE OIL PRESSURE PILOT LAMP INTERLOCK RELAY ENGINE ACCESSORY 9 BUCKUP BUZZER SWITC...

Page 161: ...ative terminal to horn terminal wire E side If horn does not sound horn is faulty Replace horn 2 Horn Relay 1 When starter switch is ON and horn switch is pressed measure voltage between horn relay terminal 2 and chassis ground Standard voltage 12 V or more 2 When starter switch is ON and horn switch is pressed measure voltage between horn relay terminal 5 and chassis ground Standard voltage 12 V ...

Page 162: ...17A S B REGULATOR RECTIFIER G 25A 15A NC NO f e a c b 15A AC 30 17 NC NO f e a c b 2 E E E E 12 6 4 HOUR METER HORN HORN BUTTON HORN RELAY VIBRATOR SOLENOID F R LEVER VIBRATION SWITCH NO 5 1 3 2 SOL 3 2 START 1 ON 0 OFF E AV20 B AV20 R BATTERY 12V45AH BUCKUP BUZZER 55B24R SPARK PLUG IGNITION COIL ENGINE ACCESSORY ENGINE OIL PRESSURE PILOT LAMP INTERLOCK RELAY ENGINE ACCESSORY 9 BUCKUP BUZZER SWITC...

Page 163: ...itch is ON measure voltage between F R lever vibration switch terminal wire marked VIB SW1 1 and chassis ground Standard voltage 12 V or more 2 When starter switch is ON and F R lever vibration switch is pressed once measure voltage between F R lever vibration switch terminal wire marked VIB SW1 2 and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG F R lever vib...

Page 164: ...ipes and components in order to prevent foreign substances from entering Never leave the openings exposed or put a shop cloth into them There is the danger of foreign substances entering or of leaking oil causing environmental contamination Do not dispose of waste oil on site Either deliver it to the customer and request disposal or take it back with you and dispose of it 4 Prevent entry of foreig...

Page 165: ...on filter or replace it if necessary 6 Propulsion Circuit Pressure Circuit does not obtain required pressure because setting pressure of high pressure relief is low Measure propulsion circuit pressure If low inspect high pressure relief valve or replace it if necessary 7 Propulsion Motor Propulsion circuit pressure is not held in propulsion motor case If pressure in propulsion motor case is not wi...

Page 166: ...ump Flow rate of charge pump decreases as well as charge pressure decreases due to clogged filter Clean suction filter or replace it if necessary 5 Propulsion Motor Propulsion motor inlet pressure is low Measure propulsion motor inlet pressure If low inspect high pressure relief valve or replace it if necessary Propulsion circuit pressure is not held in propulsion motor case If pressure in propuls...

Page 167: ...il in circuit to rise Measure propulsion circuit pressure If high decrease propulsion load 3 Suction Filter for Charge Pump Load of charge pump increases due to clogged filter causing temperature of hydraulic oil in circuit to rise Clean suction filter or replace it if necessary 3 2 6 Abnormal noise from propulsion system Check point Cause Check Action 1 Axle Bearings Axle bearings supporting fron...

Page 168: ... Clean hydraulic oil filter or replace it if necessary 4 Steering Cylinder Cylinder thrust decreases due to internal leakage of steering cylinder Repair steering cylinder or replace it if necessary 5 Suction Filter for Steering Vibrator Charge Pump Charge pump discharge rate decreases due to clogged filter Clean suction filter or replace it if necessary 6 Steering Vibrator Charge Pump Discharging ...

Page 169: ...easure steering circuit pressure If high decrease steering load 3 Suction Filter for Steering Vibrator Charge Pump Load of steering pump increases due to clogged filter causing temperature of hydraulic oil in circuit to rise Clean suction filter or replace it if necessary 3 3 5 Abnormal noise from steering system Check point Cause Check Action 1 O i l L e v e l o f Hydraulic Oil Tank Pump suction ...

Page 170: ...Printed in Japan 2013 11 00 0 C D 0404 99053 0 32048 0 SAKAI HEAVY INDUSTRIES LTD Head office Seiwa Bldg 4 8 Shibadaimon 1 chome Minato ku Tokyo Japan Telephone 81 3 3434 3401 Global Service Division 2500 Takayanagi Kuki shi Saitama Japan Telephone 81 480 52 1111 ...

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