Sakai R2-4 Shop Manual Download Page 49

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3-005

ENGINE AND CONTROLS

3. PUMP MOUNT

3-1. Pump Mount

0634-36815-0-11241-B

VIEW A

SECTION B-B

(1) Bolt

: M10×30 P=1.25

(5) Bolt

: M14×40

(2) Flange

(6) Pump

(3) Hub

(7) Bolt

: M10×25 P=1.25

(4) Housing

(8) Bolt

: M12×35

N•m

(1) Bolt M10×30 P=1.25 : 49 N·m ( 36 lbf·ft )

(5) Bolt M14×40

: 167 N·m ( 123 lbf·ft )

(7) Bolt M10×25 P=1.25 : 69 N·m ( 51 lbf·ft )

(8) Bolt M12×35

: 86 N·m ( 63 lbf·ft )

Summary of Contents for R2-4

Page 1: ...R2 4 SHOP MANUAL 3498 6634A 0...

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Page 3: ...e 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 m...

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Page 5: ...tarting 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 R2 4 2 001 1 2 R2 4 ROPS 2 004 1 3 R2H 4 2 007...

Page 6: ...lsion Hydraulic Piping 4 004 2 1 1 Propulsion hydraulic piping 1 4 004 2 1 2 Propulsion hydraulic piping 2 4 005 2 1 3 Propulsion hydraulic piping 3 4 006 2 1 4 Propulsion hydraulic piping R 4 007 2 2...

Page 7: ...6 Floor Board Harness 5 016 4 7 Engine Harness 5 018 4 8 Starter Switch Harness 5 019 4 9 Control Switch Harness 5 020 4 10 Lighting Switch Harness 5 021 4 11 Hazard Switch Harness 5 022 4 12 F R Lev...

Page 8: ...9 003 3 MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT PRESSURE 3 1 Measurement 9 004 3 2 Adjustment 9 005 4 MEASUREMENT OF PROPULSION SERVO CIRCUIT PRESSURE 4 1 Measurement 9 006 5 MEASUREME...

Page 9: ...2 2 Table of the diagnostic trouble code DTC 10 012 2 3 Engine 10 019 2 3 1 Engine will not start Starter motor does not run 1 2 10 019 2 3 1 Engine will not start Starter motor does not run 2 2 10 02...

Page 10: ...3 Fuel meter is abnormal 10 055 2 6 14 Charge warning lamp remains ON 10 057 2 6 15 Water spray indicator lamp does not light 10 057 2 6 16 Flood lamp indicator lamp does not light 10 059 2 6 17 Side...

Page 11: ...071 3 3 1 Steering wheel is hard to turn 10 071 3 3 2 Steering response is slow 10 071 3 3 3 Steering wheel backlash or play is large 10 072 3 3 4 Steering system is overheating 10 072 3 3 5 Abnormal...

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Page 13: ...SAFETY...

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Page 15: ...achine 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...

Page 16: ...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 spec...

Page 17: ...eadable 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 t...

Page 18: ...o 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 ra...

Page 19: ...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...

Page 20: ...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 corros...

Page 21: ...ke 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 o...

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Page 23: ...SPECIFICATIONS...

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Page 26: ...s Load on front axle with operating weight 4 850 kg 10 690 lbs Load on rear axle with operating weight 4 950 kg 10 915 lbs Dimensions Overall length 5 020 mm 198 in Overall width 2 100 mm 83 in Overal...

Page 27: ...ear pressure Front drum Operating weight 432 N cm 245 lbf in Rear drum Operating weight 441 N cm 250 lbf in Dynamic linear pressure Front drum Operating weight Low amplitude N A N cm N A lbf in High a...

Page 28: ...er forced circulation Cooling fan type Inhale Electrical system Alternator 12 V 90 A Starter 12 V 3 0 kW Battery 12 V 72 Ah CCA750 1 pc 12 V Dry weight 311 kg 686 lbs Drive system Transmission Type Hy...

Page 29: ...nt axle with operating weight 5 060 kg 11 155 lbs Load on rear axle with operating weight 5 000 kg 11 025 lbs Dimensions Overall length 5 020 mm 198 in Overall width 2 100 mm 83 in Overall height with...

Page 30: ...pressure Front drum Operating weight 451 N cm 260 lbf in Rear drum Operating weight 445 N cm 255 lbf in Dynamic linear pressure Front drum Operating weight Low amplitude N A N cm N A lbf in High ampl...

Page 31: ...water forced circulation Cooling fan type Inhale Electrical system Alternator 12 V 90 A Starter 12 V 3 0 kW Battery 12 V 72 Ah CCA750 1 pc 12 V Dry weight 311 kg 686 lbs Drive system Transmission Type...

Page 32: ...d on front axle with operating weight 6 760 kg 14 905 lbs Load on rear axle with operating weight 6 940 kg 15 300 lbs Dimensions Overall length 5 020 mm 198 in Overall width 2 100 mm 83 in Overall hei...

Page 33: ...c linear pressure Front drum Operating weight 602 N cm 345 lbf in Rear drum Operating weight 618 N cm 355 lbf in Dynamic linear pressure Front drum Operating weight Low amplitude N A N cm N A lbf in H...

Page 34: ...forced circulation Cooling fan type Inhale Electrical system Alternator 12 V 90 A Starter 12 V 3 0 kW Battery 12 V 72 Ah CCA750 1 pc 12 V Dry weight 311 kg 686 lbs Drive system Transmission Type Hydr...

Page 35: ...lbs Load on front axle with operating weight 7 010 kg 15 455 lbs Load on rear axle with operating weight 7 030 kg 15 500 lbs Dimensions Overall length 5 020 mm 198 in Overall width 2 100 mm 83 in Over...

Page 36: ...atic linear pressure Front drum Operating weight 625 N cm 355 lbf in Rear drum Operating weight 626 N cm 355 lbf in Dynamic linear pressure Front drum Operating weight Low amplitude N A N cm N A lbf i...

Page 37: ...irculation Cooling fan type Inhale Electrical system Alternator 12 V 90 A Starter 12 V 3 0 kW Battery 12 V 72 Ah CCA750 1 pc 12 V Dry weight 311 kg 686 lbs Drive system Transmission Type Hydrostatic S...

Page 38: ...t 0 13 to 0 17 mm 0 005 to 0 007 in Compression pressure 3 92 MPa 569 psi 250 min 1 2 2 Propulsion Item Standard value Remarks Travel speed Forward reverse 1st 0 to 8 km h 0 to 5 0 mph 2nd 0 to 16 km...

Page 39: ...akes Item Standard value Remarks Clearance between brake pedal and floorboard as released 120 mm 4 7 in Note 1 See dimensions R2H 2 02001 Note 1 Note 2 Clearance between brake pedal and floorboard whe...

Page 40: ...VI 110 ISO 3448 Grease Lithium type extreme pressure grease NLGI 2 Fuel Diesel oil ASTM D975 2D 3 2 Recommended Lubricants Lubricant Oil company Engine oil Gear oil API GL 5 Hydraulic oil ISO VG 46 Gr...

Page 41: ...3 253 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 1...

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Page 43: ...ENGINE AND CONTROLS...

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Page 45: ...2 Bracket 8 Bolt M12 40 P 1 25 14 Nut M12 P 1 25 3 Bolt M12 40 P 1 25 9 Stopper 15 Stopper 4 Bolt M16 130 10 Bolt M12 45 16 Nut M12 P 1 25 5 Plate 11 Nut M12 17 Damper 6 Damper 12 Bracket N m 3 Bolt M...

Page 46: ...tial pressure sensor 13 Oil drain plug 24 Flywheel 3 EGR pipe 14 Oil level gauge 25 EGR cooler 4 EGR valve 15 Oil filter cartridge 26 Starter motor 5 Air intake throttle 16 Water drain plug 27 Oil pan...

Page 47: ...9 10 8 7 11 12 13 14 1 4 5 6 Apply grease IDEL FULL 1 Throttle lever 8 Bush Apply grease 2 Shaft 9 Washer Apply grease 3 Washer 10 Bush Apply grease 4 Coned disc spring Do not apply grease 11 Lock nu...

Page 48: ...N R C 1 F R lever right 8 Lock nut M8 15 Lock nut M12 2 Shaft 9 Stopper bolt forward M8 25 16 Spring Fill grease 3 Rod end 10 Lock nut M8 17 Steel ball 4 F R lever left 11 Backup buzzer switch 18 Hold...

Page 49: ...6 5 4 7 8 3 2 1 VIEW A SECTION B B 1 Bolt M10 30 P 1 25 5 Bolt M14 40 2 Flange 6 Pump 3 Hub 7 Bolt M10 25 P 1 25 4 Housing 8 Bolt M12 35 N m 1 Bolt M10 30 P 1 25 49 N m 36 lbf ft 5 Bolt M14 40 167 N m...

Page 50: ...5 86 N m 63 lbf ft Secure flange 2 to engine flywheel with eight bolts 1 and spring washers and washers N m 1 Bolt M10 30 P 1 25 49 N m 36 lbf ft Secure housing 4 to engine flywheel housing with twelv...

Page 51: ...HYDRAULIC SYSTEMS...

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Page 54: ...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 indicate...

Page 55: ...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 tio...

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Page 57: ...opulsion pump Valve Orbitrol Suction filter Valve Steering cylinder Oil cooler Propulsion pump R Drum R Drum F R Bypass valve Steering charge pump Propulsion motor F R Drum F L Propulsion motor F L 55...

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Page 59: ...e PB2 RB PA2 RA Propulsion motor F L Propulsion pump Bypass valve Hose PB1 MR1 PA3 BV1 BV2 To propulsion hydraulic piping R The letters and numbers in the figure such as PB1 and MR1 show each port Arr...

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Page 61: ...ed change solenoid valve Propulsion pump neutral solenoid valve VSC VND VNC PNC PD1 T3 T1 BB2 BPD BCS BB1 BT1 BCO SECTION C C DETAIL B DETAIL A CS VDR VPB VCP PND RS RD RP CO E D A B C C E Oil cooler...

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Page 63: ...E E VIEW D MLV MSL PDR PD3 MRP MPL MRV The letters and numbers in the figure such as VSC and MLV show each port Arrow symbols show the hose connection and the direction of the flow of the oil Hose VS...

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Page 65: ...RA Hose RMD RD RP RMP Hose RS RMS Hose RB RMB Propulsion motor R The letters and numbers in the figure such as RMB and RB show each port Arrow symbols show the hose connection and the direction of th...

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Page 68: ...draulic pump assembly propulsion steering charge R2 4 04001 16 2 cc rev 24 9 cc rev 1 3 1 5 1 14 1 13 1 12 1 11 1 15 2 1 16 2 3 2 2 2 1 1 8 1 7 1 9 1 10 1 6 1 5 2 1 1 1 2 1 3 1 1 4 1 2 1 1 1 14 B NA 1...

Page 69: ...18UNF 1 11 Charge supply port PCS 1 5 16 12UN 1 12 Drain port PD3 1 1 16 12UN 1 13 Drain port PD2 1 1 16 12UN 1 14 Port A Forward PA SAE 1 1 15 Multi function valve Port B 1 16 Multi function valve Po...

Page 70: ...ing brake pilot port MRP G1 4 10 Shift valve assembly 4 Drain port MLD G1 2 11 Motor 5 Port B2 MLB MRB G1 2 12 Reduction gear 6 Port A2 ML2 MR2 G1 2 13 Plug PF 3 8 7 Drain port MRD G1 2 Motor specific...

Page 71: ...linder block kit 12 1 Floating seal kit 11 2 Roller bearing 12 2 Angular bearing 11 3 Oil seal 12 3 Shaft B 11 4 Shaft 12 4 Planetary gear B 11 5 Control piston 12 5 Needle roller 11 6 Swash plate ass...

Page 72: ...t For port B G1 4 10 Reduction gear 5 High pressure gauge port For port A G1 4 11 Plug 7 8 14UNF 6 Parking brake pilot port RMP G1 4 12 Charge pressure gauge port G1 8 Motor specifications Displacemen...

Page 73: ...n gear 9 1 Cylinder block kit 10 1 Floating seal kit 9 2 Control piston 10 2 Angular bearing 9 3 Bearing 10 3 Planetary gear 2nd 9 4 Oil seal 10 4 Needle roller 9 5 Shaft 10 5 Carrier 9 6 Swash plate...

Page 74: ...8 9 10 1 Parking brake solenoid valve 6 Port P VCP G1 4 2 Speed change solenoid valve 7 Port A VPB G1 4 3 Propulsion pump neutral solenoid valve 8 Port D VND G1 4 4 Block 9 Port C VNC G1 4 5 Port B V...

Page 75: ...15 HYDRAULIC SYSTEMS 2 2 5 Block A R2 4 04005 A 1 3 4 5 2 SECTION A A A 1 To propulsion motor F L port A1 PA1 G3 4 2 Body 3 To pipe PA2 G3 4 4 To bypass valve PA3 G3 8 5 From propulsion pump port A 24...

Page 76: ...16 HYDRAULIC SYSTEMS 2 2 6 Block B R2 4 04006 A 1 3 4 5 A SECTION A A 2 1 To propulsion motor F R port A1 PB1 G3 4 2 Body 3 To pipe PB2 G3 4 4 To bypass valve PB3 G3 8 5 From propulsion pump port B 24...

Page 77: ...teering cylinder T2 Hose AD4 SR Propulsion pump Hydraulic oil tank Hose AD3 SL SR SL A A SECTION A A SCS SC2 SC1 The letters and numbers in the figure such as AD4 and SR show each port Arrow symbols s...

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Page 79: ...ering Wheel 0634 32802 0 20337 A 1 7 2 3 6 4 5 1 Column shaft 5 Nut M12 P 1 25 2 Steering wheel 6 Column shaft 3 Nut M12 P 1 25 7 Roller chain 4 Steering wheel N m 3 Nut M12 P 1 25 64 N m 47 lbf ft 5...

Page 80: ...2 4 04002 1 3 4 2 1 2 4 5 3 Hydraulic circuit diagram 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 Displacement 277 cm3 rev 16 9 cu...

Page 81: ...03 4 3 5 6 1 2 5 6 4 1 Hydraulic circuit diagram 1 Port B G3 4 2 Block 3 Solenoid valve 4 Port A G3 4 5 Port T VT G3 4 6 Port P VP G3 4 Specifications Maximum flow 75 L min 19 8 gal min Maximum pressu...

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Page 83: ...ELECTRICAL SYSTEM...

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Page 85: ...50 Corrugate 70 GB 100 CB104 58X 2F 200 13 770 63 Corrugate 10 Brw 9 GB 63 LY 38 SWP 4 Mark S Starter relay harness P 5 017 J P 5 005 BrR GL Fuel sensor Wire color Reference page Marking Reference pa...

Page 86: ...ripe GY Green Yellow stripe GB Green Black stripe GL Green Blue stripe Gy Gr Gray GyR Gray Red stripe Y Yellow YR Yellow Red stripe YB Yellow Black stripe YG Yellow Green stripe YL Yellow Blue stripe...

Page 87: ...P LAMP ENGINE WARNING LAMP 3 2 1 f c a b e ECU MAIN RELAY GND2 SIG2 V2 GND1 SIG1 V1 GND 12V CAN L CAN H CAN SERVICE TOOL FUEL PUMP GLOW HEATER GLOW RELAY STARTER RELAY 87 85 86 30 BATTERY RELAY E BR N...

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Page 89: ...Flood lamp F L RG BrW Flood lamp R L B GR GY RL RY B BR W Combination lamp R L P 5 014 Frame harness R P 5 030 Combination lamp harness F R B GB RL Combination lamp F R B 2 G L WB Air flow sensor AFS...

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Page 91: ...ay mode select switch Water spray timer B LB LR LY Water spray harness P 5 028 B RB RW 2 RY Lighting LO HI relay LIG B BW GY WB Stop lamp relay BRA B G Gr Flasher unit FLA P Horn switch L B LB LW LY W...

Page 92: ...orrugate 600 Corrugate 100 Corrugate 200 Corrugate 500 Corrugate 300 Corrugate 200 Corrugate 200 Corrugate 400 Corrugate 300 Corrugate 003 WB 10 13 1 250 GY 16 1 25RW 21 LgR 24 1 25RB 42 1 25BrB 407 B...

Page 93: ...STR 2 WB 3WB 15 A E LOA MAI Fuse 5A 5 2 8 5W 2 GLO H 2 BR 3 MAI 1 2 W 2 STR Fuse 5A 2 GW 2 GLO 1 1 2Y 2 ECA Fuse 5A 2 GrR 2 ECA 1 1 L 2 ECA 1 1 Gr 2 ECA 1 1 WB 2 ECA 1 1 WR 2 ECA 1 1 GB 2 ECA 1 1 GW...

Page 94: ...7 1 25L1 25Br 55 SWP 2M 100 Tape SWP 2F CAP 50 Tape ENG P 5 026 003 WB 018 Y 020 L 021 G P 5 028 ENGINE WARNING lamp harness Water spray harness 34 LY 2 B 41 LB O 50 Tape 0 5R 163 0 5W 165 164 0 5B 0...

Page 95: ...1 1 GY 2 1 BRA 2262 1 LY 2 O WAT 2 Lg 2 H LIG 4643 2 WY 3 9 2 INT COM 3 RG 3RG 4 2 FLO Combination meter 12F 2 YL 2 S P Combination meter 16M 2 GB 5 2 G Combination meter 12F Turn signal switch 3 LB 3...

Page 96: ...59 2 CAN Machine side connector Engine side connector CAN Service tool 174257 2 100 Corrugate CAN 157 Br 2 B 158 BrW 65 Y ECU 230 Corrugate 230 Corrugate G R W W G R V10 V70 E10 E70 G 100 R 111 W W G...

Page 97: ...E73 1 0 5W 2 1 ECU E54 1 0 5R 2 1 ECU E53 1 0 5R 3 1 ECU E72 E75 2 G 4 2 ECU E14 E34 2 W 4 2 ECU E18 E38 2 R 3 1 ECU E15 E35 2 R 3 1 ECU E20 E40 2 G 3 1 ECU E19 E39 2 W 3 1 ECU E16 E36 2 RB 2 1 ECU V...

Page 98: ...0 150 150 150 5W 5W 8WR 8WR 14 1 50 48 64 63 5BR 5R 5WL 5WL 51 52 100 300 150 75A gray 65A black Fusible link 65A black 65A black Horn Battery relay 63 LA308 14 LA308 1 LA308 21 LA104 8WR 200 5W 180 L...

Page 99: ...sible link 75A 1 25RW 3 A Head lamp F L F R LgR 2 A Battery relay BR 1 25RB 3 A Head lamp F L F R 1 25BrB 3 A NEU PAR NO SIZE COLOR CONTACT POINTS CONNECTION 5W 2 B Fusible link 65A 8WR 2 C Fusible li...

Page 100: ...BrW 100 1 25RG 100 Flood lamp R L 38 400 650 F G 50 RY GR 45 371 GY 33 31 1 25RG 2 38 BrW RL B 26 40 GB 3LW 19 40 GB 31 RY 45 RL 33 GY 2 B 26 GR 31 RY 45 RL 33 GY 2 B 58X 1F Corrugate 10 Corrugate 10...

Page 101: ...er spray pump GR 2 F Combination lamp R L RY 3 F Combination lamp R L R R GY 3 F Combination lamp R L R R NO SIZE COLOR CONTACT POINTS CONNECTION 1 25RG 3 F Flood lamp R L R R GB 2 F Combination lamp...

Page 102: ...45 CB104 300 45 CB104 RL 50 2 5 0 1 5 0 1500 1 25RG 50 1000 50 500 1300 1 25RG 50 38 CB104 RL 100 38 CB104 AFS 0 5WB 003 0 5G 0 5L 213 0 5B 211 212 25 YB 26 GR 38 40 45 RL 2 1 25RG GB 1 25B 211 0 5B...

Page 103: ...D Combination lamp harness F L F R Fuel gauge unit YB 2 D Fuel gauge unit GR 2 D Combination lamp harness F L 1 25RG 3 D Flood lamp F L F R GB 2 D Combination lamp harness F R RL 4 D Combination lamp...

Page 104: ...200 5W 50 010 STA Tape 50 AV15 B 100 B 49 LA408 B PB104 S 150 ALT 49 LA406 B 100 Tape 50 6189 0443 58Y 2M Alternator Glow plug Thermo unit Starter motor 3RW 001 010 5W 001 3RW Corrugate 7 Corrugate 7...

Page 105: ...ness 2 P 5 008 48 23 LCT RL 1A 5W 50 C BR ACC B 21 LgR 4 R 120 Starter switch STA 50 LCR RL 1B LA205 C LA105 ACC LA305 B LA105 BR 3BR 50 3BR 80 R 80 LgR 80 5W 80 SWP 2M Corrugate 10 48 21 23 4 NO SIZE...

Page 106: ...ing brake switch Speed change switch 10 22 39 22 2 88 BrR 100 B 100 WB 100 YL 100 1 25WB 100 1 25O 100 1 1 Corrugate 10 NO SIZE COLOR CONTACT POINTS CONNECTION B 2 S P Parking brake switch 5 1 25O 2 S...

Page 107: ...s 2 P 5 008 SWP 3F 50 50 2 1 5 4 3 1 Lighting switch Flood lamp switch 67 66 36 44 45 44 WG 100 RL 100 WG 100 Lg 100 GR 100 Sb 100 Lg WG RL 45 44 36 Corrugate 10 NO SIZE COLOR CONTACT POINTS CONNECTIO...

Page 108: ...G 6 GR RY GB RY 26 31 40 31 6 G Main harness 2 P 5 008 Hazard switch G 100 50 5 4 2 1 26 6 40 6 G 200 GB 200 G 200 GR 200 Corrugate 10 SWP 6M Bypass NO SIZE COLOR CONTACT POINTS CONNECTION G 4 G 2 Ha...

Page 109: ...34 09027 0 40466 A NO LE104 COM LE104 F R lever switch CB104 CA104 Main harness 2 P 5 008 60 Tape BW 20 WL 20 BW 30 WL 20 3 3 30 37 30 NO SIZE COLOR CONTACT POINTS CONNECTION BW 2 F R lever switch NO...

Page 110: ...03 CB104 not in use 503 W 40 W 60 NO LE104 COM LE104 Backup buzzer switch CB104 CA104 Main harness 2 P 5 008 Tape 60 RY 40 WB 40 RY 30 WB 50 31 31 22 22 NO SIZE COLOR CONTACT POINTS CONNECTION WB 2 Ba...

Page 111: ...09028 0 40467 0 Foot brake switch Main harness 2 P 5 008 60 Tape 22 17 22 17 NO LE104 COM LE104 CB104 CA104 LgB 20 WB 20 LgB 30 WB 60 60 NO SIZE COLOR CONTACT POINTS CONNECTION LgB 2 Footbrake switch...

Page 112: ...B104 020 CA104 018 CA104 O H E S E W 50 Tape 50 Tape 50 Tape 150 G 50 ENGINE WARNING lamp L G Y 018 WB OVER HEAT lamp Main harness 2 P 5 008 021 003 020 ENGINE STOP lamp ENG 003 CB104 Y 50 L 50 WB 50...

Page 113: ...R1 25 3 R1 25 3 R1 25 3 231 X2 003 X1 230 X2 232 2 D S DAL DRL 50 Tape 50 Tape 50 Tape 100 Corrugate 7 WB 50 L 50 DPF request lamp DPF switch SWP 6F Main harness 2 P 5 008 DPF 003 1 G 50 W 50 WB 50 W...

Page 114: ...34 41 LR 100 LY 100 LB 100 LB 100 50 SWP 3F 27 2 LB 34 LR LY B 41 Corrugate 7 Water spray timer P 5 008 Main harness 2 NO SIZE COLOR CONTACT POINTS CONNECTION B 2 O Water spray timer LR 2 Water spray...

Page 115: ...04 B 30 CA104 Combination lamp F L 2 CB104 CB104 Turn signal lamp F L Side marker lamp F L Ground 400 RL 50 GR 70 45 26 Floor board harness P 5 016 NO SIZE COLOR CONTACT POINTS CONNECTION B 2 Combinat...

Page 116: ...P 5 016 CB104 CA104 CA104 2 45 40 B 90 RL 70 GB 50 2 CA104 B 30 CB104 CB104 400 RL 50 GB 70 45 40 Turn signal lamp F R Side marker lamp F R Ground NO SIZE COLOR CONTACT POINTS CONNECTION B 2 Combinat...

Page 117: ...3 2Br Vinyl tube 150 Fuse 10A 102 10A 103 2W 50 2Br 50 2Br 100 2W 500 Vinyl tube Vinyl tube Vinyl tube 2 Fuse box LCT RL 1A 102 Sub power DT04 2P E005 LA208 Ground 2B 600 2 NO SIZE COLOR CONTACT POINT...

Page 118: ...relay Starter switch BR WR BW WR WR L Option WL WY WR WB WY WR WG WL WB BY BY WY F R lever switch WB 9 8 7 13 6 5 4 3 12 2 1 11 10 14 Sub power Backup buzzer switch Speed change switch Parking brake s...

Page 119: ...LCD CPU EEPROM CAN interface Tachometer Fuel meter Temperature meter Hour meter Output interface Output interface Illumination LED Water spray indicator Liquid spray indicator Flood lamp indicator Vi...

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Page 121: ...DRUM...

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Page 123: ...nces 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 s...

Page 124: ...lant 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...

Page 125: ...M 2 1 Drum F R2 4 0634 24803 0 11400 0 1 6 5 4 3 2 1 Drum F R 3 Bolt M16 50 5 Propulsion motor F R 2 Drum F L 4 Propulsion motor F L 6 Bolt M16 50 N m 3 Bolt M16 50 265 N m 195 lbf ft 6 Bolt M16 50 26...

Page 126: ...R2H 4 0634 24804 0 11502 0 1 8 7 6 5 4 3 2 1 Drum F R 4 Propulsion motor F L 7 Propulsion motor F R 2 Drum F L 5 Plug 8 Bolt M16 50 3 Bolt M16 50 6 Plug N m 3 Bolt M16 50 265 N m 195 lbf ft 8 Bolt M16...

Page 127: ...olt M16 70 7 Retaining ring 12 Propulsion motor R 3 Ball bearing 8 Case 13 Bolt M20 60 4 Bolt M16 60 9 Flange 14 Bolt M20 70 5 Bolt M12 40 10 Plate N m 2 Bolt M16 70 265 N m 195 lbf ft 4 Bolt M16 60 2...

Page 128: ...otor R 2 Plug 7 Retaining ring 12 Bolt M20 60 3 Ball bearing 8 Case 13 Bolt M20 70 4 Bolt M16 60 9 Plate Apply liquid sealant to the threaded area 5 Bolt M12 40 10 Bolt M20 60 N m 4 Bolt M16 60 265 N...

Page 129: ...BRAKE...

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Page 131: ...RAKE PEDAL 0634 51802 0 11190 A SECTION B B A A B B SECTION A A Shaft Bolt M10 40 P 1 25 Nut M10 Nut M10 Damper Bolt M10 40 Rod end Rod Foot brake switch Bolt M10 50 Brake pedal Return spring 7 001 BR...

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Page 133: ...e is OFF with solenoid excited Parking brake switch Brake OFF condition Fuse Foot brake relay without relay excited Foot brake switch Condition in which brake pedal pressed Propulsion motor R Propulsi...

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Page 135: ...WATER SPRAY SYSTEM...

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Page 137: ...in valve From filter OUT Drain valve Valve Hose Filter OUT Tee Hose Water spray pump Filter IN Filter Drain valve Drain valve Drain valve IN OUT IN OUT Water spray diagram Valve C A B B A D C DETAIL D...

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Page 139: ...INSPECTION AND ADJUSTMENT...

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Page 141: ...n 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...

Page 142: ...arking brake switch button Set speed change switch to Start the engine and set throttle lever to FULL Establish a condition in which machine propulsion load becomes maximum Pressure does not build up...

Page 143: ...305 psi turn If there is no evidence of nut having loosened remove multifunction valve Check removed multifunction valve for trapped dirt and scratches on its seat If trapped dirt is present disassemb...

Page 144: ...ug from coupling 1 of propulsion pump Attach pressure gauge with hose and connector Coupling 9 16 18UNF M16 Adapter for hose M16 P 2 0 Pressure gauge connector M16 G3 8 Pressure gauge 0 to 5 MPa 0 to...

Page 145: ...nge rate 0 39 MPa turn 57 psi turn If there is no evidence of nut having loosened remove charge relief valve Check removed charge relief valve for trapped dirt and scratches on its seat If trapped dir...

Page 146: ...o 725 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Start the engine and set throttle lever to FULL Operate F R lever and then read pressure indicated by...

Page 147: ...isconnect hose 1 from valve Attach pressure gauge through adapter Adapter G1 4 Pressure gauge 0 to 5 MPa 0 to 725 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch b...

Page 148: ...om valve Attach pressure gauge through adapter Adapter G1 4 Pressure gauge 0 to 5 MPa 0 to 725 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Start the eng...

Page 149: ...uge 0 to 5 MPa 0 to 725 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Start the engine and set throttle lever to FULL Release parking brake by pressing pa...

Page 150: ...from steering charge pump Attach pressure gauge through adapter Adapter G1 2 Pressure gauge 0 to 25 MPa 0 to 3 625 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch...

Page 151: ...relief valve for trapped dirt scratches on its seat and other abnormalities If trapped dirt is present disassemble and clean relief valve If a scratch or any other abnormality is found on seat replace...

Page 152: ...rm that F R lever is N Apply parking brake by pressing parking brake switch button Set speed change switch to Start the engine and set throttle lever to FULL Establish a condition in which machine pro...

Page 153: ...5 MPa 0 to 725 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Set speed change switch to Start the engine and set throttle lever to FULL Establish a condit...

Page 154: ...ressing parking brake switch button Set speed change switch to Start the engine and set throttle lever to FULL Establish a condition in which machine propulsion load becomes maximum Pressure does not...

Page 155: ...rature during measurement 50 5 C 122 9 F Apply grease to shaft of potentiometer 1 Insert potentiometer shaft to the groove on shaft 3 and fix it with two screws 2 NOTICE When fixing potentiometer 1 tu...

Page 156: ...to standard value with stopper bolt 6 Engine rotational speed 975 25 min 1 After adjustment fix stopper bolt 6 with locknut 5 Set throttle lever 4 to FULL Loosen locknut 7 and adjust engine rotational...

Page 157: ...ing force at center of throttle lever 4 knob to standard operating force Do not turn nut to the loosening direction Standard operating force 45 N 10 lbf NOTICE In case of loosen nut 10 replace it with...

Page 158: ...rocedure described below N position of F R lever 1 is positioned by notches Set F R lever in N Attach both ends of control cable 2 Specified dimension a 170 mm 6 69 in Specified dimension b 172 mm 6 7...

Page 159: ...TROUBLESHOOTING...

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Page 161: ...y 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 inspectin...

Page 162: ...full details of the trouble ask questions 3 Verify the trouble by warming up the machine and operating it Check the problem yourself 4 Identify the problem with either a mechanical hydraulic or elect...

Page 163: ...al 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 su...

Page 164: ...equipment A measuring resistance between terminals 1 and 3 1 2 3 3 4 2 5 1 2 3 1 2 3 1 Equipment A Connector Harness Equipment A Ohmmeter tester Equipment B Main power source of equipment B Signal fro...

Page 165: ...ness such as broken wire 10 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 Connector A Harness Ohmm...

Page 166: ...Power to equipment A Equipment B Equipment B Equipment A TS 10005 Inspection procedure Connect the connectors of equipment A and that of equipment B Connect the test probe to connector terminal 3 of...

Page 167: ...nnected 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...

Page 168: ...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 equ...

Page 169: ...f 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 Re...

Page 170: ...entify 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 I...

Page 171: ...mp ENGINE WARNING lamp WATER PUMP SEC SPRAY PAUSE TIMER ON OFF INT 0 0 10 20 30 60 1 DTC display procedure using the DPF meter A current or past DTC stored in the engine control unit ECU is displayed...

Page 172: ...rcuit B 4 Atmospheric pressure sensor Low Short circuit in sensor ECU internal circuit ground 110 0 Overheat Engine overheat Engine water temperature abnormally high 3 Water temperature sensor abnorma...

Page 173: ...Fuel temperature sensor abnormal Fuel temperature sensor High Open circuit in sensor harness B short circuited 4 Fuel temperature sensor Low Short circuit in sensor harness ground 190 0 Overrun Engine...

Page 174: ...Low Short circuit in sensor harness ground 3246 0 Exhaust temperature rise abnormal T2 Exhaust temperature rise abnormal T2 DPF outlet temperature T2 abnormally high 3 Exhaust temperature sensor 2 T2...

Page 175: ...cuit Common 2 system or TWV 2 and 4 3rd and 2nd cylinders simultaneously Open circuit in harness 3 Short circuit in common 2 TWV driving system Short circuit in battery Injector driving circuit at ECU...

Page 176: ...tion with EGR 523580 2 Intake throttle FB feed back abnormal Intake throttle FB feed back abnormal Intake throttle DC motor feed back abnormal 523582 3 Intake throttle lift sensor abnormal Intake thro...

Page 177: ...hibit warning Exhaust temperature when abnormally high temperature generated 523602 0 Regeneration frequency abnormally high Regeneration frequency abnormally high Abnormal interval between end of reg...

Page 178: ...LAY STARTER RELAY 87 85 86 30 BATTERY RELAY E BR NO COM E B IG L STARTER MOTOR S B E 65A AV60 B HEB 60 65A 48 5W 1 5W 14 8WR 50 8WR 28 BrR 21 LgR 49 15B 21 LgR 64 5R BATTERY 6 3 5 B R ALTERNATOR 75A 1...

Page 179: ...re is continuity between connection O O If there is no continuity starter switch is faulty Replace starter switch 3 Starter Motor 1 When starter switch is ON measure voltage between starter motor term...

Page 180: ...LAY STARTER RELAY 87 85 86 30 BATTERY RELAY E BR NO COM E B IG L STARTER MOTOR S B E 65A AV60 B HEB 60 65A 48 5W 1 5W 14 8WR 50 8WR 28 BrR 21 LgR 49 15B 21 LgR 64 5R BATTERY 6 3 5 B R ALTERNATOR 75A 1...

Page 181: ...2 is NG F R lever switch is faulty Replace F R lever switch 7 Parking Interlock Relay 1 When starter switch is ON measure voltage between parking interlock relay terminal 1 inlet wire BrR and chassis...

Page 182: ...LAY STARTER RELAY 87 85 86 30 BATTERY RELAY E BR NO COM E B IG L STARTER MOTOR S B E 65A AV60 B HEB 60 65A 48 5W 1 5W 14 8WR 50 8WR 28 BrR 21 LgR 49 15B 21 LgR 64 5R BATTERY 6 3 5 B R ALTERNATOR 75A 1...

Page 183: ...2 Measure voltage between ECU main relay terminal 30 inlet wire R and chassis ground Standard voltage 12 V or more 3 When starter switch is ON measure voltage between ECU main relay terminal 87 outlet...

Page 184: ...LAY STARTER RELAY 87 85 86 30 BATTERY RELAY E BR NO COM E B IG L STARTER MOTOR S B E 65A AV60 B HEB 60 65A 48 5W 1 5W 14 8WR 50 8WR 28 BrR 21 LgR 49 15B 21 LgR 64 5R BATTERY 6 3 5 B R ALTERNATOR 75A 1...

Page 185: ...If above items 1 and 2 are OK and item 3 is NG glow relay is faulty Replace glow relay 3 Harness Connecting Between Terminals Measure resistance of harness connecting between terminals Standard resis...

Page 186: ...LAY STARTER RELAY 87 85 86 30 BATTERY RELAY E BR NO COM E B IG L STARTER MOTOR S B E 65A AV60 B HEB 60 65A 48 5W 1 5W 14 8WR 50 8WR 28 BrR 21 LgR 49 15B 21 LgR 64 5R BATTERY 6 3 5 B R ALTERNATOR 75A 1...

Page 187: ...voltage 5 0 5 V 3 When starter switch is ON measure voltage between potentiometer terminal SIG1 wire W and potentiometer terminal GND1 wire B When throttle lever is at IDLE position Standard voltage 0...

Page 188: ...TOP LAMP PARKING BRAKE SWITCH 2 B f c a b e PLOPULSION PUMP NEUTRAL SOLENOID PARKING BRAKE SOLENOID SPEED CHANGE SLENOID 10 60 BW 42 22 WB 2 B 2 B 2 B TO PARKING INTERLOCK RELAY SPEED PULSE ON OFF REL...

Page 189: ...rminal 1 inlet wire BW and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between brake relay terminal 3 inlet wire GW and chassis ground Standard voltage 12...

Page 190: ...TOP LAMP PARKING BRAKE SWITCH 2 B f c a b e PLOPULSION PUMP NEUTRAL SOLENOID PARKING BRAKE SOLENOID SPEED CHANGE SLENOID 10 60 BW 42 22 WB 2 B 2 B 2 B TO PARKING INTERLOCK RELAY SPEED PULSE ON OFF REL...

Page 191: ...rking brake switch terminal 3 outlet wire GW and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG parking brake switch is faulty Replace parking brake switch 3 Harne...

Page 192: ...TOP LAMP PARKING BRAKE SWITCH 2 B f c a b e PLOPULSION PUMP NEUTRAL SOLENOID PARKING BRAKE SOLENOID SPEED CHANGE SLENOID 10 60 BW 42 22 WB 2 B 2 B 2 B TO PARKING INTERLOCK RELAY SPEED PULSE ON OFF REL...

Page 193: ...necting Between Terminals Measure resistance of harness connecting between terminals Standard resistance 10 or less If resistance is abnormal harness is faulty Repair or replace harness 2 4 4 Speed ca...

Page 194: ...48 5W 1 5W 21 LgR BATTERY TO COMBINATION METER 12V 115D31R R2 R1 ACC BR B C WATER SPRAY MODE SELECT SWITCH 4 1 5 6 3 2 WATER SPRAY RELAY G g e B 2 4 3 1 WATER SPRAY TIMER 41 LB 41 LB 41 3LB 41 LB 34...

Page 195: ...wire LY and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between water spray relay terminal G inlet wire LB and chassis ground Standard voltage 12 V or more...

Page 196: ...48 5W 1 5W 21 LgR BATTERY TO COMBINATION METER 12V 115D31R R2 R1 ACC BR B C WATER SPRAY MODE SELECT SWITCH 4 1 5 6 3 2 WATER SPRAY RELAY G g e B 2 4 3 1 WATER SPRAY TIMER 41 LB 41 LB 41 3LB 41 LB 34...

Page 197: ...If above item 1 is OK and item 2 is NG water spray timer is faulty Replace water spray timer 2 Water Spray Mode Select Switch 1 When starter switch is ON measure voltage between water spray mode sele...

Page 198: ...LAMP R 21W TAIL LAMP R 5W LICENSE LAMP 10W 2 TAIL LAMP L 5W STOP LAMP L 21W TURN SIGNAL LAMP R L 21W BACKUP LAMP L 21W R G GR RY TURN SIGNAL SWITCH TO COMBINATION METER GB 5 RY 6 RW 7 RB 8 G 3 GR 4 LI...

Page 199: ...ing switch is measure voltage between lighting switch terminal 3 outlet wire RL and chassis ground Standard voltage 12 V or more 3 When starter switch is ON and lighting switch is measure voltage betw...

Page 200: ...LAMP R 21W TAIL LAMP R 5W LICENSE LAMP 10W 2 TAIL LAMP L 5W STOP LAMP L 21W TURN SIGNAL LAMP R L 21W BACKUP LAMP L 21W R G GR RY TURN SIGNAL SWITCH TO COMBINATION METER GB 5 RY 6 RW 7 RB 8 G 3 GR 4 LI...

Page 201: ...ood lamp does not light 1 2 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 contact failure Bulb is faulty or poorly connected Repla...

Page 202: ...LAMP R 21W TAIL LAMP R 5W LICENSE LAMP 10W 2 TAIL LAMP L 5W STOP LAMP L 21W TURN SIGNAL LAMP R L 21W BACKUP LAMP L 21W R G GR RY TURN SIGNAL SWITCH TO COMBINATION METER GB 5 RY 6 RW 7 RB 8 G 3 GR 4 LI...

Page 203: ...t wire RW and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG turn signal switch is faulty Replace turn signal switch 3 Lighting LO HI Relay 1 When starter switch i...

Page 204: ...LAMP R 21W TAIL LAMP R 5W LICENSE LAMP 10W 2 TAIL LAMP L 5W STOP LAMP L 21W TURN SIGNAL LAMP R L 21W BACKUP LAMP L 21W R G GR RY TURN SIGNAL SWITCH TO COMBINATION METER GB 5 RY 6 RW 7 RB 8 G 3 GR 4 LI...

Page 205: ...item 2 is NG flasher unit is faulty Replace flasher unit 3 Turn Signal Switch 1 When starter switch is ON and turn signal switch lever is moved measure voltage between turn signal switch terminal inl...

Page 206: ...LAMP R 21W TAIL LAMP R 5W LICENSE LAMP 10W 2 TAIL LAMP L 5W STOP LAMP L 21W TURN SIGNAL LAMP R L 21W BACKUP LAMP L 21W R G GR RY TURN SIGNAL SWITCH TO COMBINATION METER GB 5 RY 6 RW 7 RB 8 G 3 GR 4 LI...

Page 207: ...ace hazard switch 3 Harness Connecting Between Terminals Measure resistance of harness connecting between terminals Standard resistance 10 or less If resistance is abnormal harness is faulty Repair or...

Page 208: ...LAMP R 21W TAIL LAMP R 5W LICENSE LAMP 10W 2 TAIL LAMP L 5W STOP LAMP L 21W TURN SIGNAL LAMP R L 21W BACKUP LAMP L 21W R G GR RY TURN SIGNAL SWITCH TO COMBINATION METER GB 5 RY 6 RW 7 RB 8 G 3 GR 4 LI...

Page 209: ...ace foot brake switch 3 Stop Lamp Relay 1 When starter switch is ON while foot brake is depressed measure voltage between stop lamp relay terminal a inlet wire BW and chassis ground There is no electr...

Page 210: ...SEL 2 GND REV RATIO SEL 1 OPEN PREHEATING CHARGE WARNING ENGINE OIL PRESSUER WARNING HYDRAULIC OIL FILTER WARNING PARKING BRAKE LAMP CHECK TEMPERATURE METER FUEL METER REV PULSE INPUT 2 16 15 14 13 1...

Page 211: ...assis ground Standard voltage 12 V or more If above items 1 and 2 are OK and combination meter does not turn on combination meter is faulty Replace combination meter 2 6 9 Combination meter warning la...

Page 212: ...SEL 2 GND REV RATIO SEL 1 OPEN PREHEATING CHARGE WARNING ENGINE OIL PRESSUER WARNING HYDRAULIC OIL FILTER WARNING PARKING BRAKE LAMP CHECK TEMPERATURE METER FUEL METER REV PULSE INPUT 2 16 15 14 13 1...

Page 213: ...ground Standard pulse 3 pulses rotation of engine If above item is OK and tachometer reading is NG combination meter is faulty Replace combination meter 2 Harness Connecting Between Terminals Measure...

Page 214: ...SEL 2 GND REV RATIO SEL 1 OPEN PREHEATING CHARGE WARNING ENGINE OIL PRESSUER WARNING HYDRAULIC OIL FILTER WARNING PARKING BRAKE LAMP CHECK TEMPERATURE METER FUEL METER REV PULSE INPUT 2 16 15 14 13 1...

Page 215: ...rness connecting between terminals Standard resistance 10 or less If resistance is abnormal harness is faulty Repair or replace harness 2 6 13 Fuel meter is abnormal Reference Fig 2 6 2 Check point Ch...

Page 216: ...SEL 2 GND REV RATIO SEL 1 OPEN PREHEATING CHARGE WARNING ENGINE OIL PRESSUER WARNING HYDRAULIC OIL FILTER WARNING PARKING BRAKE LAMP CHECK TEMPERATURE METER FUEL METER REV PULSE INPUT 2 16 15 14 13 1...

Page 217: ...ck that water spray pump can be activated Reference Fig 2 6 2 Check point Check Cause Action 1 Harness Measure resistance between water spray relay terminal B wire LW and combination meter connector t...

Page 218: ...NG HYDRAULIC OIL FILTER WARNING PARKING BRAKE LAMP CHECK TEMPERATURE METER FUEL METER REV PULSE INPUT 2 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 VIBRATOR LIQUID SPRAY WATER SPRAY FLOOD LAMP SIDE MARKER...

Page 219: ...mp indicator lamp does not light combination meter is faulty Replace combination meter 2 6 17 Side marker lamp indicator lamp does not light Check that side marker lamp tail lamp and license lamp ligh...

Page 220: ...NG HYDRAULIC OIL FILTER WARNING PARKING BRAKE LAMP CHECK TEMPERATURE METER FUEL METER REV PULSE INPUT 2 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 VIBRATOR LIQUID SPRAY WATER SPRAY FLOOD LAMP SIDE MARKER...

Page 221: ...uity parking brake switch is faulty Replace parking brake switch 3 Combination Meter Parking brake indicator lamp 1 When starter switch is ON measure voltage between combination meter terminal wires a...

Page 222: ...NG HYDRAULIC OIL FILTER WARNING PARKING BRAKE LAMP CHECK TEMPERATURE METER FUEL METER REV PULSE INPUT 2 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 VIBRATOR LIQUID SPRAY WATER SPRAY FLOOD LAMP SIDE MARKER...

Page 223: ...en wire G and wire GB There is continuity in normal condition If there is no continuity turn signal switch is faulty Replace turn signal switch 3 Combination Meter Turn signal indicator lamp 1 When st...

Page 224: ...31 RY BrW 371 R 20A 15A 15A 15A 15A 15A 20A 20A 20A 20A FUSE BOX WL WG 10 14 12 11 13 9 8 7 6 5 4 3 2 1 BACKUP BUZZER SWITCH HORN SWICTH WB 22 31 RY COM NO NC 1 25Gr BACKUP BUZZER 3 1 2 5 HORN RELAY H...

Page 225: ...Replace horn switch 4 Harness Connecting Between Terminals Measure resistance of harness connecting between terminals Standard resistance 10 or less If resistance is abnormal harness is faulty Repair...

Page 226: ...pes 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...

Page 227: ...il supply circuit with charge circuit Parking brake solenoid valve Speed change solenoid valve When solenoid is energized check if oil flows in return circuit to tank If oil is flowing repair solenoid...

Page 228: ...just F R lever linkage or replace it if necessary 2 Multifunction Valve Low circuit pressure due to incorrect high pressure relief setting or internal leakage of multifunction valve Interchange two mu...

Page 229: ...charge flow rate is insufficient due to wear of propulsion pump drive shaft splines Replace propulsion pump Propulsion circuit pressure is not held in propulsion pump case If pressure in propulsion pu...

Page 230: ...vely heavy relief valve opens causing temperature of hydraulic oil in circuit to rise Measure propulsion circuit pressure If high decrease propulsion load 5 Suction Filter for Steering Charge Pump Loa...

Page 231: ...ing cylinder Repair steering cylinder or replace it if necessary 5 Suction Filter for Steering Charge Pump Steering charge pump discharge rate decreases due to clogged filter Clean suction filter or r...

Page 232: ...replace relief valve If load is excessively heavy relief valve is open causing temperature of hydraulic oil in circuit to rise Measure steering circuit pressure If high decrease steering load 4 Sucti...

Page 233: ......

Page 234: ...Printed in Japan 2016 3 50 0 H S 0634 99373 0 31526 A 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 2...

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