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Sakai R2H-2, Shop Manual

The Sakai R2H-2 Shop Manual is a comprehensive and user-friendly resource for anyone operating this powerful machine. With easy-to-follow instructions and detailed diagrams, this manual ensures smooth operation and maintenance. For a hassle-free experience, download it for free from our website, manualshive.com, today!

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10-021

TROUBLESHOOTING

Fig.: 2-3-1

2

R2H-2-10002 

TO 

COMBINATION 

METER 

TO 

PARKING INTERLOCK RELAY

YL

YL

WB

G

GW

B

BR

2

39

22

BrY

18

BrB

73

42 1.25BrB

BRAKE RELAY

17 LgB

2 B

18 BrY

PARKING 

BRAKE 

SWITCH 

(WHEN RELEASE 

BRAKE) 

B

SOL

PARKING BRAKE 

SOLENOID

1.25BrB

DIODE

42

1.25BrB

42

2

B

SOL

SERVO BYPASS

SOLENOID

DIODE

2

3

5

2

1

1

4

3
6

5

WB (COM)

22

LgB (NO)

17

FOOT BRAKE 

SWITCH 

(WHEN NOT DEPRESS)

FUSE BOX

20A

15A

15A

15A

15A

15A

20A

20A

20A

20A

WY

WL

22

WB

7

6

30

WL

2

1

SPEED 

CHANGE

SWITCH

1.25 O

WL

10

30

B

B

1.25 O

DIODE

10

2

2

SOL

SPEED CHANGE 

SOLENOID

Summary of Contents for R2H-2

Page 1: ...R2H 2 SHOP MANUAL 3498 66344 0 ...

Page 2: ...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...

Page 3: ...1 004 1 10 Maintenance 1 005 1 11 Transporting the Machine 1 007 2 SPECIFICATIONS 1 SPECIFICATION DATA 2 001 2 TABLE OF STANDARD VALUES 2 1 Engine 2 003 2 2 Propulsion 2 003 2 3 Hydraulic System 2 003 2 4 Steering 2 004 2 5 Brakes 2 004 2 6 Capacities 2 004 3 FUEL AND LUBRICANTS SPECIFICATION 3 1 Rating 2 005 3 2 Recommended Lubricants 2 005 4 TIGHTENING TORQUE CHART 2 006 3 ENGINE AND CONTROLS 1 ...

Page 4: ...lic pump assembly propulsion steering charge 4 007 2 2 2 Propulsion hydraulic motor front 4 009 2 2 3 Propulsion hydraulic motor rear 4 011 3 STEERING SYSTEM 3 1 Steering Hydraulic Piping 4 013 3 2 Steering Wheel 4 014 3 3 Hydraulic Component Specifications 4 015 3 3 1 Orbitrol 4 015 3 4 Frame Center Pin 4 016 5 ELECTRICAL SYSTEM 1 ELECTRICAL CIRCUIT 1 1 Electrical Circuit Diagram 5 001 2 ELECTRIC...

Page 5: ...DJUSTMENT 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 MEASUREMENT OF Machine HIGH LOW SPEED CHANGE CIRCUIT PRESSURE 5 1 Measurement 9 007 6 MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE 6 1 Measurement 9 008 7 MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE 7 1 Measurement 9 009 ...

Page 6: ... not run 3 3 10 016 2 2 2 Engine will not start But starter motor runs 10 018 2 2 3 Engine does not stop running 10 018 2 2 4 No charging 10 020 2 2 5 Glow plug is not heated Engine starting performance is bad in cold weather 10 020 2 2 6 Starter motor runs even when F R lever is not at neutral 10 020 2 3 Propulsion 10 022 2 3 1 Machine moves neither forward nor backward 10 022 2 3 2 Machine speed...

Page 7: ... signal indicator lamp does not light 10 060 2 5 21 Glow Preheating plug indicator lamp does not light 10 062 2 5 22 Horn does not sound 10 064 2 5 23 Backup buzzer does not sound 10 064 3 HYDRAULIC SYSTEM TROUBLESHOOTING 3 1 When Performing Hydraulic System Troubleshooting 10 065 3 2 Propulsion System 10 066 3 2 1 Machine moves neither forward nor backward 1 2 10 066 3 2 1 Machine moves neither f...

Page 8: ...SAFETY ...

Page 9: ...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 10: ... 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 11: ...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 12: ...anging banks or on grades that could cause the compactor to slide or roll over Avoid any areas that may be a risk to machine stability 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...

Page 13: ...it until the machine has cooled down Use care when attaching and securing lifting tackle to individual parts and large assemblies being removed or repositioned for repair purposes 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 wh...

Page 14: ...t or perform grinding on the machine unless expressly authorized as there may be a risk of fire or explosion Disconnect the battery when welding on the machine Clean the machine and its surrounding from dust or other flammable substances and make sure the area is adequately ventilated before beginning welding flame cutting or grinding operations Inspect hydraulic hoses at regular intervals and imm...

Page 15: ...idth Block the drums or tires front and rear of the hauling vehicle when loading and unloading the compactor Ensure that the haul vehicle is on level ground and approach the loading ramps squarely to make 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...

Page 16: ...SPECIFICATIONS ...

Page 17: ...s Dimensions Overall length 5 020 mm 198 in Overall width 2 100 mm 83 in Overall height without ROPS 2 290 mm 90 in with ROPS 3 115 mm 123 in Wheelbase 3 400 mm 134 in Compaction width 2 100 mm 83 in Minimum height above ground 340 mm 13 5 in Speed 1st 0 to 8 km h 0 to 5 0 mph 2nd 0 to 16 km h 0 to 9 9 mph Minimum turning radius 6 3 m 248 in Gradability 1 31 17 1 The gradability is the calculated ...

Page 18: ...g system Centrifugal pump forced feeding system Cooling fan Exhaling type Electrical system Alternator 12 V 80 A Starter 12 V 3 0 kW Battery 12 V 72 Ah 1 pcs 12 V Power line Transmission Type Hydrostatic transmission Speed 2 speed shifts Reverser Switching the direction of flow delivered from the variable pump Final drive Planetary gear Braking device Service brake Hydrostatic and mechanical multi...

Page 19: ...9 psi 250 min 1 rpm Service limit 2 90 MPa 421 psi 250 min 1 rpm Injection pressure 1st stage 18 64 to 19 61 MPa 2 703 to 2 843 psi 2nd stage 22 56 to 23 53 MPa 3 271 to 3 412 psi Fuel consumption rate 239 g kW h 0 393 lb HP h Engine dry weight 268 kg 591 lbs 2 2 Propulsion Item Standard value Remarks Speed Forward reverse 1st 0 to 8 km h 0 to 5 0 mph 2nd 0 to 16 km h 0 to 9 9 mph 2 3 Hydraulic Sy...

Page 20: ... R2H 2 02001 Note 1 Note 2 Clearance between brake pedal and floorboard when pressed down 90 mm 3 5 in Note 2 See dimensions Propulsion motor inner brake wear limit Thickness of disc assembly 7 discs 18 5 to 19 1 mm 0 73 to 0 75 in Note 3 See dimensions Allowable when thickness is within this range Replace all 7 discs when thickness becomes 18 5 or less SW880 02002 Note 3 2 6 Capacities Item Stand...

Page 21: ... 3448 Grease Lithium type extreme pressure grease NLGI 2 Fuel Diesel oil ASTM D975 2D 3 2 Recommended Lubricants Lubricant Oil company Engine oil API CC Gear oil API GL 4 Hydraulic oil VG 46 Grease NLGI II CALTEX RPM DELO 300 oil Universal Thuban 90 Rando Oil HD 46 Martifack EP 2 BP BP Vanellus M30 BP Gear Oil EP 90 BP Energol HLP 46 BP Energrease LS EP 2 ESSO Esso Lube HDX 30 Esso Gear Oil GP 90 ...

Page 22: ...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...

Page 23: ...ENGINE AND CONTROLS ...

Page 24: ... 2 Bracket 7 Bolt M12 40 P 1 25 12 Bolt M14 35 P 1 5 3 Bolt M16 130 8 Stopper 13 Nut M12 P 1 25 4 Plate 9 Bolt M12 45 14 Stopper 5 Damper 10 Nut M12 15 Nut M12 P 1 25 16 Damper N m 3 Bolt M16 130 265 N m 195 lbf ft 7 Bolt M12 40 P 1 25 118 N m 87 lbf ft 12 Bolt M14 35 P 1 5 186 N m 137 lbf ft 13 Nut M12 P 1 25 78 N m 58 lbf ft 15 Nut M12 P 1 25 78 N m 58 lbf ft ...

Page 25: ...e 1 Injection pump 8 Engine oil filter 15 Oil filler cap 2 Engine stop solenoid 9 Oil pressure switch 16 Speed control lever 3 EGR valve 10 Oil drain plug 17 Fuel filter 4 Cooling fan 11 Oil level gauge 18 Turbocharger 5 Intake manifold 12 Starter motor 19 Exhaust manifold 6 Alternator 13 Engine stop lever 20 Flywheel 7 Fan drive pulley 14 Fuel supply pump 21 Oil pan ...

Page 26: ...B B A A 1 7 2 6 3 4 5 1 Control cable 8 Nut M16 2 Lock nut M8 9 Washer Apply lithium based grease 3 Stopper bolt FULL M8 35 10 Shaft 4 Stopper bolt IDLE M8 35 11 Rod end Apply lithium based grease 5 Lock nut M8 12 Bush Apply lithium based grease 6 Throttle lever 13 Bush Apply lithium based grease 7 Governor 14 Rod end Apply lithium based grease ...

Page 27: ...R C 1 F R lever right 8 F R lever switch 15 Set screw M12 30 2 Shaft 9 Stopper bolt reverse M8 25 16 Set screw M12 30 3 Rod end 10 Lock nut M8 17 Lock nut M12 4 F R lever left 11 Stopper bolt forward M8 25 18 Spring Fill grease 5 Control cable 12 Lock nut M8 19 Steel ball 6 Rod end 13 Backup buzzer switch 20 Holder 7 Pump lever 14 Lock nut M12 21 Coned disc spring Apply grease ...

Page 28: ...ON B B VIEW A 1 A 2 3 4 5 6 7 8 B B 1 Bolt M10 30 P 1 25 5 Bolt M14 40 2 Flange 6 Pump 3 Hub 7 Bolt M10 20 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 20 P 1 25 69 N m 51 lbf ft 8 Bolt M12 35 86 N m 63 lbf ft ...

Page 29: ... m 8 Bolt M12 35 86 N m 63 lbf ft Install housing 4 to pump 6 and tighten with four bolts 5 and washers N m 5 Bolt M14 40 167 N m 123 lbf ft Install flange 2 to engine flywheel and tighten eight bolts 1 and spring washers and washers N m 1 Bolt M10 30 P 1 25 49 N m 36 lbf ft Ensure engagement of flange 2 with hub 3 and install pump subassembly to engine Tighten with twelve bolts 7 N m 7 Bolt M10 2...

Page 30: ...HYDRAULIC SYSTEMS ...

Page 31: ...Reservoir 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 Bidirect...

Page 32: ...es 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 33: ...ar 0 21 MPa VO VS TU TF TR CO CS OUT IN 150mesh C2 C1 R L P T PD PS B A CSP PD1 PDR PDL SG5 SG4 PC1 PC2 SB3 SB4 10μm 15 2 MPa cc rev 277 cc rev 24 9 Ф0 8 2 4MPa 41 8MPa 41 8MPa 54 6kW 2200min 1 55 4kＷ 2200min 1 SAE J1995 JUN95 KUBOTA V3307 DI T KDN 3331L BV1 MRD ML1 PA3 PA1 PA2 PB3 PB1 PB2 MLP ML2 MLB MLS MLD Ф80XФ40 310 st 1 7MPa i 32 11 55 1 28 5 cc rev 1 7MPa cc rev 55 1 28 5 Ф1620 550 Ф1620 i ...

Page 34: ...2 PA3 PB3 PB1 PB2 MR1 MR2 MRB MLB ML1 ML2 PA2 PA1 BV1 Hose PB3 BV2 Hose PA3 BV1 Hose ML2 MRB Hose MR2 MLB Hose PA1 ML1 Propulsion motor Front Right Hose RA RB Hose PB2 RB PA2 RA Propulsion motor Front Left Propulsion pump Bypass valve Hose PB1 MR1 To propulsion hydraulic piping Rear 2 PROPULSION HYDRAULIC SYSTEM 2 1 Propulsion Hydraulic Piping 2 1 1 Propulsion hydraulic piping Front 1 4 004 HYDRAU...

Page 35: ...S CO Hose CO T1 Hose TU T2 PC1 MLS MRS SG4 Hose PC1 MLS The letters and figures such as TU and T2 show each port and the arrow symbols show the hose connection and the direction of the flow of the oil Hose MRP MLP Hose PD1 TF Hose SG5 SB3 Hose SB4 SG4 Hose MLS MRS Hose MRD PDR Hose MLD PDL Hose PC2 MRP To propulsion hydraulic piping Rear A A 2 1 2 Propulsion hydraulic piping Front 2 4 005 HYDRAULI...

Page 36: ...ipe RA The letters and figures such as RMB and RB show each port and the arrow symbols show the hose connection and the direction of the flow of the oil Hose RMD RD RP RMP Hose RS RMS Hose RB RMB To propulsion hydraulic piping Front Propulsion motor Rear 2 1 3 Propulsion hydraulic piping Rear 4 006 HYDRAULIC SYSTEMS ...

Page 37: ... assembly propulsion steering charge R2H 2 04001 A 2 1 1 1 1 2 1 3 1 6 1 5 1 4 1 7 1 8 2 1 1 10 1 9 1 11 1 12 1 13 1 14 1 15 Pump circuit diagram 2 1 1 9 1 19 1 21 1 20 1 15 1 11 1 2 1 18 1 4 1 17 1 16 1 10 1 6 1 8 2 2 1 1 1 3 1 5 BNA 1 20 1 21 1 22 1 16 1 17 1 19 1 18 VIEW A 1 23 2 2 ...

Page 38: ... 1 14 Servo bypass solenoid 1 15 Pilot charge pressure port PC2 9 16 18UNF 1 16 Charge supply port CSP 1 5 16 12UN 1 17 Drain port PDL 1 1 16 12UN 1 18 Drain port PDR 1 1 16 12UN 1 19 Port A Forward A SAE 1 1 20 Servo bypass solenoid port SB4 9 16 18UNF 1 21 Servo bypass solenoid port SB3 9 16 18UNF 1 22 Multi function valve Port B 1 23 Multi function valve Port A Specifications Displacement 75 cm...

Page 39: ... brake pilot port MRP G1 4 10 Motor 4 Drain port MLD G1 2 11 Reduction gear 5 Port B2 MLB MRB G1 2 12 Filler cap PF 3 8 6 Port A2 ML2 MR2 G1 2 13 Shift valve assembly 7 Drain port MRD G1 2 Motor specifications Displacement max 55 1 cm3 rev 3 36 cu in rev min 28 5 cm3 rev 1 74 cu in rev Brake release pressure 1 3 to 1 7 MPa 189 to 247 psi Allowable motor case pressure 0 3 MPa 44 psi or less Reducti...

Page 40: ...ylinder 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 assembly 12 6 Carrier B 11 7 Brake stopper 12 7 Carrier A 11 8 Friction plate 12 8 Planetary gear A 11 9 Separate plate 12 9 Needle roller 11 10 Piston brake 12 10 Shaft A 11 11 Journal bearing 12 11 Su...

Page 41: ...port B G1 4 10 Filler cap 7 8 14UNF 5 High pressure gauge port For port A G1 4 11 Charge pressure gauge port G1 8 6 Parking brake pilot port RMP G1 4 12 Shift valve assembly Motor specifications Displacement max 75 0 cm3 rev 4 58 cu in rev min 28 0 cm3 rev 1 71 cu in rev Charge relief valve pressure setting 2 4 MPa 348 psi Brake release pressure 1 3 to 1 7 MPa 189 to 247 psi Allowable motor case p...

Page 42: ...tion 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 assembly 10 6 Planetary gear 1st 9 7 Brake stopper 10 7 Needle roller 9 8 Friction plate 10 8 Sun gear 2nd 9 9 Separate plate 10 9 Sun gear 1st 9 10 Piston brake 9 11 Journal bearing 9 12 Shift val...

Page 43: ... CSP C1 Hose AD1 P Hose PD AD1 Propulsion pump Hose R AD4 Hose AD4 C2 The letters and figures such as AD2 and CSP show each port and the arrow symbols show the hose connection and the direction of the flow of the oil Hose L AD3 Hose AD3 C1 Hose AD4 C2 Hose AD2 CSP Hose PD AD1 Hose T AD2 Steering Charge pump B B 3 STEERING SYSTEM 3 1 Steering Hydraulic Piping 4 013 HYDRAULIC SYSTEMS ...

Page 44: ...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 Nut M12 P 1 25 64 N m 47 lbf ft Steering wheel assembly weight 12 kg 26 lbf ft ...

Page 45: ...rbitrol R2H 2 04006 1 4 3 2 1 2 3 4 Hydraulic circuit diagram 1 Port L L 3 4 16UNF 2 Port R R 3 4 16UNF 3 Port T T 3 4 16UNF 4 Port P P 3 4 16UNF Specifications Displacement 277 cm3 rev 16 9 cu in rev Relief valve pressure setting 15 2 MPa 2 204 psi Weight 7 3 kg 16 1 lbs ...

Page 46: ...1 10 1 Bolt M16 60 5 Yoke 9 Bracket upper 2 Bolt M16 80 6 Bolt M16 45 10 Bracket lower 3 Bolt M20 70 7 Cover 11 O ring 4 Swing bearing 8 Roller bearing N m 1 Bolt M16 60 265 N m 196 lbf ft 2 Bolt M16 80 265 N m 196 lbf ft 3 Bolt M20 70 539 N m 398 lbf ft 6 Bolt M16 45 265 N m 196 lbf ft ...

Page 47: ...ELECTRICAL SYSTEM ...

Page 48: ...BRAKE SWITCH 18 BrY 73 BrB 22 WB 39 YL BR 2 15 1 25BW 2Y 1 25RB YL R 4 96 15A LgB WB 2 5 2 1 25 O 21 4 STARTER SWITCH G B C R2 BR R1 ACC 1 3 1 4 1 25BR 5W 1 25LｇR R WL YL GW B FUSE 1 25RB 15A 49 2 5 1 3 Bｒ 8 WY 37 12 P 13 GY 11 2 B 47 GL 23 BR 3 2 STOP TRAVEL 17 22 11 2 6 E L B B FLASHER UNIT FOOT BRAKE SWITCH HORN RELAY COM NO NC 671 25BY 671 25BY 67 68 1 25GW FUSE 5A L 57 W 48 1 25LgR ａ c f e b ...

Page 49: ...tch Starter motor Tacho meter sensor Fuel unit Combination lamp F L A B B Flood lamp F R Licence lamp Licence lamp Combination lamp R R Combination lamp R L Combination lamp R L Flood lamp R R Flood lamp F L Flood lamp F L Flood lamp R L Flood lamp R L Battery relay Water spray pump DETAIL A SECTION B B Speed change solenoid Parking brake solenoid Servo bypass solenoid Combination lamp F R Thermo ...

Page 50: ...itch Water spray timer Water spray switch Starter switch Combination meter Lighting switch Delay relay Safety relay Horn relay Foot brake switch Backup buzzer switch F R lever switch Water spray relay Turn signal switch Flood lamp relay Brake relay Lighting relay Flasher unit Stop lamp relay Starter relay Interlock relay Glow lamp timer Parking interlock relay Glow relay Fuse box 0634 09814 0 1110...

Page 51: ... meter sensor Flood lamp switch Flasher unit Horn relay Lighting switch Lighting relay BW WR WL WB Gy WG Parking brake switch Foot brake switch Stop lamp relay 1 4 8 10 20 A 15 A 15 A 15 A 20 A 20 A 20 A 20 A 15 A 15 A 9 7 6 5 3 2 BR WY BY WL Harness color codes BW Black White stripe WL White Blue stripe WR White Red stripe WY White Yellow stripe BY Black Yellow stripe WG White Green stripe WB Whi...

Page 52: ...terface TA pulse pickup TA pulse square wave Fuel sensor Temperature sensor Engine speed 1 Engine speed 2 Engine speed 3 Engine speed 4 Position lamp Backlight Turn signal right Turn signal left Vibration Liquid spray Water spray Flood lamp Glow plug Parking brake Engine charge warning Engine oil pressure Hydraulic filter Lamp check Coolant temperature 1 Coolant temperature 2 System configuration ...

Page 53: ...DRUM ...

Page 54: ...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 55: ...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 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 56: ... 4 3 5 6 7 8 9 10 11 12 1 Drum F R 5 Plate 9 Propulsion motor F R 2 Drum F L 6 Propulsion motor F L 10 Plate 3 Bolt M16 50 7 Plug 11 Bolt M8 12 4 Bolt M8 12 8 Plug 12 Bolt M16 50 3 Bolt M16 50 265 N m 195 lbf ft 12 Bolt M16 50 265 N m 195 lbf ft N m ...

Page 57: ...tor R 2 Plug 7 Retaining ring 12 Bolt M20 60 3 Ball bearing 8 Case 13 Bolt M20 70 4 Bolt M16 50 9 Plate Apply liquid sealant to the threaded area 5 Bolt M12 40 10 Bolt M20 60 4 Bolt M16 50 265 N m 195 lbf ft 10 Bolt M20 60 539 N m 398 lbf ft 12 Bolt M20 60 539 N m 398 lbf ft 13 Bolt M20 70 539 N m 398 lbf ft N m ...

Page 58: ...BRAKE ...

Page 59: ...34 51802 0 11190 0 SECTION B B A A B B SECTION A A Shaft Bolt M10x40 P 1 25 Nut M10 Nut M10 Damper Bolt M10x40 Rod end Rod Foot brake switch Bolt M10x50 Brake pedal Return spring 7 001 BRAKE 1 BRAKE PEDAL ...

Page 60: ...ke 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 Propulsion motor F R Propulsion motor F L Brake Brake ON condition Brake Brake ON condition Brake Brake ON condition The arrow symbol shows the direction of the hydraulic oil flow ...

Page 61: ...WATER SPRAY SYSTEM ...

Page 62: ... pipe R Drain 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 To water spray pipe F Hose Tee Water spray pipe F Level gauge Hose Water spray tank Pump Tee Filler The letters and figures such as Filter and Water spray pipe show each port and the arrow...

Page 63: ...INSPECTION AND ADJUSTMENT ...

Page 64: ...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 65: ...e switch to position Start the engine and set throttle lever to Full position Establish a condition in which machine propulsion load becomes maximal 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 Neutral position ...

Page 66: ...e change rate 9 MPa turn 1 305 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 disassemble and clean multifunction valve If a scratch is found on seat replace multifunction valve After adjustment measure pressure again and check that pressure reaches maximum ci...

Page 67: ...e plug from charge pressure gauge port 1 2 Attach pressure gauge with adapter ⓗ Adapter ⓗ 9 16 18UNF Pressure gauge 0 to 5 MPa 0 to 725 psi Apply parking brake by pressing parking brake switch button Start the engine and set throttle lever to Full position Then read pressure indicated by pressure gauge Standard charge relief valve setting 2 4 0 2 MPa 348 29 psi The number 1 2 appearing in above il...

Page 68: ...ressure drop Pressure change 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 dirt is present disassemble and clean charge relief valve If a scratch is found on seat replace charge relief valve After adjustment measure pressure again and check that pressur...

Page 69: ...G1 4 Pressure gauge 0 to 5 MPa 0 to 725 psi Apply parking brake by pressing parking brake switch button Start the engine and set throttle lever to Full position Operate F R lever and then read pressure indicated by pressure gauge With parking brake ON measured pressures of 1 and 2 are same With parking brake OFF measured pressures of 1 and 2 are different Standard charge relief pressure setting 2 ...

Page 70: ...50 5 C 122 41 F Disconnect hose 1 from rear propulsion motor Attach pressure gauge through adapter ⓜ Adapter ⓜ G1 4 Pressure gauge 0 to 5 MPa 0 to 725 psi Apply parking brake by pressing parking brake switch button Set propulsion speed change switch to position Start the engine and set throttle lever to Full position Then read pressure indicated by pressure gauge Standard charge relief valve setti...

Page 71: ...essure gauge with adapter ⓑ Adapter ⓑ G1 4 Pressure gauge 0 to 5 MPa 0 to 725 psi Confirm that F R lever is in Neutral position Apply parking brake by pressing parking brake switch button Start the engine and set throttle lever to the Full position Release parking brake by pressing parking brake switch button Then read brake release pressure indicated by pressure gauge Brake release pressure Front...

Page 72: ...F Disconnect hose 1 from steering charge pump Attach pressure gauge through adapter ⓠ Adapter ⓠ G3 4 Pressure gauge 0 to 25 MPa 0 to 3 625 psi Confirm that F R lever is in Neutral position properly Start the engine and set throttle lever to Full position Turn steering wheel to operate relief valve Then read pressure indicated by pressure gauge Standard maximum circuit pressure orbitroll relief pre...

Page 73: ...removed 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 relief valve After inspection measure pressure again and check that pressure reaches standard maximum circuit pressure range NOTICE Carefully disassemble and reassemble after taking steps to ...

Page 74: ... MPa 0 to 725 psi Set propulsion speed change switch to position Start the engine and set throttle lever to Full position Establish a condition in which machine propulsion load becomes maximal Pressure does not build up unless propulsion load is applied With propulsion load at maximum measure pressure when speed change switch is in and positions and F R lever is in neutral forward and reverse posi...

Page 75: ... psi Set propulsion speed change switch to position Start the engine and set throttle lever to Full position Establish a condition in which machine propulsion load becomes maximal Pressure does not build up unless propulsion load is applied With propulsion load at maximum measure pressure when speed change switch is in and positions and F R lever is in neutral forward and reverse positions respect...

Page 76: ...d change switch to position Start the engine and set throttle lever to Full position Establish a condition in which machine propulsion load becomes maximal Pressure does not build up unless propulsion load is applied With propulsion load at maximum measure pressure when speed change switch is in and positions and F R lever is in neutral forward and reverse positions respectively Allowable motor ca...

Page 77: ...r bolt IDLE 1 adjust so that standard minimum no load rotational speed is achieved Standard minimum no load rotational speed 1 000 50 rpm Set throttle lever 3 in maximum no load rotational speed position Loosen lock nut 6 Using stopper bolt FULL 5 adjust so that control lever 8 contacts the stopper 7 Confirm that engine speed is within standard range Standard maximum no load rotational speed 2 400...

Page 78: ... on forward reverse side are positioned by notches Firmly secure F R lever in neutral position Firmly secure both ends of control cable 2 Specified dimension of control cable ends a 170 mm 6 69 in Specified dimension of control cable ends b 172 mm 6 77 in Confirm stroke of control lever 3 on propulsion pump side Specified dimension of control lever c 22 mm 0 9 in R2H 2 09019 N VIEW A A 2 1 a R2H 2...

Page 79: ...TROUBLESHOOTING ...

Page 80: ...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 81: ...ecting surfaces on the connector side Wire number wire size and wire color are shown as above in electrical circuit diagrams 100 3 BW Wire color AVS wire size Wire number SW880 11020 B Black BW Black White stripe BY Black Yellow stripe BR Black Red stripe BG Black Green stripe BL Black Blue stripe O Orange YO Yellow Orange stripe W White WR White Red stripe WB White Black stripe WL White Blue stri...

Page 82: ... 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 83: ... 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 84: ...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 5 of equipment B and the t...

Page 85: ...ent 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 measurement Be sure to connect the p...

Page 86: ...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 87: ...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 88: ...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 89: ...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 90: ... 25BW WR 13 50 5WR WR 50 5WR B S STARTER MOTOR 62 2Gr 65A 48 5W 1 5W 8BYx3 ALTERNATOR FUSIBLE LINKx3 FUSIBLE LINK 75A B BATTERY RELAY 5W 1 25LgY 2 29 1 25LgY 29 1 5WB 61 8WR 14 5WB 61 5WB 20 AV60 B AV60 B 65A BATTERY 12V 115D31R 54 b a e c f 67 1 25BY 101 GR 101 GR DELAY RELAY 67 1 25BY 63 1 25P 9 3Lg 20 3WB STARTER RELAY 23 1 25BR 56 1 25LW DIODE DIODE DIODE DIODE FUSE 15A 49 1 25RB 100 1 25RB FU...

Page 91: ...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 Safety Relay 1 When starter switch is ON measure voltage between safety relay terminal R inlet wire GW and chassis ground Standard voltage 12 V or more 2 When starter switch is START measure voltage between sa...

Page 92: ... 25BW WR 13 50 5WR WR 50 5WR B S STARTER MOTOR 62 2Gr 65A 48 5W 1 5W 8BYx3 ALTERNATOR FUSIBLE LINKx3 FUSIBLE LINK 75A B BATTERY RELAY 5W 1 25LgY 2 29 1 25LgY 29 1 5WB 61 8WR 14 5WB 61 5WB 20 AV60 B AV60 B 65A BATTERY 12V 115D31R 54 b a e c f 67 1 25BY 101 GR 101 GR DELAY RELAY 67 1 25BY 63 1 25P 9 3Lg 20 3WB STARTER RELAY 23 1 25BR 56 1 25LW DIODE DIODE DIODE DIODE FUSE 15A 49 1 25RB 100 1 25RB FU...

Page 93: ...on 2 When starter switch is START measure voltage between interlock relay terminal c inlet wire Br and chassis ground Standard voltage 12 V or more 3 When starter switch is START measure voltage between interlock relay terminal f outlet wire Gr and chassis ground Standard voltage 12 V or more If above items 1 and 2 are OK and item 3 is NG interlock relay is faulty Replace interlock relay 8 Parking...

Page 94: ... 25BW WR 13 50 5WR WR 50 5WR B S STARTER MOTOR 62 2Gr 65A 48 5W 1 5W 8BYx3 ALTERNATOR FUSIBLE LINKx3 FUSIBLE LINK 75A B BATTERY RELAY 5W 1 25LgY 2 29 1 25LgY 29 1 5WB 61 8WR 14 5WB 61 5WB 20 AV60 B AV60 B 65A BATTERY 12V 115D31R 54 b a e c f 67 1 25BY 101 GR 101 GR DELAY RELAY 67 1 25BY 63 1 25P 9 3Lg 20 3WB STARTER RELAY 23 1 25BR 56 1 25LW DIODE DIODE DIODE DIODE FUSE 15A 49 1 25RB 100 1 25RB FU...

Page 95: ...utlet wire Lg and chassis ground Standard voltage 12 V or more If above items 1 and 2 are OK and item 3 is NG starter relay is faulty Replace starter relay 10 Parking Brake Switch 1 When starter switch is ON measure voltage between parking brake switch terminal 1 inlet wire GW and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between parking brake switch ...

Page 96: ... 25BW WR 13 50 5WR WR 50 5WR B S STARTER MOTOR 62 2Gr 65A 48 5W 1 5W 8BYx3 ALTERNATOR FUSIBLE LINKx3 FUSIBLE LINK 75A B BATTERY RELAY 5W 1 25LgY 2 29 1 25LgY 29 1 5WB 61 8WR 14 5WB 61 5WB 20 AV60 B AV60 B 65A BATTERY 12V 115D31R 54 b a e c f 67 1 25BY 101 GR 101 GR DELAY RELAY 67 1 25BY 63 1 25P 9 3Lg 20 3WB STARTER RELAY 23 1 25BR 56 1 25LW DIODE DIODE DIODE DIODE FUSE 15A 49 1 25RB 100 1 25RB FU...

Page 97: ...oltage 12 V or more If above items 1 and 2 are OK and engine does not start engine stop solenoid is faulty Replace engine stop solenoid 3 Harness Connecting Between Terminals Measure resistance of harness connecting between terminals Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 2 2 3 Engine does not stop running Reference Fig 2 2 1 Check po...

Page 98: ... 25BW WR 13 50 5WR WR 50 5WR B S STARTER MOTOR 62 2Gr 65A 48 5W 1 5W 8BYx3 ALTERNATOR FUSIBLE LINKx3 FUSIBLE LINK 75A B BATTERY RELAY 5W 1 25LgY 2 29 1 25LgY 29 1 5WB 61 8WR 14 5WB 61 5WB 20 AV60 B AV60 B 65A BATTERY 12V 115D31R 54 b a e c f 67 1 25BY 101 GR 101 GR DELAY RELAY 67 1 25BY 63 1 25P 9 3Lg 20 3WB STARTER RELAY 23 1 25BR 56 1 25LW DIODE DIODE DIODE DIODE FUSE 15A 49 1 25RB 100 1 25RB FU...

Page 99: ...rminal G inlet wire WB and chassis ground Standard voltage 12 V or more 2 When starter switch is HEAT measure voltage between glow relay terminal g inlet wire Y and chassis ground Standard voltage 12 V or more 3 When starter switch is HEAT measure voltage between glow relay terminal B outlet wire WG and chassis ground Standard voltage 12 V or more If above items 1 and 2 are OK and items 3 is NG gl...

Page 100: ... BrY PARKING BRAKE SWITCH WHEN RELEASE BRAKE B SOL PARKING BRAKE SOLENOID 1 25BrB DIODE 42 1 25BrB 42 2 B SOL SERVO BYPASS SOLENOID DIODE 2 3 5 2 1 1 4 3 6 5 WB COM 22 LgB NO 17 FOOT BRAKE SWITCH WHEN NOT DEPRESS FUSE BOX 20A 15A 15A 15A 15A 15A 20A 20A 20A 20A WY WL 22 WB 7 6 30 WL 2 1 SPEED CHANGE SWITCH 1 25 O WL 10 30 B B 1 25 O DIODE 10 2 2 SOL SPEED CHANGE SOLENOID ...

Page 101: ... or more 3 When starter switch is ON measure voltage between brake relay terminal 5 outlet wire BrB and chassis ground Standard voltage 12 V or more If above items 1 and 2 are OK and item 3 is NG brake relay is faulty Replace brake relay 4 Parking Brake Switch 1 When starter switch is ON measure voltage between parking brake switch terminal 1 inlet wire WB and chassis ground Standard voltage 12 V ...

Page 102: ... BrY PARKING BRAKE SWITCH WHEN RELEASE BRAKE B SOL PARKING BRAKE SOLENOID 1 25BrB DIODE 42 1 25BrB 42 2 B SOL SERVO BYPASS SOLENOID DIODE 2 3 5 2 1 1 4 3 6 5 WB COM 22 LgB NO 17 FOOT BRAKE SWITCH WHEN NOT DEPRESS FUSE BOX 20A 15A 15A 15A 15A 15A 20A 20A 20A 20A WY WL 22 WB 7 6 30 WL 2 1 SPEED CHANGE SWITCH 1 25 O WL 10 30 B B 1 25 O DIODE 10 2 2 SOL SPEED CHANGE SOLENOID ...

Page 103: ...ch is ON measure voltage between speed change switch terminal 1 inlet wire WL and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between speed change switch terminal 2 outlet wire O and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG speed change switch is faulty Replace speed change switch 3 Harness Connecting Between T...

Page 104: ... BrY PARKING BRAKE SWITCH WHEN RELEASE BRAKE B SOL PARKING BRAKE SOLENOID 1 25BrB DIODE 42 1 25BrB 42 2 B SOL SERVO BYPASS SOLENOID DIODE 2 3 5 2 1 1 4 3 6 5 WB COM 22 LgB NO 17 FOOT BRAKE SWITCH WHEN NOT DEPRESS FUSE BOX 20A 15A 15A 15A 15A 15A 20A 20A 20A 20A WY WL 22 WB 7 6 30 WL 2 1 SPEED CHANGE SWITCH 1 25 O WL 10 30 B B 1 25 O DIODE 10 2 2 SOL SPEED CHANGE SOLENOID ...

Page 105: ...NG brake relay is faulty Replace brake relay 3 Parking Brake Switch 1 When starter switch is ON measure voltage between parking brake switch terminal 1 inlet wire WB and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between parking brake switch terminal 3 outlet wire BrY and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is ...

Page 106: ... BrY PARKING BRAKE SWITCH WHEN RELEASE BRAKE B SOL PARKING BRAKE SOLENOID 1 25BrB DIODE 42 1 25BrB 42 2 B SOL SERVO BYPASS SOLENOID DIODE 2 3 5 2 1 1 4 3 6 5 WB COM 22 LgB NO 17 FOOT BRAKE SWITCH WHEN NOT DEPRESS FUSE BOX 20A 15A 15A 15A 15A 15A 20A 20A 20A 20A WY WL 22 WB 7 6 30 WL 2 1 SPEED CHANGE SWITCH 1 25 O WL 10 30 B B 1 25 O DIODE 10 2 2 SOL SPEED CHANGE SOLENOID ...

Page 107: ...d item 2 is NG brake relay is faulty Replace brake relay 3 Parking Brake Switch 1 When starter switch is ON measure voltage between parking brake switch terminal 1 inlet wire GW and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between parking brake switch terminal 3 outlet wire G and chassis ground There is no electricity in normal condition If above ite...

Page 108: ...04 34 LY WATER SPRAY PUMP 19 3LW 34 LY 19 3LW WATER SPRAY SWITCH WATER SPRAY RELAY WATER SPRAY TIMER 41 LB 41 LB 41 3LB 41 LB 34 LY 27 LR 27 LR 2 B 2 B TO BATTERY RELAY FUSE 41 3LB 52 3WL TO COMBINATION METER 2 5 1 4 B g e G 1 1 3 3 4 2 4 2 30A ...

Page 109: ...tage 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 3 When starter switch is ON measure voltage between water spray relay terminal B outlet wire LW and chassis ground Standard voltage 12 V or more If above items 1 and 2 are OK and item 3 is NG water spray relay is faulty Replace water spra...

Page 110: ...04 34 LY WATER SPRAY PUMP 19 3LW 34 LY 19 3LW WATER SPRAY SWITCH WATER SPRAY RELAY WATER SPRAY TIMER 41 LB 41 LB 41 3LB 41 LB 34 LY 27 LR 27 LR 2 B 2 B TO BATTERY RELAY FUSE 41 3LB 52 3WL TO COMBINATION METER 2 5 1 4 B g e G 1 1 3 3 4 2 4 2 30A ...

Page 111: ... more Electricity flows for a definite time If above item 1 is OK and item 2 is NG water spray timer is faulty Replace water spray timer 2 Water Spray Switch 1 When starter switch is ON measure voltage between water spray switch terminal 4 inlet wire LB and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between water spray switch terminal 5 outlet wire LR ...

Page 112: ...VER SWITCH B COM W NO WB COM 22 LgB NO FOOT BRAKE SWITCH WHEN NOT DEPRESS 20A 15A 15A 15A WL 15A WG 15A 20A WR 20A 20A 20A FUSE BOX WB 2GB 2WR 2WG 1 25Gy WG 2 B 33 GY 17 LgB 22 WB STOP LAMP RELAY LIGHTING SWITCH Lg RL WG R2H 2 10005 22 44 11 6 5 5WR 50 5WR 50 3 17 44 c a f e b 2 3 5 6 1 4 44 45 36 6 6 HAZARD SWITCH 3 2 6 5 1 4 GY GY 40 GB 26 GR 3 2 1 5 2 1 3 LIGHTING RELAY 2WG Lg B 2BrW 44 36 2 64...

Page 113: ...starter switch is ON and lighting 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 between lighting switch terminal 5 outlet wire Lg and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 or 3 is NG lighting switch is faulty Repla...

Page 114: ...VER SWITCH B COM W NO WB COM 22 LgB NO FOOT BRAKE SWITCH WHEN NOT DEPRESS 20A 15A 15A 15A WL 15A WG 15A 20A WR 20A 20A 20A FUSE BOX WB 2GB 2WR 2WG 1 25Gy WG 2 B 33 GY 17 LgB 22 WB STOP LAMP RELAY LIGHTING SWITCH Lg RL WG R2H 2 10005 22 44 11 6 5 5WR 50 5WR 50 3 17 44 c a f e b 2 3 5 6 1 4 44 45 36 6 6 HAZARD SWITCH 3 2 6 5 1 4 GY GY 40 GB 26 GR 3 2 1 5 2 1 3 LIGHTING RELAY 2WG Lg B 2BrW 44 36 2 64...

Page 115: ...eck 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 Replace each bulb 2 Flood Lamp Switch 1 When starter switch is ON measure voltage between flood lamp switch terminal 1 inlet wire Gy and chassis ground Standard voltage 12 V or more 2 When starter switch is ON and flood lamp switch is ON measure voltage b...

Page 116: ...VER SWITCH B COM W NO WB COM 22 LgB NO FOOT BRAKE SWITCH WHEN NOT DEPRESS 20A 15A 15A 15A WL 15A WG 15A 20A WR 20A 20A 20A FUSE BOX WB 2GB 2WR 2WG 1 25Gy WG 2 B 33 GY 17 LgB 22 WB STOP LAMP RELAY LIGHTING SWITCH Lg RL WG R2H 2 10005 22 44 11 6 5 5WR 50 5WR 50 3 17 44 c a f e b 2 3 5 6 1 4 44 45 36 6 6 HAZARD SWITCH 3 2 6 5 1 4 GY GY 40 GB 26 GR 3 2 1 5 2 1 3 LIGHTING RELAY 2WG Lg B 2BrW 44 36 2 64...

Page 117: ...Switch 1 When starter switch is ON and lighting switch is measure voltage between lighting Lo Hi switch terminal 2 inlet wire BrW terminal 5 inlet wire BrW and chassis ground Standard voltage 12 V or more 2 When starter switch is ON lighting switch is and lighting Lo Hi switch is measure voltage between lighting Lo Hi switch terminal wires and chassis ground Head lamp R Terminal 3 outlet wire RW H...

Page 118: ...VER SWITCH B COM W NO WB COM 22 LgB NO FOOT BRAKE SWITCH WHEN NOT DEPRESS 20A 15A 15A 15A WL 15A WG 15A 20A WR 20A 20A 20A FUSE BOX WB 2GB 2WR 2WG 1 25Gy WG 2 B 33 GY 17 LgB 22 WB STOP LAMP RELAY LIGHTING SWITCH Lg RL WG R2H 2 10005 22 44 11 6 5 5WR 50 5WR 50 3 17 44 c a f e b 2 3 5 6 1 4 44 45 36 6 6 HAZARD SWITCH 3 2 6 5 1 4 GY GY 40 GB 26 GR 3 2 1 5 2 1 3 LIGHTING RELAY 2WG Lg B 2BrW 44 36 2 64...

Page 119: ...er unit is faulty Replace flasher unit 3 Turn Signal Switch 1 When starter switch is ON and turn signal lever is moved measure voltage between turn signal switch terminal inlet wire GY and chassis ground Standard voltage 12 V or more with constant intervals 2 When starter switch is ON and turn signal lever is moved measure voltage between turn signal switch terminal wires and chassis ground Front ...

Page 120: ...VER SWITCH B COM W NO WB COM 22 LgB NO FOOT BRAKE SWITCH WHEN NOT DEPRESS 20A 15A 15A 15A WL 15A WG 15A 20A WR 20A 20A 20A FUSE BOX WB 2GB 2WR 2WG 1 25Gy WG 2 B 33 GY 17 LgB 22 WB STOP LAMP RELAY LIGHTING SWITCH Lg RL WG R2H 2 10005 22 44 11 6 5 5WR 50 5WR 50 3 17 44 c a f e b 2 3 5 6 1 4 44 45 36 6 6 HAZARD SWITCH 3 2 6 5 1 4 GY GY 40 GB 26 GR 3 2 1 5 2 1 3 LIGHTING RELAY 2WG Lg B 2BrW 44 36 2 64...

Page 121: ...t intervals 2 When starter switch is ON and hazard switch is ON measure voltage between hazard switch terminal 2 outlet wire GB and chassis ground Standard voltage 12 V or more with constant intervals 3 When starter switch is ON and hazard switch is ON measure voltage between hazard switch terminal 5 outlet wire GR and chassis ground Standard voltage 12 V or more with constant intervals If above 1...

Page 122: ...VER SWITCH B COM W NO WB COM 22 LgB NO FOOT BRAKE SWITCH WHEN NOT DEPRESS 20A 15A 15A 15A WL 15A WG 15A 20A WR 20A 20A 20A FUSE BOX WB 2GB 2WR 2WG 1 25Gy WG 2 B 33 GY 17 LgB 22 WB STOP LAMP RELAY LIGHTING SWITCH Lg RL WG R2H 2 10005 22 44 11 6 5 5WR 50 5WR 50 3 17 44 c a f e b 2 3 5 6 1 4 44 45 36 6 6 HAZARD SWITCH 3 2 6 5 1 4 GY GY 40 GB 26 GR 3 2 1 5 2 1 3 LIGHTING RELAY 2WG Lg B 2BrW 44 36 2 64...

Page 123: ... or poorly connected Replace each bulb 2 Foot Brake Switch 1 When starter switch is ON measure voltage between foot brake switch terminal inlet wire WB and chassis ground Standard voltage 12 V or more 2 When starter switch is ON while foot brake is depressed measure voltage between foot brake switch terminal outlet wire LgB and chassis ground There is no electricity in normal condition If above 1 ...

Page 124: ...indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator Note The circuit in the dashed box is not mounted 12V 12V 12V BATT 12V KEY SW Input interface TA input interface Frequency divider selector AD input interface Input interface Input interface TA pulse pickup TA pulse square wave Fuel sensor Temperature sensor Engine speed 1 Engine ...

Page 125: ... wire RL and chassis 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 5 9 Combination meter warning lamp or indicator lamp is abnormal Reference Fig 2 5 2 Check point Check Cause Action 1 Combination Meter Lamp check 1 When starter switch is ON measure voltage between combination meter ...

Page 126: ...indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator Note The circuit in the dashed box is not mounted 12V 12V 12V BATT 12V KEY SW Input interface TA input interface Frequency divider selector AD input interface Input interface Input interface TA pulse pickup TA pulse square wave Fuel sensor Temperature sensor Engine speed 1 Engine ...

Page 127: ... 2 are OK and pulse is NG in item 3 tacho meter sensor is faulty If above items 1 and 2 are OK and tachometer reading is NG in item 3 combination meter is faulty Replace tachometer sensor or combination meter 2 Harness Connecting Between Terminals Measure resistance of harness connecting between terminals Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replac...

Page 128: ...indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator Note The circuit in the dashed box is not mounted 12V 12V 12V BATT 12V KEY SW Input interface TA input interface Frequency divider selector AD input interface Input interface Input interface TA pulse pickup TA pulse square wave Fuel sensor Temperature sensor Engine speed 1 Engine ...

Page 129: ...onnecting between terminals Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 2 5 13 Fuel meter is abnormal Reference Fig 2 5 2 Check point Check Cause Action 1 Fuel Unit Disconnect harness and measure resistance of fuel unit Standard resistance 13 5 Ω with float in Full position 80 0 Ω with float in Empty position If resistance is abnormal fuel...

Page 130: ...indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator Note The circuit in the dashed box is not mounted 12V 12V 12V BATT 12V KEY SW Input interface TA input interface Frequency divider selector AD input interface Input interface Input interface TA pulse pickup TA pulse square wave Fuel sensor Temperature sensor Engine speed 1 Engine ...

Page 131: ...stance between oil pressure switch terminal wire YG and chassis ground Combination meter connector terminal wire No 32 wire YG and chassis ground Standard resistance 100k Ω or more If resistance is abnormal harness is faulty Repair or replace harness 2 Oil Pressure Switch Disconnect oil pressure switch and check continuity between its terminals There is continuity in normal condition If there is n...

Page 132: ...R ACC R1 R2 2 3 5 6 1 4 44 45 36 Lg RL 48 5A 48 W 57 L 5W WG 3 1 2 5 44 2WG 36 Lg LIGHTING RELAY 64 2BrW 2 B 3 1 2 5 66 2GB 65 Sb FLOOD LAMP RELAY 38 2RG 2 B 22 44 11 6 WB WY 37 9 5 3 12 2 B Gy 11 6 GY B E L GY L R G GR GR GY GB 26 6 40 3 2 1 11 1 25Gy 65 Sb 1 25LgR 21 DIODE B R1 R2 Acc BR C R1 OFF ACC ST Movement Movement Movement LCD EEPROM Tachometer Fuel meter Temperature meter Hour meter Illu...

Page 133: ...arking brake switch is faulty Replace parking brake switch 3 Combination Meter Parking brake indicator 1 When starter switch is ON measure voltage between combination meter terminal wires and ground terminal wire Battery terminal wire No 57 inlet wire L and ground terminal wire No 2 wire B Starter switch terminal wire No 37 inlet wire WY and ground terminal wire No 2 wire B Standard voltage 12 V o...

Page 134: ...5A 20A 20A 20A 20A 3WL 52 WR 11 5WR 50 WR 12 5WR 50 WR 13 WB 9 C B BR ACC R1 R2 48 FUSE 5A 48 W 57 L 5W 1 4 8 W R B R1 R2 Acc BR C R1 OFF ACC ST Movement Movement Movement LCD EEPROM Tachometer Fuel meter Temperature meter Hour meter Illumination LED Water spray indicator Liquid spray indicator Position lamp indicator Flood lamp indicator Vibration indicator Turn signal indicator left Turn signal ...

Page 135: ...r 1 When starter switch is ON measure voltage between combination meter terminal wires and ground terminal wire Battery terminal wire No 57 inlet wire L and ground terminal wire No 2 wire B Starter switch terminal wire No 37 inlet wire WY and ground terminal wire No 2 wire B Standard voltage 12 V or more 2 When starter switch is ON and water spray switch is ON measure voltage between combination m...

Page 136: ...R ACC R1 R2 2 3 5 6 1 4 44 45 36 Lg RL 48 5A 48 W 57 L 5W WG 3 1 2 5 44 2WG 36 Lg LIGHTING RELAY 64 2BrW 2 B 3 1 2 5 66 2GB 65 Sb FLOOD LAMP RELAY 38 2RG 2 B 22 44 11 6 WB WY 37 9 5 3 12 2 B Gy 11 6 GY B E L GY L R G GR GR GY GB 26 6 40 3 2 1 11 1 25Gy 65 Sb 1 25LgR 21 DIODE B R1 R2 Acc BR C R1 OFF ACC ST Movement Movement Movement LCD EEPROM Tachometer Fuel meter Temperature meter Hour meter Illu...

Page 137: ...indicator lamp does not light combination meter is faulty Replace combination meter 2 5 19 Side marker lamp indicator lamp does not light Check that head lamp side marker lamp tail lamp and license lamp light Reference Fig 2 5 3 Check point Check Cause Action 1 Harness Measure resistance between lighting switch terminal 3 wire RL and combination meter connector terminal wire No 45 wire RL Standard...

Page 138: ...R ACC R1 R2 2 3 5 6 1 4 44 45 36 Lg RL 48 5A 48 W 57 L 5W WG 3 1 2 5 44 2WG 36 Lg LIGHTING RELAY 64 2BrW 2 B 3 1 2 5 66 2GB 65 Sb FLOOD LAMP RELAY 38 2RG 2 B 22 44 11 6 WB WY 37 9 5 3 12 2 B Gy 11 6 GY B E L GY L R G GR GR GY GB 26 6 40 3 2 1 11 1 25Gy 65 Sb 1 25LgR 21 DIODE B R1 R2 Acc BR C R1 OFF ACC ST Movement Movement Movement LCD EEPROM Tachometer Fuel meter Temperature meter Hour meter Illu...

Page 139: ...here 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 1 When starter switch is ON measure voltage between combination meter terminal wires and ground terminal wire Battery terminal wire No 57 inlet wire L and ground terminal wire No 2 wire B Starter switch terminal wire No 37 inlet wire WY ...

Page 140: ...input interface Frequency divider selector AD input interface Input interface Input interface TA pulse pickup TA pulse square wave Fuel sensor Temperature sensor Engine speed 1 Engine speed 2 Engine speed 3 Engine speed 4 Position lamp Backlight Turn signal right Turn signal left Vibration Liquid spray Water spray Flood lamp Glow plug Parking brake Engine charge warning Engine oil pressure Hydraul...

Page 141: ... timer terminal 4 inlet wire Y and chassis ground Glow lamp timer terminal 5 inlet wire BR and chassis ground Standard voltage 12 V or more 3 When starter switch is HEAT measure voltage between glow lamp timer terminal 6 inlet wire GL and chassis ground Standard voltage 12 V or more Electricity flows for a definite time If items 1 and 2 are OK and item 3 is NG glow lamp timer is faulty Replace glo...

Page 142: ...VER SWITCH B COM W NO WB COM 22 LgB NO FOOT BRAKE SWITCH WHEN NOT DEPRESS 20A 15A 15A 15A WL 15A WG 15A 20A WR 20A 20A 20A FUSE BOX WB 2GB 2WR 2WG 1 25Gy WG 2 B 33 GY 17 LgB 22 WB STOP LAMP RELAY LIGHTING SWITCH Lg RL WG R2H 2 10005 22 44 11 6 5 5WR 50 5WR 50 3 17 44 c a f e b 2 3 5 6 1 4 44 45 36 6 6 HAZARD SWITCH 3 2 6 5 1 4 GY GY 40 GB 26 GR 3 2 1 5 2 1 3 LIGHTING RELAY 2WG Lg B 2BrW 44 36 2 64...

Page 143: ...ure resistance of harness connecting between terminals Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 2 5 23 Backup buzzer does not sound Reference Fig 2 5 1 Check point Check Cause Action 1 Backup Buzzer Disconnect backup buzzer and directly connect battery positive terminal to backup buzzer terminal wire RY side and negative terminal to bac...

Page 144: ...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 145: ...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 valve or replace it if necessary 5 Servo Bypass Solenoid Valve If spool of servo bypass solenoid valve is stuck pressure in both sides of servo cylinder chamber is equalized This causes propulsion pump unable to discharge oil Measure pressure in servo...

Page 146: ...kage is faulty Check and adjust 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 multifunction valves If faulty condition is accordingly reversed check and adjust multifunction valve or replace it if necessary 3 2 3 Slow machine speed or small drive force ...

Page 147: ...arge 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 pump case is not within allowable range repair propulsion pump or replace it if necessary 3 2 4 Machine speed does not change Check point Cause Check Action 1 Speed Change Solenoid Valve Vehicle speed doe...

Page 148: ...d is excessively 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 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 6 Hydraulic Oil Filter Charge circuit pressu...

Page 149: ...s due to internal leakage of steering cylinder Repair steering cylinder or replace it if necessary 5 Suction Filter for Charge Pump Charge pump discharge rate decreases due to clogged filter Clean suction filter or replace it if necessary 6 Charge Pump Discharging pressure is insufficient due to efficiency degradation of charge pump Measure steering circuit pressure If low replace charge pump 7 St...

Page 150: ...pressure If low 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 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 3...

Page 151: ... Printed in Japan 2012 01 50 M B 0634 99234 0 31172 E 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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