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Sakai SV400D-2, Shop Manual

The Sakai SV400D-2 shop manual is a reliable resource for equipment owners seeking comprehensive maintenance instructions. This manual is available for free download on our website, providing users with easy access to the essential information they need to keep their Sakai SV400D-2 running smoothly.

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9-006

ELECTRICAL SYSTEM TROUBLESHOOTING 

Fig. : 2-2

SV400-2-09001

NC NO COM

B

NC NO COM

10

20A

9

8

7

6

5

4

3

2

15A

15A

15A

15A

15A

20A

20A

20A

20A

1

+

-

50
45

30

B

C

BR

ACC

D+

B+

W

2

1

7

8

F.L. 45A

F.L. 65A

F.L. 75A

F.L. 75A

F.L. 85A

G

RG

WR

WY

WY

BW

R

W

W

BY

Battery

relay

Battery

AV60

A

V

60

COM

NO

BR

B

AV60

RB

Starter relay

B

R

RB

W

Fuse box

F-R lever switch

R

W

R

BW

W

LgR

BrY

Lg

W

B

B

3

1

5

2

3

5

1

1

1

2

A

2

A

2

Lg

BR

LgW

WB

B

Shutdown

solenoid

Fuse

10A

Starter motor

Negative torque
control solenoid

Alternator

Starter switch

L-interlock

relay

P-interlock

relay

ACC

C

BR

R2

R1

B

Terminal

Starter

switch

position

R1

OFF

ACC

ST

Starter switch 

internal connection

Lamp

check

relay

Combination

meter lamp check

Combination

meter parking brake

indicator lamp

LgB

B

BY

LgW

5

1

3

2

Foot brake switch

1

4

3

2

5

BrW

Parking brake 

switch

Neutral

relay

GR

LgR

SV400-2-09001

NC NO COM

B

NC NO COM

10

20A

9

8

7

6

5

4

3

2

15A

15A

15A

15A

15A

20A

20A

20A

20A

1

+

-

50
45

30

B

C

BR

ACC

D+

B+

W

2

1

7

8

F.L. 45A

F.L. 65A

F.L. 75A

F.L. 75A

F.L. 85A

G

RG

WR

WY

WY

BW

R

W

W

BY

Battery

relay

Battery

AV60

A

V

60

COM

NO

BR

B

AV60

RB

Starter relay

B

R

RB

W

Fuse box

F-R lever switch

R

W

R

BW

W

LgR

BrY

Lg

W

B

B

3

1

5

2

3

5

1

1

1

2

A

2

A

2

Lg

BR

LgW

WB

B

Shutdown

solenoid

Fuse

10A

Starter motor

Negative torque
control solenoid

Alternator

Starter switch

L-interlock

relay

P-interlock

relay

ACC

C

BR

R2

R1

B

Terminal

Starter

switch

position

R1

OFF

ACC

ST

Starter switch 

internal connection

Lamp

check

relay

Combination

meter lamp check

Combination

meter parking brake

indicator lamp

LgB

B

BY

LgW

5

1

3

2

Foot brake switch

1

4

3

2

5

BrW

Parking brake 

switch

Neutral

relay

GR

LgR

Summary of Contents for SV400D-2

Page 1: ...SV400 2 SHOP MANUAL 0404 99027 0 31649 B ...

Page 2: ......

Page 3: ...l will help provide for your safety for the safety of those around you and for the proper operation and maintenance of the 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 wa...

Page 4: ......

Page 5: ...enance 1 004 1 11 Transporting the Machine 1 006 2 SPECIFICATIONS 1 SPECIFICATION DATA 2 001 1 1 SV400D 2 2 001 1 2 SV400T 2 2 003 1 3 SV400TB 2 2 005 1 4 SV400TF 2 2 007 1 5 SV400FB 2 2 009 2 SPECIFICATIONS AND SETTING 2 011 2 1 Engine 2 011 2 2 Propulsion 2 011 2 3 Hydraulic Devices 2 012 2 4 Steering Devices 2 012 2 5 Brakes 2 013 2 6 Oil and Grease Capacity 2 013 3 FUEL AND LUBRICANTS SPECIFIC...

Page 6: ... 2 4 007 2 3 2 Propulsion pump propulsion vibrator steering charge SV400TB FB 2 4 009 2 3 3 Propulsion hydraulic motor front 4 011 2 3 4 Internal structure of propulsion hydraulic motor front 4 012 2 3 5 Propulsion hydraulic motor rear 4 013 2 3 6 Block 4 014 3 VIBRATOR HYDRAULIC SYSTEM 4 015 3 1 Vibrator Hydraulic Piping 4 015 3 2 Hydraulic Equipment Specifications 4 016 3 2 1 Vibrator hydraulic ...

Page 7: ...02 2 1 Removal and Installation of Vibratory Drum 6 002 2 1 1 Removal of vibratory drum 6 002 2 1 2 Installation of vibratory drum 6 005 2 2 Vibratory Drum Assembly 6 006 2 3 Disassembly and Reassembly of Vibratory Drum 6 007 2 3 1 Disassembly of vibratory drum 6 007 2 3 2 Reassembly of vibratory drum 6 013 3 AXLE 6 021 3 1 Rear Axle 6 021 3 2 Rear Axle Lubrication 6 022 3 3 Rear Axle Structure 6 ...

Page 8: ...EASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT PRESSURE 8 005 3 1 Measurement 8 005 3 2 Adjustment 8 006 4 MEASUREMENT OF VEHICLE HIGH LOW SPEED CHANGE CIRCUIT PRESSURE 8 007 4 1 Measurement 8 007 5 MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE 8 008 5 1 Measurement 8 008 6 MEASUREMENT AND INSPECTION OF VIBRATOR CIRCUIT PRESSURE 8 009 6 1 Measurement 8 009 6 2 Inspection 8 010 7 MEASUREMEN...

Page 9: ...1 Vehicle speed does not change 9 015 2 3 2 Brake does not release 9 015 2 3 3 Brake does not operate 9 019 2 3 4 Vehicle moves neither forward nor backward 9 021 2 4 Vibrator 9 025 2 4 1 No vibration occurs 9 025 2 4 2 Amplitude does not change remains either low or high 9 025 2 4 3 Vibrator control is continuously engaged or does not change when the forward reverse lever is operated 9 027 2 5 Li...

Page 10: ...vibration 9 043 3 3 2 Vibrator frequency is too low 9 044 3 3 3 Vibrator L H does not switch 9 044 3 3 4 Vibrator does not stop 9 044 3 3 5 Vibrator system is overheating 9 045 3 3 6 Abnormal noise from vibrator system 9 045 3 4 Steering 9 046 3 4 1 Steering wheel is hard to turn 9 046 3 4 2 Steering response is slow 9 046 3 4 3 Steering wheel backlash or play is large 9 047 3 4 4 Steering system ...

Page 11: ...SAFETY ...

Page 12: ......

Page 13: ... for slinging operation In the assembly operation tightening torque in locations that require particular attention 1 2 General Operators and maintenance personnel must be alert to recognize and avoid potential hazards They should also have comprehensive training the required skills and necessary tools to perform the job safely The machine was built in accordance to the latest safety standards and ...

Page 14: ...azardous substances the required proper personal safety and protective equipment and traffic or jobsite regulations Machine operating instructions should also be supplemented with detailed instructions pertaining to the specific jobsite or work location Always be sure the persons working on the machine have read the operating instructions and all safety precautions before beginning work Reading sa...

Page 15: ...Safety Instructions Take all necessary precautions to ensure that the machine is used only when in a safe and reliable condition Avoid any operational mode that might compromise safety Operate the machine only if all protective and safety devices are in place and fully functional Always use the hand rails and steps to get on and off your machine maintaining 3 point contact using both hands 1 7 Sta...

Page 16: ...to OFF Lock all lockable compartments Park behind a safe barrier use proper flags and warning devices especially when parking in areas of heavy traffic 1 10 Maintenance In any performing any work concerning the operation adjustment or modification of the machine or it s safety devices or any work related to maintenance inspection or repair always follow the start up and shut down procedures in the...

Page 17: ...attery area is well ventilated clear of fumes should it be necessary to connect a jumper cable or battery charger Fumes can ignite from a spark and may explode Be sure battery charger is OFF when making connections if charging is required Use only original fuses with the specified rating Switch off the machine immediately if trouble occurs in the electrical system Work on the electrical system may...

Page 18: ...ing of crane operators Only experienced persons familiar with the operation of the machine may load and unload the machine Use ramps or a loading dock when loading or unloading the machine Ramps must be the proper strength low angle and the proper height and width Block the wheels front and rear of the hauling vehicle when loading and unloading the compactor Ensure that the haul vehicle is on leve...

Page 19: ...SPECIFICATIONS ...

Page 20: ......

Page 21: ...ow amplitude 38 Hz High amplitude 30 Hz Centrifugal force Low amplitude 93 kN 20 945 lbf High amplitude 118 kN 26 445 lbf Amplitude Low amplitude 0 7 mm 0 03 in High amplitude 1 4 mm 0 06 in Minimum turning radius 4 9 m 193 in Gradability 62 32 Engine Model DEUTZ TCD2011L04W diesel engine Type Water cooled 4 cycle in line direct injection with turbocharger Number of cylinders Bore Stroke 4 96 mm 1...

Page 22: ...12 V 100 Ah 1 unit 12 V Power line Transmission Model Hydrostatic transmission Speed 2 speed shifts Reversing gear Switching the direction of flow delivered from the variable pump Differential Auto lock type Final reduction gear Planetary gear type Vibrating system Transmission Hydrostatic transmission Vibrator Eccentric shaft type Braking device Service brake Hydrostatic and mechanical type Parki...

Page 23: ...e 38 Hz High amplitude 30 Hz Centrifugal force Low amplitude 103 kN 23 150 lbf High amplitude 127 kN 28 660 lbf Amplitude Low amplitude 0 7 mm 0 03 in High amplitude 1 4 mm 0 06 in Minimum turning radius 4 9 m 193 in Gradability 62 32 Engine Model DEUTZ TCD2011L04W diesel engine Type Water cooled 4 cycle in line direct injection with turbocharger Number of cylinders Bore Stroke 4 96 mm 125 mm 4 3 ...

Page 24: ...mission device Transmission Model Hydrostatic transmission Speed 2 speed shifts Reversing gear Switching the direction of flow delivered from the variable pump Differential Auto lock type Final reduction gear Planetary gear type Vibrating system Transmission Hydrostatic transmission Vibrator Eccentric shaft type Braking device Driving brake Hydrostatic and mechanical type Parking brake Mechanical ...

Page 25: ...Hz High amplitude 30 Hz Centrifugal force Low amplitude 103 kN 23 150 lbf High amplitude 127 kN 28 660 lbf Amplitude Low amplitude 0 7 mm 0 03 in High amplitude 1 4 mm 0 06 in Minimum turning radius 4 9 m 193 in Gradability 59 30 Engine Model DEUTZ TCD2011L04W diesel engine Type Water cooled 4 cycle in line direct injection with turbocharger Number of cylinders Bore Stroke 4 96 mm 125 mm 4 3 780 i...

Page 26: ...ission device Transmission Model Hydrostatic transmission Speed 2 speed shifts Reversing gear Switching the direction of flow delivered from the variable pump Differential Auto lock type Final reduction gear Planetary gear type Vibrating system Transmission Hydrostatic transmission Vibrator Eccentric shaft type Braking device Driving brake Hydrostatic and mechanical type Parking brake Mechanical t...

Page 27: ...ude 38 Hz High amplitude 30 Hz Centrifugal force Low amplitude 103 kN 23 150 lbf High amplitude 127 kN 28 660 lbf Amplitude Low amplitude 0 5 mm 0 02 in High amplitude 0 9 mm 0 04 in Minimum turning radius 4 9 m 193 in Gradability 50 26 Engine Model DEUTZ TCD2011L04W diesel engine Type Water cooled 4 cycle in line direct injection with turbocharger Number of cylinders Bore Stroke 6 96 mm 125 mm 6 ...

Page 28: ...mission device Transmission Model Hydrostatic transmission Speed 2 speed shifts Reversing gear Switching the direction of flow delivered from the variable pump Differential Auto lock type Final reduction gear Planetary gear type Vibrating system Transmission Hydrostatic transmission Vibrator Eccentric shaft type Braking device Driving brake Hydrostatic and mechanical type Parking brake Mechanical ...

Page 29: ...Hz High amplitude 30 Hz Centrifugal force Low amplitude 103 kN 23 150 lbf High amplitude 127 kN 28 660 lbf Amplitude Low amplitude 0 5 mm 0 02 in High amplitude 0 9 mm 0 04 in Minimum turning radius 4 9 m 193 in Gradability 48 25 Engine Model DEUTZ TCD2011L04W diesel engine Type Water cooled 4 cycle in line direct injection with turbocharger Number of cylinders Bore x Stroke 4 96 mm 125 mm 4 3 780...

Page 30: ...mission device Transmission Model Hydrostatic transmission Speed 2 speed shifts Reversing gear Switching the direction of flow delivered from the variable pump Differential Auto lock type Final reduction gear Planetary gear type Vibrating system Transmission Hydrostatic transmission Vibrator Eccentric shaft type Braking device Driving brake Hydrostatic and mechanical type Parking brake Mechanical ...

Page 31: ...m 41 lbf ft Fan belt tension deflection volume 10 15 mm 0 39 0 59 in When pressure of 10 kg is applied at belt center Valve clearance intake 0 3 mm 0 012 in Valve clearance exhaust 0 5 mm 0 020 in Compression pressure 2 2 2 7 MPa 319 392 psi Injection pressure 11 5 MPa 1668 psi Fuel consumption rate 230 g kW h 0 378 lb HP h When engine is at rated output Engine dry mass 268 kg 590 lb 2 2 Propulsio...

Page 32: ... 435 psi Vibration circuit Relief pressure setting front wheels 25 0 1 0 MPa 3625 145 psi Charge relief pressure setting 2 5 0 2 MPa 363 30 psi Vibrator motor drainage Less than 8 1 L min less than 2 1 gal min Allowable maximum value at maximum rotation Steering circuit Orbitrol relief pressure setting charge relief pressure setting 17 5 1 0 MPa 2538 145 psi Maximum stroke of drive pump control va...

Page 33: ...ensions Standard dimensions 38 4 35 2 mm 1 51 1 38 in Note 3 2 6 Oil and Grease Capacity Classifi cation Item Standard value Remarks Oil grease capacity Engine oil 10 5 L 2 8 gal Cooling water 13 L 3 4 gal Wheel motor reduction gear case Gear oil front 3 2 L 0 8 gal Differential case rear 7 3 L 1 9 gal Final drive case rear 1 25 L 2 0 3 gal 2 Vibrator case gear oil front 21 L 5 5 gal Wheel motor g...

Page 34: ...Lithium type extreme pressure NLGI 2 Fuel Diesel oil ASTM D975 2D 3 2 Recommended Lubricants Lubricant Oil company Engine oil API CF 4 Gear oil API GL 4 Hydraulic oil VG 46 Grease NLGI II CALTEX Universal Thuban 90 Rando Oil HD 46 Martifack EP 2 BP Vanellus C Extra BP Gear Oil EP 90 BP Energol HLP 46 BP Energrease LS EP 2 ESSO Esso Gear Oil GP 90 Nuto H 46 Beacon EP 2 MOBIL Delvac MX Mobil Pegasus...

Page 35: ...253 343 253 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 3...

Page 36: ......

Page 37: ...ENGINE AND CONTROLS ...

Page 38: ......

Page 39: ...ngine Mount 1 Damper 2 Nut M12 3 Damper 4 Damper 5 Damper 6 Bolt M12 100 108 N m 80 lbf ft Engine dry weight 268 kg 591 lbs Engine oil quantity 10 5 L 2 8 gal SV400 2 03001 3 2 6 1 A VIEW A 5 4 SV400 2 03001 3 2 6 1 A VIEW A 5 4 ...

Page 40: ...linder head cover 8 Lubricating oil filling 22 Fuel return line to the tank 9 Lubricating oil pump 23 Connections charge air cooler 10 Lubricating oil drain plug 24 Flywheel 11 Adjustment lever 25 Starter cover 12 Lubricating oil dipstick 26 Coolant inlet from cooler 13 Fuel pump with fuel cleaning 27 Turbocharger 14 Exchangeable fuel filter 28 Exhaust manifold line 15 Lube oil replacement filter ...

Page 41: ... M10 25 49 N m 36 lbf ft 8 Bolt M10 20 49 N m 36 lbf ft 9 Bolt M10 20 49 N m 36 lbf ft 10 Bolt M10 25 49 N m 36 lbf ft 11 Bolt M10 20 49 N m 36 lbf ft SV400 2 03003 A A 1 8 6 7 5 2 3 9 C C 11 B B 4 SECTION C C SECTION B B SECTION A A 10 SV400 2 03003 A A 1 8 6 7 5 2 3 9 C C 11 B B 4 SECTION C C SECTION B B SECTION A A 10 ...

Page 42: ...nut 2 Control cable 7 Shaft 3 Adjusting bolt Full 8 Nut 4 Locknut 9 Rod end 5 Adjusting bolt Idle SV400 2 03004 C 2 IDEL A FULL IDLE FULL 9 SECTION B B SECTION A A VIEW C 8 7 A B B 1 3 4 5 6 SV400 2 03004 C 2 IDEL A FULL IDLE FULL 9 SECTION B B SECTION A A VIEW C 8 7 A B B 1 3 4 5 6 ...

Page 43: ...1 Control cable 5 Bolt 2 Forward reverse lever 6 Spring 3 Interlock switch 7 Steel ball 4 Backup buzzer switch 8 Rod end SV400 2 03005 1 2 3 B B 4 8 5 6 7 VIEW A A A A F N R SECTION B B SV400 2 03005 1 2 3 B B 4 8 5 6 7 VIEW A A A A F N R SECTION B B ...

Page 44: ...et head bolt M10 35 49 N m 36 1 lbf ft 9 Hexagon socket head bolt M12 35 86 N m 63 4 lbf ft 10 Bolt M10 25 59 N m 43 5 lbf ft 11 Bolt M14 45 167 N m 123 2 lbf ft 12 Bolt M10 30 59 N m 43 5 lbf ft SV400 2 03006 7 10 11 12 9 8 3 5 6 4 2 12 A B B SECTION A A SECTION B B 1 8 3 2 A SV400 2 03006 7 10 11 12 9 8 3 5 6 4 2 12 A B B SECTION A A SECTION B B 1 8 3 2 A ...

Page 45: ...cified dimensions 9 mm 4 33 in Attach the housing 7 to the pump 1 and firmly secure with the four bolts 11 spring washers and washers 11 M14 45 167 N m 123 2 lbf ft Attach the flange 2 to the engine fly wheel and firmly secure with the eight bolts 8 8 M10 35 49 N m 36 1 lbf ft Ensuring engagement of the flange 2 and hub 3 attach the pump assembly to the flywheel Tighten and firmly secure the pump ...

Page 46: ......

Page 47: ...HYDRAULIC SYSTEMS ...

Page 48: ......

Page 49: ......

Page 50: ...ional Bidirectional Variable displacement Unidirectional Bidirectional Variable displacement pressure compensated unidirectional Arrow Direction of flow Orifice Hydraulic Motor Unidirectional Bidirectional Test port pressure measurement Double acting hydraulic cylinder Differential cylinder Temperature measurement gauge Pressure measurement gauge Electric motor Reservoir Filter Cooler Quick discon...

Page 51: ... Manual Relief valve Pressure compensation Rotating electric actuator Variable orifice Pilot control Hydraulic pilot control Direct pilot control Two port two position direction control valve Four port three position direction control valve Solenoid Single winding Multiple winding Electromagnetic hydraulic pilot Servo valve ...

Page 52: ......

Page 53: ...NE DEUTZ TCD2011 74 9 ｋW 2300 min 1 350 Ｎ ｍ 1600 min 1 MAX min 1 2480 ｍin 1 ４００ ｃｃ ｒ ｅｖ Ａ Ｔ Ｂ Ｐ T TF 103 0 kＮ 2300vpm 10 5 ton 127 5 kＮ 1800vpm 13 ton 1 4 1 4 3 8 3 8 ２ 67 ＭＰａ 1 6000PSI 1 6000PSI 3 4 3 4 3 4 3 4 3 4 3 4 1 2 1 2 3 4 3 4 7 8 14UNF 1 1 16 12UNF 1 1 16 12UNF 1 4 1 6000PSI 1 6000PSI 1 1 16 12UNF 9 16 18UNF 3 4 3 8 3 8 3 4 16UNF 3 4 16UNF 3 4 16UNF 3 4 16UNF 1 2 1 1 16 12UN 1 1 16 12UN ...

Page 54: ......

Page 55: ... 1 6000PSI 1 6000PSI 3 4 3 4 3 4 3 4 3 4 3 4 1 2 1 2 3 4 3 4 7 8 14UNF 1 1 16 12UNF 1 1 16 12UNF 1 4 1 6000PSI 1 6000PSI 1 1 16 12UNF 9 16 18UNF 3 4 3 8 3 8 3 4 16UNF 3 4 16UNF 3 4 16UNF 3 4 16UNF 1 2 1 1 16 12UN 1 1 16 12UN 1 2 1 2 1 2 1 1 4 7 8 14UNF 9 16 18UNF 9 16 18UNF 1 1 16 12UNF S E R V O S E R V O 35 0 ｃｃ ｒｅｖ 28 0 75 0 ｃｃ ｒｅｖ 150ｍｅｓｈ φ70Xφ35 380 ｓｔ φ70Xφ35 380 ｓｔ １５ ０ＭＰａ 103 0 kＮ 2300vpm ...

Page 56: ......

Page 57: ...UNF 2B 1 2 Port B forward SAE 1 1 3 Port A reverse SAE 1 2 Block 2 1 Port BB 1 1 16 12UNF 2B 2 2 Port BP 1 1 16 12UNF 2B 2 3 Port BX 3 4 16UNF 2B 2 4 Port BA 1 1 16 12UNF 2B 3 Propulsion motor rear 3 1 Port RB1 1 1 16 12UNF 2B 4 Hose 1 2 3 1 5 Hose 1 1 Hydraulic oil tank 6 Hose 1 3 2 1 The figures such as 1 1 and 2 1 show each port and the arrow symbols show the hose connection and the direction o...

Page 58: ......

Page 59: ...NF 2B 2 2 Port BP 1 1 16 12UNF 2B 2 3 Port BX 3 4 16UNF 2B 2 4 Port BA 1 1 16 UNF 2B 3 Stop valve 3 1 Port A1 3 4 16UNF 2B 3 2 Port B1 3 4 16UNF 2B 4 Propulsion pump 4 1 Port PA1 SAE 1 4 2 Port PB1 SAE 1 4 3 Drain port 1 1 16 12UN 2B 4 4 Drain port 1 1 16 12UN 2B 5 Oil cooler 5 1 IN G1 5 2 OUT G1 6 Hydraulic oil tank 7 Suction filter 8 Hose 4 2 1 3 9 Hose 4 4 1 4 10 Hose 4 1 2 2 11 Hose 4 3 5 1 12...

Page 60: ......

Page 61: ......

Page 62: ...pump propulsion vibrator steering charge SV400D T TF 2 SV400 2 04005 1 1 1 2 3 3 1 2 5 2 7 1 9 2 3 1 8 1 3 1 7 1 4 2 9 2 6 2 4 1 9 1 2 3 2 2 2 2 8 1 6 1 10 1 11 1 5 2 1 2 10 SV400 2 04005 1 1 1 2 3 3 1 2 5 2 7 1 9 2 3 1 8 1 3 1 7 1 4 2 9 2 6 2 4 1 9 1 2 3 2 2 2 2 8 1 6 1 10 1 11 1 5 2 1 2 10 ...

Page 63: ...tor pump 2 1 Port A2 high amplitude side 1 1 16 12UN 2B 2 2 Port B2 low amplitude side 1 1 16 12NU 2B 2 3 High pressure relief valve port A2 side 2 4 High pressure relief valve port B2 side 2 5 Charge pressure gauge port 1 2 20UNF 2B 2 6 Charge pressure gauge port 9 16 18UNF 2B 2 7 Charge relief valve 2 8 Drain port 1 5 16 12UN 2B 2 9 Servo pressure gauge port 9 16 18UNF 2B 2 10 Amplitude solenoid...

Page 64: ...rator steering charge SV400TB FB 2 SV400 2 04006 1 1 1 2 3 3 1 2 5 2 7 1 9 2 3 1 8 1 7 1 4 2 9 2 6 2 4 3 2 1 2 1 9 2 2 2 8 1 6 1 10 1 11 1 5 2 1 1 3 2 10 SV400 2 04006 1 1 1 2 3 3 1 2 5 2 7 1 9 2 3 1 8 1 7 1 4 2 9 2 6 2 4 3 2 1 2 1 9 2 2 2 8 1 6 1 10 1 11 1 5 2 1 1 3 2 10 ...

Page 65: ...2 Vibrator pump 2 1 Port A2 high amplitude side 1 1 16 12UN 2B 2 2 Port B2 low amplitude side 1 1 16 12NU 2B 2 3 High pressure relief valve port A2 side 2 4 High pressure relief valve port B2 side 2 5 Charge pressure gauge port 1 2 20UNF 2B 2 6 Charge pressure gauge port 9 16 18UNF 2B 2 7 Charge relief valve 2 8 Drain port 1 5 16 12UN 2B 2 9 Servo pressure gauge port 9 16 18UNF 2B 2 10 Amplitude s...

Page 66: ...sure gauge port port A side 9 16 18UNF 2B 5 Drain port 7 8 14UNF 2B 6 Reduction gear 7 Filler cap 7 8 14UNF 2B Motor specifications Model MF55AK 24EH Displacement 55 1 cm rev 3 4 cu in rev Maximum working pressure 41 8 MPa 6061 psi Reduction gear specifications Reduction ratio 1 24 457 Propulsion hydraulic motor weight 167 kg 368 lbs SV400 2 04007 1 2 3 5 4 5 5 6 7 SV400 2 04007 1 2 3 5 4 5 5 6 7 ...

Page 67: ... 1 Cylinder block kit 2 1 Floating seal kit 1 2 Roller bearing 2 2 Angular bearing 1 3 Oil seal 2 3 Shaft B 1 4 Swashplate assembly 2 4 Needle roller 1 5 Shaft 2 5 Shaft A 1 6 Journal bearing SV400 2 04008 1 1 6 1 5 1 4 1 3 2 2 1 1 1 2 2 1 2 2 3 2 4 2 4 2 5 SV400 2 04008 1 1 6 1 5 1 4 1 3 2 2 1 1 1 2 2 1 2 2 3 2 4 2 4 2 5 ...

Page 68: ...F 2B Displacement 4 Servo pressure gauge port 9 16 18UNF 2B Maximum 75 cm rev 4 58 cu in rev 5 Servo pressure gauge port 9 16 18UNF 2B Minimum 28 cm rev 1 71 cu in rev 6 Port A forward side SAE 1 Charge relief 7 Port B reverse side SAE 1 Pressure setting 2 67 MPa 387 psi 8 Speed change solenoid valve Weight 48 kg 106 lbs SV400 2 04009 3 8 4 1 5 7 8 6 2 2 SV400 2 04009 3 8 4 1 5 7 8 6 2 2 ...

Page 69: ...4 014 PROPULSION HYDRAULIC SYSTEM 2 3 6 Block 1 Port BB 1 1 16 12UNF 2B 2 Port BP 1 1 16 12UNF 2B 3 Port BA 1 1 16 12UNF 2B 4 Port BX 3 4 16UNF 2B SV400 2 04010 3 1 2 4 SV400 2 04010 3 1 2 4 ...

Page 70: ......

Page 71: ...UNF 2B 2 Return filter 2 1 OUT 1 1 16 12UN 2B 2 2 IN 1 1 16 12UN 2B 3 Propulsion pump 3 1 Drain port 1 1 16 12UN 2B 4 Vibrator pump 4 1 Port PB2 1 1 16 12UN 2B 4 2 Port PA2 1 1 16 12UN 2B 4 3 Drain port 1 5 16 12UN 2B 4 4 Drain port 1 5 16 12UN 2B 5 Hose 1 3 Hydraulic oil tank 6 Hose 4 1 1 1 7 Hose 4 2 1 2 8 Hose 2 1 Hydraulic oil tank 9 Hose 4 3 2 2 10 Hose 3 1 4 4 The figures such as 1 1 and 2 1...

Page 72: ......

Page 73: ...Drain port D3 7 8 14UNF 2B Specifications Model 4353054 MF35 Displacement 35 0 cm rev 2 1 cu in Working pressure 34 5 MPa 5003 psi Weight 11 kg 24 3 lbs SV400 2 04012 1 2 3 4 5 3 D1 D2 D3 A B Hydraulic circuit diagram Flow of oil A B Clockwise rotation B A Counterclockwise rotation SV400 2 04012 1 2 3 4 5 3 D1 D2 D3 A B Hydraulic circuit diagram Flow of oil A B Clockwise rotation B A Counterclockw...

Page 74: ......

Page 75: ...3 Power cylinder R 3 1 Port R1 2 3 4 16UNF 3 2 Port R2 2 3 4 16UNF 4 Power cylinder L 4 1 Port L1 2 3 4 16UNF 4 2 Port L2 2 3 4 16UNF 5 Line filter 5 1 IN 1 1 16 12UN 2B 5 2 OUT 1 1 16 12UN 2B 6 Orbitrol 6 1 Port P 3 4 16UNF 6 2 Port T 3 4 16UNF 6 3 Port L 3 4 16UNF 6 4 Port R 3 4 16UNF 8 Hose 6 4 3 1 9 Hose 1 2 6 1 10 Hose Hydraulic oil tank 1 1 11 Hose 4 1 3 2 12 Hose 5 2 2 1 13 Hose 3 1 4 2 14 ...

Page 76: ......

Page 77: ...Port R2 2 3 4 16UNF 4 Power cylinder L 4 1 Port L1 2 3 4 16UNF 4 2 Port L2 2 3 4 16UNF 5 Line filter 5 1 IN 1 1 16 12UN 2B 5 2 OUT 1 1 16 12UN 2B 6 Orbitrol 6 1 Port P 3 4 16UNF 6 2 Port T 3 4 16UNF 6 3 Port L 3 4 16UNF 6 4 Port R 3 4 16UNF 7 Flow dividing valve 7 1 Port BA PF1 2 7 2 Port BP PF3 4 8 Hose 6 4 3 1 9 Hose 1 2 7 2 10 Hose Hydraulic oil tank 1 1 11 Hose 4 1 3 2 12 Hose 5 2 2 1 13 Hose ...

Page 78: ......

Page 79: ...4 Roller bearing 9 Bolt M16 80 265 N m 195 lbf ft 5 Bracket top side 10 Nut M20 539 N m 398 lbf ft 6 Bracket bottom side 11 Bolt M20 100 7 O ring P 112 12 Bolt M16 45 265 N m 195 lbf ft Center pin assembly weight 200 kg 441 lbs SV400 2 04015 5 6 7 8 9 10 11 1 2 12 3 4 SV400 2 04015 5 6 7 8 9 10 11 1 2 12 3 4 ...

Page 80: ... shaft 6 Nut M12 P 1 25 35 N m 101 lbf ft 3 Orbitrol 7 Bolt M10 30 49 N m 36 lbf ft 4 Bracket 8 Bolt M 8 12 23 N m 17 lbf ft 5 Damper 9 Nut M10 49 N m 36 lbf ft Steering wheel assembly weight 18 kg 40 lbs SV400 2 04016 1 6 2 7 4 8 9 5 3 SV400 2 04016 1 6 2 7 4 8 9 5 3 ...

Page 81: ... 4 16UNF 7 Pin 16 O ring 25 Port R 3 4 16UNF 8 Spool 17 Plate 26 Port T 3 4 16UNF 9 Relief valve 18 G rotor 27 Port P 3 4 16UNF Specifications Model OSPC 400 ON Displacement 400 cm rev 24 4 cu in rev Relief valve pressure setting 15 0 MPa 2175 psi Weight 8 kg 18 lbs SV400 2 04017 26 27 24 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 SV400 2 04017 26 27 24 25 1 2 3 4 5 6 7 8 9 10 ...

Page 82: ...5 Steering Cylinder 1 Steering cylinder 2 Pin 3 Collar 4 Plate 5 Bolt M10 25 49 N m 36 lbf ft SV400 2 04018 B B A A 1 1 SECTION A A SECTION B B 2 3 4 5 5 4 3 2 SV400 2 04018 B B A A 1 1 SECTION A A SECTION B B 2 3 4 5 5 4 3 2 ...

Page 83: ... Stopper 16 Piston 7 Rod cover 17 Nylon nut M24 8 O ring G 70 18 O ring port 3 4 16UNF 9 O ring G 65 19 Tube 10 Backup ring 20 Grease nipple R1 8 Specifications Maximum working pressure 17 2 MPa 2488 psi Stroke 380 mm 15 in 17 Nylon nut M24 382 559 N m 282 412 lbf ft Weight 20 1 kg 44 3 lbs 18 18 20 1 4 3 4 3 17 15 14 16 10 9 13 12 11 8 6 5 7 2 19 18 18 20 1 4 3 4 3 17 15 14 16 10 9 13 12 11 8 6 5...

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Page 85: ...ort P G3 4 2 4 Port T G3 4 3 Power cylinder L 3 1 Port L1 up side G3 8 3 2 Port L2 down side G3 8 4 Power cylinder R 4 1 Port R1 up side G3 8 4 2 Port R2 down side G3 8 5 Flow dividing valve 5 1 Port BB PF1 2 6 Hose 4 1 9 7 Hose 4 2 10 8 Hose 3 2 10 9 Hose 3 1 9 10 Hose 3 1 4 1 2 1 11 Hose 3 2 4 2 2 2 12 Hose 2 4 Hydraulic oil tank 13 Hose 5 1 2 3 The figures such as 1 1 and 2 1 show each port and...

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Page 87: ...ort T tank port G3 4 4 L block assembly 8 Port P pump port G3 4 9 Port G pressure gauge connection port RC1 4 Specifications Model SV11 F L 7 F Maximum working pressure 20 6 MPa 2987 psi Rated flow 70 L min 18 5 gal min Main relief pressure setting 13 7 MPa 1987 psi at 30 L min 8 gal min Weight 6 6 kg 14 6 lbs 6 7 8 9 4 3 1 2 5 Hydraulic circuit diagram 6 7 8 9 4 3 1 2 5 Hydraulic circuit diagram ...

Page 88: ...ring 16 Piston ring 6 Cylinder head 17 Piston 7 Lock washer 8 O ring G 65 9 O ring P 60 18 U nut M20 1 5 314 N m 232 lbf ft 10 Bush 19 O ring port G3 8 11 U ring 20 Tube Specifications Relief valve pressure setting 11 8 MPa 1711 psi Stroke 260 mm 8 5 in Weight 10 kg 22 0 lbs 14 4 3 20 19 19 18 17 16 13 12 11 10 9 8 7 6 5 15 4 3 1 2 14 4 3 20 19 19 18 17 16 13 12 11 10 9 8 7 6 5 15 4 3 1 2 ...

Page 89: ... 1BP 36 6 Port A G1 2 7 Port B G1 2 8 Port P G3 4 Specifications Model FDT3 06 60S 2 1 Rated pressure 29 4 MPa 4263 psi Standard flow 60 L min 16 gal min Flow division ratio A B 2 1 Weight 5 kg 11 lbs 6 7 1 8 2 3 4 5 Hydraulic oil pressure symbol 6 7 1 8 2 3 4 5 Hydraulic oil pressure symbol ...

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Page 91: ...ELECTRICAL SYSTEM ...

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Page 93: ...Y Y HYDRAULIC OIL FILTER SWITCH HYDRAULIC OIL FILTER SWITCH YB B FUEL UNIT YR THERMO UNIT LgW B HORN SWITCH HORN LgW Lg HORN RELAY R3 5 3 1 2 RY 1 25RY L INTERLOCK RELAY R1 2Ｌｇ W B 2 1 5 3 LAMP CHECK RELAY R4 B BY ＬｇＢ 2 3 5 1 RY RG Y 1 3 2 Br G Y Y YR YB YB YR DIODE UNIT A C E F H I D B G 1 2 VIBRATOR L H CHANGE SWITCH VIBRATOR SOLENOID VALVE SOL HIGH LOW B 4 1 2 5 a b N100 95E41R B AV60 BATTERY A...

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Page 95: ...Negative torque control solenoid Backup buzzer Fuel unit Battery relay Fusible link Speed change solenoid valve Parking brake solenoid Hydraulic oil filter switch Horn switch Vibrator ON OFF switch Control box F R lever switch Backup buzzer switch Tachometer sensor Startor relay Starter motor Horn Foot brake switch Vibrator solenoid a Vibrator solenoid b Alternator Thermo unit VIEW A ...

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Page 97: ... 11 Lamp check relay 4 Parking brake switch 12 Neutral holding relay 5 Starter switch 13 Neutral relay 6 Vibrator L H change switch 14 Diode unit 7 Vibrator selector switch 15 Fuse box 8 L Interlock relay 16 Control box SV400 2 05003 14 13 15 12 8 9 10 11 VIEW B VIEW A 6 7 1 2 3 4 5 A 16 B SV400 2 05003 14 13 15 12 8 9 10 11 VIEW B VIEW A 6 7 1 2 3 4 5 A 16 B ...

Page 98: ...out 1 Battery cable L 1900 mm 74 8 in 5 Cushion 2 Battery relay 6 Battery 3 Battery cable L 250 mm 9 8 in 7 Battery cable L 350 mm 13 8 in 4 Plate lauan 8 Battery cable L 350 mm 13 8 in SV400 2 05004 1 2 3 4 5 6 7 8 SV400 2 05004 1 2 3 4 5 6 7 8 ...

Page 99: ...ch Neutral holding relay Vibrator selector switch Horn relay Hour meter Combination meter power source Control box Engine warning lamp Thermo unit Deutz installed Diode unit Speed change switch Combination meter lamp SV400 2 05005 Fuse box Relay panel 20A 15A 15A 15A 15A 15A 20A 20A 20A 20A 10 9 8 7 6 5 4 3 2 1 Starter relay W Battery relay R Battery relay RG Fuse box BW R RY YW L RY P interlock r...

Page 100: ...tified current 3 A Maximum surge current 180 A Insulation resistance At least 3 MΩ with a 500 VM insulation tester between each connector terminal and cover Storage operating temperature 30 C to 75 C 22 F to 167 F SV400 2 05006 1 2 A B C D E F G H I A B C D E F G H I Schematic diagram SV400 2 05006 1 2 A B C D E F G H I A B C D E F G H I Schematic diagram ...

Page 101: ...VIBRATORY DRUM REAR AXLE ...

Page 102: ......

Page 103: ...rque 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 plates with new parts Properly bend split cotter pins and lock plates When applying an adhesive first clean and remove oil grease from the surfaces properly Then apply two or three drops to the threaded areas When applying a liqui...

Page 104: ... or wooden blocks at the rear end of the rear frame Do not allow the rear wheel tires to leave the ground The tires must support the vehicle s body weight too Rear lift weight 2 960 kg 6 530 lbs When lifting the vehicle use an appropriate hoist of sufficient strength Confirm that the surrounding area is safe and work in a natural unstrained posture Also to firmly secure the vehicle body use a supp...

Page 105: ... installing 2 M20 100 540 N m 398 lbf ft 5 Disconnecting piping Propulsion motor piping Disconnect the hydraulic hoses 4 5 and 6 that are connected to the propulsion motor Either plug both sides of disconnected connections or take other steps to prevent dust from getting inside Immediately after the vehicle has stopped the hydraulic oil will be hot and under builtup pressure If under these conditi...

Page 106: ...e side too Separate the drum assembly and front frame When installing 10 M20 90 540 N m 398 lbf ft 7 As shown in the figure on the right use support stands or other means to firmly secure the side of the vehicle body on which the drum was removed Ensure that the vehicle body does not move SV400 2 06006 7 8 9 SV400 2 06006 7 8 9 SV400 2 06007 Support stand Lift with crane Support stand 10 11 SV400 ...

Page 107: ... 2 When installing the vibratory drum pay particular attention to the items mentioned below If the engine is run at high speed or the cylinder is operated to full stroke when the engine is started for the first time after work is completed the piston packing or other items may be damaged by air entering into the cylinder Fill the hydraulic oil tank to the specified level to make up for any oil lea...

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Page 109: ...e shaft 33 Vibrator bearing 34 Bolt M16 50 35 O ring 36 Axle shaft 37 Bolt M16 50 38 Disc 39 Bolt M20 90 40 Bolt M16 50 41 Holder 42 Damper 43 Bolt M12 25 44 Bolt M12 40 45 Propulsion motor 46 Vibrator motor SV400 2 06010 Propulsion motor side SECTION A A Vibrator motor side Level plug 10 2 10 1 10 3 Oil filler plug Drain plug Vibrator mode is Low with motor rotating clockwise Vibrator mode is Hig...

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Page 111: ...m the vibrator case Gear oil quantity 21 L 5 5 gal 2 Lift the vibratory drum with a crane As shown in the figure on the right stand it up with the propulsion motor side facing downward After standing up the drum place wooden blocks that have sufficient strength underneath Stabilize the drum so that it is not unsteady Vibratory drum assembly SV400D 2 2 640 kg 5 820 lbs SV400T TB 2 2 860 kg 6 305 lb...

Page 112: ...ttach the lifting bolts nuts M20 2 5 as shown in the figure on the right Using a crane lift and remove the holder 19 damper 18 and disc 14 together Total of lifted parts 19 30 18 and 14 120 kg 265 lbs 5 Remove the sixteen bolts 9 Remove the sleeve 7 SV400 2 06014 21 46 24 SV400 2 06014 21 46 24 SV400 2 06015 Lift with crane 19 16 18 14 30 SV400 2 06015 Lift with crane 19 16 18 14 30 SV400 2 00016 ...

Page 113: ...0 kg 309 lbs When attaching the lifting bolts screw in the threads fully before using 7 Attach a lifting bolt M10 1 5 to the end of the vibrator shaft 4 Then lift with a crane and remove Vibrator Shaft 140 kg 309 lbs 8 In the figure on the right the vibrator motor side is up From the top the figure shows the condition with the part removed SV400 2 06017 Lift with crane Wooden block Wooden hammer 3...

Page 114: ...ing area is safe and work in a natural unstrained posture 10 Remove the sixteen bolts 40 As shown in the figure on the right attach the lifting bolt M20 2 5 to the holder 41 and slowly lift Remove together with the damper 42 and disc 38 Total of lifted parts 41 42 and 38 115 kg 255 lbs 11 Remove the sixteen bolts 37 Remove the propulsion motor 45 Propulsion motor 180 kg 397 lbs SV400 2 06020 SV400...

Page 115: ...hows the condition in which all parts have been removed from the vibratory drum assembly 14 The figure on the right shows the axle shaft subassembly removed from the vibratory drum Remove the six bolts 29 Remove the cover 22 SV400 2 06023 34 36 SV400 2 06023 34 36 SV400 2 06024 SV400 2 06024 SV400 2 06025 22 29 SV400 2 06025 22 29 ...

Page 116: ...over 27 16 Place the plate at the end of the axle shaft With the puller against the housing 11 separate the housing including the roller bearing from the axle shaft SV400 2 06026 23 27 SV400 2 06026 23 27 SV400 2 06027 Puller Plate 11 SV400 2 06027 Puller Plate 11 ...

Page 117: ...aft 32 with support stands and or wooden blocks Lightly apply gear oil to the press fitting surface of the vibrator bearing 33 Drive in the vibrator bearing 33 3 Using a crane lift and invert the axle shaft 32 subassembly Lightly apply gear oil to the press fitting surface of the roller bearing Attach the inner race of the roller bearing 13 Axle shaft subassembly 90 kg 198 lbs SV400 2 06028 11 13 ...

Page 118: ... 31 approximately 1 mm to create a gap between the axle shaft end face and cover 27 interior surface Then install the cover 27 Install washers to the four bolts 23 and tighten to a tightening torque of 108 N m 80 lbf ft Rotate the housing 11 two or three times Then tighten the same bolts again to a tightening torque of 108 N m 80 lbf ft Repeat this procedure two or three times until the bolt tight...

Page 119: ...imension A Preload adjustment shim thickness A 0 1 mm Remove the bolts 23 Remove the cover 27 Insert the shim 31 whose preload adjustment shim thickness equal to A 0 1 mm Then firmly secure the cover 27 again by installing washers to the eight bolts 23 23 M14 40 170 N m 125 lbf ft SV400 2 06034 23 27 31 SV400 2 06034 23 27 31 SV400 2 06035 A There must be no gap 23 27 SV400 2 06035 A There must be...

Page 120: ...shaft 97 kg 214 lbs Vibrator bearing 7 kg 15 lbs 10 Install the O ring 35 to the axle shaft 36 Lightly apply grease to the entire circumference of the O ring 35 Using the sixteen bolts 34 and washers firmly secure the axle shaft 36 to the drum 34 M16 50 270 N m 199 lbf ft NOTE When installing make sure that the O ring does not protrude from the groove Use aids such as work stepladders when working...

Page 121: ... subassembly of the holder 41 damper 42 and disc 38 to the propulsion motor Total of lifted parts 41 42 and 38 115 kg 255 lbs 40 M16 50 270 N m 199 lbf ft 13 Lifting with a crane invert the drum as shown in the figure on the right Lifted weight in figure on the right SV400D 2 2 240 kg 4 938 lbs SV400T TB 2 2 460 kg 5 423 lbs SV400TF FB 2 3 810 kg 8 400 lbs Inverting the drum can be dangerous work ...

Page 122: ... the axle shaft 32 subassembly with a crane When attaching the axle shaft move the vibrator shaft until the center of the vibrator bearing inner race is aligned with the center of the shaft Be careful not to allow the vibrator bearing to lean Axle shaft 32 subassembly 140 kg 309 lbs 16 Using the sixteen bolts 9 and washers firmly secure the axle shaft subassembly to the drum NOTE When attaching ma...

Page 123: ...8 and 14 120 kg 265 lbs 19 Using the sixteen bolts 16 and washers firmly secure the holder subassembly to the housing Apply a molybdenum based grease to the spline surface of the sleeve 7 and attach it to the spline shaft at the end of the vibrator shaft 16 M20 50 540 N m 398 lbf ft SV400 2 06045 Lift with crane Shaft must move 1 to 3 mm SV400 2 06045 Lift with crane Shaft must move 1 to 3 mm SV40...

Page 124: ... with a crane and set it sideways at the position of the plug shown in the figure on the right Remove the oil filler plug and level plug From the oil filler plug hole add approximately 21 L 5 5 gal of gear oil until gear oil drips from the level plug hole Attach the oil filler plug and level plug SV400 2 06048 21 46 24 25 SV400 2 06048 21 46 24 25 SV400 2 06049 Chock block Chock block Oil filler p...

Page 125: ...ubrication and level gauge 10 Bolt for brake adjustment 11 Plug for differential component lubrication 12 Plug for differential component drain 13 Plug for brake component drain 14 Bolt M20 220 540 N m 398 lbf ft 15 Valve 16 Plug for hub reduction gear component lubrication level gauge and drain Rear axle assembly weight 600 kg 1 323 lbs Tire assembly weight 135 kg 297 lbs SV400 2 06050 9 10 11 10...

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Page 127: ...ousing component 7 3 L 1 9 gal Hub reduction gear component 1 25 L 2 0 33 gal 2 1 Filler port plug 2 Drain plug 3 Level gauge plug SV400 2 06051 1 3 2 2 1 3 2 1 1 3 Center housing component differential brake Hub reduction gear component SV400 2 06051 1 3 2 2 1 3 2 1 1 3 Center housing component differential brake Hub reduction gear component ...

Page 128: ...ture 3 3 1 Center housing 1 Cover 5 Bolt 9 Magnet plug 2 O ring 6 Vent 10 Plug 3 Housing 7 Seal washer 11 Snap ring 4 Seal washer 8 Plug SV400 2 06052 2 2 1 2 2 1 3 7 9 11 10 6 8 7 5 4 SV400 2 06052 2 2 1 2 2 1 3 7 9 11 10 6 8 7 5 4 ...

Page 129: ...l 11 Shim 2 Ring nut 7 Ring nut 12 Shim 3 Cylinder bolt 8 Bevel gear set 13 Spacer 4 Tapered roller bearing 9 Bolt 5 Differential carrier 10 Tapered roller bearing SV400 2 06053 7 10 13 12 11 10 8 1 2 4 3 5 6 9 4 2 1 SV400 2 06053 7 10 13 12 11 10 8 1 2 4 3 5 6 9 4 2 1 ...

Page 130: ... Nut 5 Plug 15 Lock plate 25 Stud bolt 6 Seal 16 Circlip 26 Friction washer 7 Axle shaft 17 Planetary gear 27 Nut 8 Hub bolt 18 Bearing 28 Stud bolt 9 Wheel hub 19 Hub nut 10 O ring 20 Seal SV400 2 06054 4 21 22 19 11 23 26 18 17 16 15 29 14 13 12 25 24 10 8 9 11 6 20 1 27 2 21 21 5 4 28 7 3 2 SV400 2 06054 4 21 22 19 11 23 26 18 17 16 15 29 14 13 12 25 24 10 8 9 11 6 20 1 27 2 21 21 5 4 28 7 3 2 ...

Page 131: ... 19 Bolt 4 O ring 12 Adjustment bolt 20 Seal washer 5 Cover 13 Hexagon bolt 21 Bolt 6 O ring 14 Sheet 22 Vent 7 Cylinder bolt 15 O ring 23 Bolt 8 Brake disc 16 Pinion SV400 2 06055 1 2 3 4 5 6 7 18 19 21 20 22 23 13 14 15 12 11 10 16 9 17 8 SV400 2 06055 1 2 3 4 5 6 7 18 19 21 20 22 23 13 14 15 12 11 10 16 9 17 8 ...

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Page 133: ...BRAKES ...

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Page 135: ...E SYSTEM 1 1 Brake Pedal 1 Brake pedal 2 Return spring 3 Foot brake switch 4 Bolt M10 40 5 Nut M10 6 Bolt M10 25 49 N m 36 lbf ft SV400 2 07001 1 1 2 3 A A 6 5 3 20 4 SECTION A A SV400 2 07001 1 1 2 3 A A 6 5 3 20 4 SECTION A A ...

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Page 137: ...ion and when brake is ON 15A 15A Fuse Fuse Condition in which brake pedal is pressed Foot brake switch Steering pump charge pump Rear propulsion motor Parking brake switch Brake ON condition Speed change solenoid valve The arrow symbol shows the direction of the hydraulic oil flow A B P T Propulsion pump Engine Neutral solenoid without solenoid excited Diode unit Neutral holding relay without rela...

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Page 139: ...is not pressed Foot brake switch Steering pump charge pump Rear propulsion motor Parking brake switch Brake OFF condition Speed change solenoid valve The arrow symbol shows the direction of the hydraulic oil flow A B P T Propulsion pump Engine Neutral solenoid with solenoid excited Diode unit Neutral holding relay with relay excited Neutral relay with relay excited REVERSE FORWARD Parking brake in...

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Page 141: ...rt P1 M14 6 Hose 1 3 3 2 3 1 Port A 9 16 18UNF 2B 3 2 Port P 9 16 18UNF 2B 3 3 Port T 9 16 18UNF 2B 7 Hose 2 1 3 2 8 Hose 3 1 5 1 9 Hose 5 1 4 1 The figures such as 1 3 and 2 1 show each port and the arrow symbols show the hose connection and the direction of the flow of the oil SV400 2 07003 6 7 3 2 8 1 3 1 5 1 4 5 9 4 1 2 1 2 3 3 3 1 3 2 SV400 2 07003 6 7 3 2 8 1 3 1 5 1 4 5 9 4 1 2 1 2 3 3 3 1 ...

Page 142: ...16 18UNF 4 O ring 1B P14 9 Port T 9 16 18UNF 5 Solenoid Specifications Rated pressure 4 9 MPa Ports A P 710 psi 0 5 MPa Port T 72 psi Rated flow 30 L min 7 9 gal min Voltage 12 V Power 13 W SV400 2 07004 8 2 1 9 6 1 3 2 4 5 P A T 7 Electric circuit SV400 2 07004 8 2 1 9 6 1 3 2 4 5 P A T 7 Electric circuit ...

Page 143: ...TRUCTURE 1 Friction plate 2 Separating plate 3 Adjusting pinion for brake adjustment 4 Bolt for brake adjustment 5 Piston 6 Drain plug Brake release pressure 1 5 3 0 MPa 218 435 psi SV400 2 07005 1 2 5 6 3 4 SV400 2 07005 1 2 5 6 3 4 ...

Page 144: ...wise making the inside of the cover 8 and ring 9 adhere together To create an inside clearance of 1 mm 0 04 in between the cover 8 and ring 9 rotate the adjusting pinion 3 counterclockwise four complete turns Pinion 3 adjustment quantity 0 25 mm rotation 0 01 in rotation Brake disc assembly wear limit 1 6 mm 0 063 in 3 Attach the safety plate 7 and tighten the bolt 4 Bolt 4 11 N m 8 1 lbf ft SV400...

Page 145: ...rake disc After the bolt end makes contact with the pressure plate 14 strictly observe not tightening the bolt 10 more than one complete turn 4 Adjustment after manual release of brake Remove the bolt 10 nut 11 and seal washer 15 Replace the seal washer 15 with a new one Apply grease to the bolt 10 threads As shown in the figure on the right install the bolt 10 nut 11 and seal washer 15 SV400 2 07...

Page 146: ...y adjust the bolt on the opposite side too Tighten the nut 11 and firmly secure the bolt 10 When tightening the nut 11 make sure that the bolt 10 does not move After securing the bolt check the dimensions of the bolt again SV400 2 07013 30 0 5 0 SV400 2 07013 30 0 5 0 SV400 2 07014 11 SV400 2 07014 11 ...

Page 147: ...INSPECTION AND ADJUSTMENT ...

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Page 149: ...on the hydraulic system while the engine is running and the system is hot and under pressure Do not disconnect hydraulic hoses or fittings until the system has cooled and pressure has been properly relieved Before removing any plugs from the pressure measurement ports always release any residual pressure from the piping and open the cap of the fluid tank to release and pressure WARNING Inadvertent...

Page 150: ... the instruments regularly An instrument that does not start from the appropriate zero point may give an inaccurate reading 1 1 3 Precautions for inspection and adjustment When performing inspections and adjustments pay special attention to safety For each inspection always take three measurements for each measurement point If the measurements significantly differ the measurement method may be inc...

Page 151: ...sure gauge through the adapter Gauge port 9 16 18UNF Forward side gauge port 1 6 Reverse side gauge port 1 5 Pressure gauge 0 49 MPa 0 7105 psi Press the parking brake switch turn the parking brake ON and move the speed change switch to the Low position Start the engine Then move the throttle lever to the high idling position Slowly operate the forward reverse lever to the side to be measured and ...

Page 152: ...MPa rotation 305 psi rotation If no evidence of looseness exists remove the multifunction valve 1 3 or 1 4 Check for dust lodged in the removed multifunction valve and for damage to the seat surface If dust is present disassemble and clean the multifunction valve If the seat surface is scratched or damaged replace the multifunction valve After adjustment is completed measure the pressure again Con...

Page 153: ...cape from the charge relief valve on the vibrator pump side Remove the plug 1 from the charge relief valve 2 7 on the vibrator pump side Insert a spacer ø12 mm t 10 mm as shown in the figure on the right Attach the plug 1 3 1 Measurement Oil temperature during measurement 50 5 C 122 41 F Remove the plug from the charge pressure gauge port 1 8 Attach the pressure gauge through the adapter ⓕ Gauge p...

Page 154: ...crew Pressure drops Pressure change 0 29 MPa rotation 42 psi rotation If no evidence of looseness exists remove the charge relief valve 1 10 Check for dust lodged in the removed charge relief valve and for damage to the seat surface If dust is present disassemble and clean the charge relief valve If the seat surface is scratched or damaged replace the charge relief valve After adjustment is comple...

Page 155: ...tach the pressure gauge through the adapter Gauge port 9 16 18UNF Low speed side gauge port 5 High speed side gauge port 4 Pressure gauge 0 4 9 MPa 0 711 psi Press the parking brake switch turn the parking brake ON and move the speed change switch to the Low or High position Start the engine move the throttle lever to the high idling position and measure the pressure Standard charge relief pressur...

Page 156: ...re gauge through the adapter Gauge port G1 4 Pressure gauge 0 4 9 MPa 0 711 psi Confirm that the forward reverse lever is in the neutral position Press the parking brake switch and turn the parking brake ON Start the engine Then move the throttle lever to the high idling position Turn the parking brake switch OFF and measure the brake release pressure Standard charge relief pressure setting 2 5 0 ...

Page 157: ...auge port 2 Pressure gauge 0 34 3 MPa 0 4975 psi Press the parking brake switch and turn the parking brake ON Start the engine Then move the throttle lever to the high idling position Press the vibrator switch and turn vibration ON Measure the maximum value of vibrator circuit pressure NOTE If the vehicle is subjected to vibration for a long period while in a stopped condition the vibrator bearing...

Page 158: ...sassemble and clean the high pressure relief valve If after disassembly and cleaning you remeasure the pressure and find that it deviates from the maximum standard vibration pressure setting replace the high pressure relief valve After the inspection is completed measure the pressure again Confirm whether the pressure rises to the maximum standard vibration pressure setting range High pressure rel...

Page 159: ...its and vibration charge circuits consist of parallel circuits Thus in order to measure whether the vibration charge circuit pressure is within the standard value use the following operation to ensure that oil does not escape from the charge relief valve on the propulsion pump side Loosen the locknut 2 from the charge relief valve 2 7 on the propulsion pump side Tighten the adjustment screw 3 by o...

Page 160: ...e gauge port 2 5 Attach the pressure gauge through the adapter ⓖ Gauge port 1 2 20UNF Pressure gauge 0 4 9 MPa 0 711 psi Press the parking brake switch and turn the parking brake ON Start the engine move the throttle lever to the high idling position and measure the pressure Standard charge relief pressure setting 2 5 0 2 MPa 362 29 psi SV400 2 08015 2 5 SV400 2 08015 2 5 g g ...

Page 161: ...ibration charge relief valve If after disassembly and cleaning you remeasure the pressure and find that it deviates from the standard charge pressure setting replace the vibration charge relief valve After the inspection is completed measure the pressure again Confirm whether the pressure rises to the standard charge relief pressure setting range 2 7 Vibration charge relief valve 74 N m 55 lbf ft ...

Page 162: ...p s discharge side 1 1 16 12UN Attach the pressure gauge through the adapter Adapter size G3 4 Pressure gauge 0 24 5 MPa 0 3553 psi Confirm that the forward reverse lever is properly in the neutral position Start the engine Then move the throttle lever to the high idling position Turn the steering wheel and measure the steering hydraulic circuit maximum pressure Maximum standard circuit pressure 1...

Page 163: ...the relief valve 2 from the orbitrol Check the removed relief valve for dust damage to the seat surface and other abnormalities If dust is present clean the relief valve Then reattach it If there is damage to the seat surface or other abnormalities replace the relief valve After the inspection is completed measure the pressure again Confirm whether the pressure rises to the maximum standard circui...

Page 164: ...e stop bolt 5 adjust so that the standard minimum no load rotational speed is achieved Standard minimum no load rotational speed 750 25 min 1 Set the throttle lever 1 in the maximum no load rotational speed position Loosen the locknut 7 Using the stop bolt 8 adjust so that the control lever 3 contacts the stopper Standard maximum no load rotational speed 2530 0 50 min 1 Using the locknuts 4 and 7 ...

Page 165: ...ide Specified dimension of control lever 3 c 24 29 mm 0 94 1 14 in Firmly secure both ends of the control cable 2 Specified dimensions of control cable 2 ends a 238 mm 9 37 in b 210 mm 8 27 in After the work is completed confirm the following items The forward reverse lever operates smoothly The stroke of the control lever 3 on the propulsion pump side is the specified dimension The interlock swit...

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Page 167: ...TROUBLESHOOTING ...

Page 168: ......

Page 169: ...he engine is running and the system is hot and under pressure Do not disconnect hydraulic hoses or fittings until the system has cooled and pressure has been properly relieved Before removing any plugs from the pressure measurement ports always release any residual pressure from the piping and open the cap of the fluid tank to release and pressure WARNING Inadvertent starting the engine may cause ...

Page 170: ...sk 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 electrical system source 5 Isolate the problem to a particular component or circuit 6 Eliminate the simplest or easiest to check possibilities first to prevent unnecessary disassembly of components 7 Following repair or replacement of ...

Page 171: ...ate the applicable switches and turn the relays ON and OFF Ultimately if the solenoid valve operates makes a sound and the pump runs the electrical system is OK If there is a failure fault narrow the range of the inspection to the six broad steps described below 1 Grounding inspection Check for disconnected or loose grounding If rust is present which can cause faulty contact remove the rust 2 Fuse...

Page 172: ...mp may be damaged electrically and may not operate There may simply be a disconnection in the interior or an abnormal heat up Even if the fuse is not burnt abnormal heat up hot enough to cause burns if touched may occur if a relay timer diode or other semiconductor fails 3 Connector inspection Is a connector disconnected or loose If faulty contact is suspected Turn the starter switch OFF Then disc...

Page 173: ...he connector and check the resistance between the solenoid valve terminal Voltage With the connector disconnected turn the starter switch ON and check whether 24 V or 12 V exists between the harness side connector and vehicle body ground If YES Replace the valve If NO Investigate and identify the location section to which 24 V or 12 V reaches Then replace the harness or take other action 6 Harness...

Page 174: ... parking brake indicator lamp LgB B BY LgW 5 1 3 2 Foot brake switch 1 4 3 2 5 BrW Parking brake switch Neutral relay GR LgR SV400 2 09001 NC NOCOM B NC NOCOM 10 20A 9 8 7 6 5 4 3 2 15A 15A 15A 15A 15A 20A 20A 20A 20A 1 50 45 30 B C BR ACC D B W 2 1 7 8 F L 45A F L 65A F L 75A F L 75A F L 85A G RG WR WY WY BW R W W BY Battery relay Battery AV60 AV60 COM NO BR B AV60 RB Starter relay B R RB W Fuse ...

Page 175: ... 2 are OK the motor is faulty Replace the starter motor 4 Starter Relay 1 When turning starter switch ON measure voltage between starter relay pin 2 inlet RB wire and chassis ground Standard voltage 12 V or more 2 When starting starter switch measure voltage between starter relay pin A1 inlet W wire and chassis ground Standard voltage 12 V or more If above item 1 and 2 are OK and electricity does ...

Page 176: ... parking brake indicator lamp LgB B BY LgW 5 1 3 2 Foot brake switch 1 4 3 2 5 BrW Parking brake switch Neutral relay GR LgR SV400 2 09001 NC NOCOM B NC NOCOM 10 20A 9 8 7 6 5 4 3 2 15A 15A 15A 15A 15A 20A 20A 20A 20A 1 50 45 30 B C BR ACC D B W 2 1 7 8 F L 45A F L 65A F L 75A F L 75A F L 85A G RG WR WY WY BW R W W BY Battery relay Battery AV60 AV60 COM NO BR B AV60 RB Starter relay B R RB W Fuse ...

Page 177: ...he foot brake switch 9 Parking Brake Switch 1 When turning starter switch ON measure voltage between parking brake switch pin 1 inlet LgR wire and chassis ground Standard voltage 12 V or more 2 When turning starter switch ON measure voltage between parking brake switch pin 2 inlet BrY wire and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG the parking brake swi...

Page 178: ... parking brake indicator lamp LgB B BY LgW 5 1 3 2 Foot brake switch 1 4 3 2 5 BrW Parking brake switch Neutral relay GR LgR SV400 2 09001 NC NOCOM B NC NOCOM 10 20A 9 8 7 6 5 4 3 2 15A 15A 15A 15A 15A 20A 20A 20A 20A 1 50 45 30 B C BR ACC D B W 2 1 7 8 F L 45A F L 65A F L 75A F L 75A F L 85A G RG WR WY WY BW R W W BY Battery relay Battery AV60 AV60 COM NO BR B AV60 RB Starter relay B R RB W Fuse ...

Page 179: ...n solenoid 2 2 4 No charging Reference Fig 2 2 Check point Check Cause Action 1 Alternator 1 When starting starter switch measure voltage between alternator pin B and chassis ground Standard voltage At least the intermediate engine speed or 15 V or more 2 When starting starter switch the measured voltage between alternator pin D and chassis ground must be 15 V or higher If above item 1 is NG the a...

Page 180: ... parking brake indicator lamp LgB B BY LgW 5 1 3 2 Foot brake switch 1 4 3 2 5 BrW Parking brake switch Neutral relay GR LgR SV400 2 09001 NC NOCOM B NC NOCOM 10 20A 9 8 7 6 5 4 3 2 15A 15A 15A 15A 15A 20A 20A 20A 20A 1 50 45 30 B C BR ACC D B W 2 1 7 8 F L 45A F L 65A F L 75A F L 75A F L 85A G RG WR WY WY BW R W W BY Battery relay Battery AV60 AV60 COM NO BR B AV60 RB Starter relay B R RB W Fuse ...

Page 181: ...e Action 1 Negative Torque Control Solenoid When starting starter switch measure voltage between negative torque control solenoid inlet wire and chassis ground It is normal that electricity flows If electricity flows but starting engine is difficult the solenoid is faulty Replace the negative torque control solenoid ...

Page 182: ...brake solenoid SOL Speed change switch Fuse box LY BrW 5 1 2 3 B GW GW LY 5 1 2 3 B R R R W W GW Diode unit F R lever switch SV400 2 09002 A C E F H I D B G Combination meter parking brake indicator lamp COM NO NC COM NO NC Parking brake switch 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A 1 R L LgR 1 4 3 2 5 BrW BrY B GR L 1 SOL 2 3 LW B B LY LY B P interlock relay L interlock relay ...

Page 183: ...uity indicates that harness is open or poorly connected Repair or replace the harness 2 3 2 Brake does not release The parking brake switch is turned OFF The foot brake switch is turned ON the brake pedal is not depressed Reference Fig 2 3 Check point Check Cause Action 1 F R Lever Switch 1 When turning the forward reverse lever to forward with the starter switch is OFF check the continuity betwee...

Page 184: ...brake solenoid SOL Speed change switch Fuse box LY BrW 5 1 2 3 B GW GW LY 5 1 2 3 B R R R W W GW Diode unit F R lever switch SV400 2 09002 A C E F H I D B G Combination meter parking brake indicator lamp COM NO NC COM NO NC Parking brake switch 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A 1 R L LgR 1 4 3 2 5 BrW BrY B GR L 1 SOL 2 3 LW B B LY LY B P interlock relay L interlock relay ...

Page 185: ...holding relay 5 Parking Brake Solenoid Disconnect harness and measure resistance of coil Standard resistance 11 1 Ω If measured resistance is abnormal the parking brake solenoid is faulty Replace the parking brake solenoid 6 Parking Brake Switch 1 When the starter switch is ON measure the voltage between parking brake switch pin 3 inlet BrW wire and chassis ground Standard voltage 12 V or more 2 W...

Page 186: ...brake solenoid SOL Speed change switch Fuse box LY BrW 5 1 2 3 B GW GW LY 5 1 2 3 B R R R W W GW Diode unit F R lever switch SV400 2 09002 A C E F H I D B G Combination meter parking brake indicator lamp COM NO NC COM NO NC Parking brake switch 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A 1 R L LgR 1 4 3 2 5 BrW BrY B GR L 1 SOL 2 3 LW B B LY LY B P interlock relay L interlock relay ...

Page 187: ...ke switch is faulty Replace the parking brake switch 3 Neutral Relay 1 When the starter switch is ON measure the voltage between the neutral relay pin 1 inlet BrW wire and chassis ground Standard voltage 12 V or more 2 When the starter switch is ON measure the voltage between the neutral relay pin 3 inlet GW wire and chassis ground Standard voltage 12 V or more If above items 1 and 2 are OK and el...

Page 188: ...brake solenoid SOL Speed change switch Fuse box LY BrW 5 1 2 3 B GW GW LY 5 1 2 3 B R R R W W GW Diode unit F R lever switch SV400 2 09002 A C E F H I D B G Combination meter parking brake indicator lamp COM NO NC COM NO NC Parking brake switch 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A 1 R L LgR 1 4 3 2 5 BrW BrY B GR L 1 SOL 2 3 LW B B LY LY B P interlock relay L interlock relay ...

Page 189: ... and chassis ground Standard voltage 12 V or more 2 When the starter switch is ON measure the voltage between the neutral relay pin 3 inlet GW wire and chassis ground Standard voltage 12 V or more If above items 1 and 2 are OK and electricity does not flow through neutral relay pin 5 the neutral relay is faulty Replace the neutral relay 4 Neutral Holding Relay 1 When the starter switch is ON measu...

Page 190: ...brake solenoid SOL Speed change switch Fuse box LY BrW 5 1 2 3 B GW GW LY 5 1 2 3 B R R R W W GW Diode unit F R lever switch SV400 2 09002 A C E F H I D B G Combination meter parking brake indicator lamp COM NO NC COM NO NC Parking brake switch 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A 1 R L LgR 1 4 3 2 5 BrW BrY B GR L 1 SOL 2 3 LW B B LY LY B P interlock relay L interlock relay ...

Page 191: ...ssis ground Standard voltage 12 V or more 2 When turning starter switch ON measure voltage between foot brake switch NO terminal inlet LgR wire and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG the foot brake switch is faulty Replace the foot brake switch 8 Harness Connecting Between Terminals Check harness between terminals for continuity No continuity indica...

Page 192: ...Y B HIGH LOW F R lever vibrator ON OFF switch Vibrator L H change switch Vibrator selector switch Vibrator solenoid Fuse box SV400 2 09004 20A 15A 15A 15A 15A 15A 20A 20A 20A 20A 10 9 8 7 6 5 4 3 2 1 a b 5 2 1 4 B SOL 2 1 YR YB Y Y G Br 2 3 1 Y RG RY B HIGH LOW F R lever vibrator ON OFF switch Vibrator L H change switch Vibrator selector switch Vibrator solenoid Fuse box ...

Page 193: ...minals for continuity No continuity indicates that harness is open or poorly connected Repair or replace the harness 2 4 2 Amplitude does not change remains either low or high The vibrator L H change switch on the control panel is not turned OFF Reference Fig 2 4 Check point Check Cause Action 1 Vibrator Solenoid Disconnect the harness of the a or b vibrator solenoid and measure the coil resistanc...

Page 194: ...Y B HIGH LOW F R lever vibrator ON OFF switch Vibrator L H change switch Vibrator selector switch Vibrator solenoid Fuse box SV400 2 09004 20A 15A 15A 15A 15A 15A 20A 20A 20A 20A 10 9 8 7 6 5 4 3 2 1 a b 5 2 1 4 B SOL 2 1 YR YB Y Y G Br 2 3 1 Y RG RY B HIGH LOW F R lever vibrator ON OFF switch Vibrator L H change switch Vibrator selector switch Vibrator solenoid Fuse box ...

Page 195: ...ove is OK and no electricity flows to the pin 2 inlet Y wire or pin 3 inlet RG wire when the vibrator selector switch position is changed then the vibrator selector switch is faulty Replace the vibrator selector switch 2 F R Lever Vibrator ON OFF Switch When the starter switch is ON measure the voltage between F R lever vibrator ON OFF switch pin 1 inlet Br wire and chassis ground Standard voltage...

Page 196: ... filter switch Hydraulic oil filter switch Horn Horn relay Starter switch Lamp check relay YL YW YG B BrR LoY L L Alternator SV400 2 09003 N C N O C O M B B YW YW YW BY RY G H I F E D C B A 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A 1 Fuse box HIGH LOW Diode unit RY RY GB R YB YG Br RY Y GR B LgW ACC B C BR a b 5 2 1 4 SOL YR YB YB YR Br YL 1 5 3 2 BY B RY RY 2 1 3 5 Lg LgW B B 1 4...

Page 197: ... when above items 1 and 2 are OK and item 3 is NG the lamp check relay is faulty Replace the lamp check relay 3 Harness Connecting Between Terminals Check harness between terminals for continuity No continuity indicates that harness is open or poorly connected Repair or replace the harness 2 5 2 Tachometer reading is abnormal The other lamps light correctly Reference Fig 2 5 Check point Check Caus...

Page 198: ... filter switch Hydraulic oil filter switch Horn Horn relay Starter switch Lamp check relay YL YW YG B BrR LoY L L Alternator SV400 2 09003 N C N O C O M B B YW YW YW BY RY G H I F E D C B A 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A 1 Fuse box HIGH LOW Diode unit RY RY GB R YB YG Br RY Y GR B LgW ACC B C BR a b 5 2 1 4 SOL YR YB YB YR Br YL 1 5 3 2 BY B RY RY 2 1 3 5 Lg LgW B B 1 4...

Page 199: ...sure voltage between temperature gauge plus terminal WR wire and chassis ground Standard voltage 12 V or more If the above is OK and there is no problem with the thermo unit then the thermometer is faulty Replace the combination meter 3 Harness Connecting Between Terminals Check harness between terminals for continuity No continuity indicates that harness is open or poorly connected Repair or repl...

Page 200: ... filter switch Hydraulic oil filter switch Horn Horn relay Starter switch Lamp check relay YL YW YG B BrR LoY L L Alternator SV400 2 09003 N C N O C O M B B YW YW YW BY RY G H I F E D C B A 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A 1 Fuse box HIGH LOW Diode unit RY RY GB R YB YG Br RY Y GR B LgW ACC B C BR a b 5 2 1 4 SOL YR YB YB YR Br YL 1 5 3 2 BY B RY RY 2 1 3 5 Lg LgW B B 1 4...

Page 201: ... terminal and chassis ground No continuity indicates normal condition If any continuity is present the oil pressure switch is faulty Replace the oil pressure switch 2 5 8 Vibrator operation indicator lamp does not turn ON Reference Fig 2 5 Check point Check Cause Action 1 Bulb Check if bulb has burnt out or is poorly connected Bulb is faulty or poorly connected Replace the bulb 2 Diode Unit 1 Meas...

Page 202: ... filter switch Hydraulic oil filter switch Horn Horn relay Starter switch Lamp check relay YL YW YG B BrR LoY L L Alternator SV400 2 09003 N C N O C O M B B YW YW YW BY RY G H I F E D C B A 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A 1 Fuse box HIGH LOW Diode unit RY RY GB R YB YG Br RY Y GR B LgW ACC B C BR a b 5 2 1 4 SOL YR YB YB YR Br YL 1 5 3 2 BY B RY RY 2 1 3 5 Lg LgW B B 1 4...

Page 203: ... 5 Check point Check Cause Action 1 Horn Disconnect horn and connect the horn terminal to the battery directly If the horn does not sound it is faulty Replace the horn 2 Horn Relay 1 When pressing horn switch with starter switch ON measure voltage between horn relay pin 1 RY wire and chassis ground Standard voltage 12 V or more 2 When pressing horn switch with starter switch ON measure voltage bet...

Page 204: ... filter switch Hydraulic oil filter switch Horn Horn relay Starter switch Lamp check relay YL YW YG B BrR LoY L L Alternator SV400 2 09003 N C N O C O M B B YW YW YW BY RY G H I F E D C B A 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A 1 Fuse box HIGH LOW Diode unit RY RY GB R YB YG Br RY Y GR B LgW ACC B C BR a b 5 2 1 4 SOL YR YB YB YR Br YL 1 5 3 2 BY B RY RY 2 1 3 5 Lg LgW B B 1 4...

Page 205: ...andard voltage 12 V or more If above item 1 is OK and item 2 is NG the backup buzzer switch is faulty Replace the backup buzzer switch 3 Harness Connecting Between Terminals Check harness between terminals for continuity No continuity indicates that harness is open or poorly connected Repair or replace the harness 2 5 12 Engine warning lamp remains ON Confirm the engine is cold If the coolant is m...

Page 206: ...s and devices 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 foreign subs...

Page 207: ...n circuit to tank If oil flows carry out the following actions Repair or replace the solenoid valve Repair or replace the solenoid valve 5 Neutral Solenoid Valve Propulsion pump does not discharge oil because the spool of the neutral solenoid valve does not shift Repair or replace the neutral solenoid valve if the spool of the valve does not shift 6 Suction Filter for Charge Pump The charge pump f...

Page 208: ...use charge pressure is low decreasing the discharge rate of propulsion pump Measure the charge pressure If low check the propulsion or vibrator charge relief valve and then adjust the setting pressure or replace the valve Insufficient charge pump discharge Repair or replace charge pump Charge pressure decreases due to internal leakage of solenoid valve connecting oil supply circuit with charge cir...

Page 209: ...enoid valve 2 Speed Change Solenoid Valve The vehicle speed does not change because the spool of the speed change solenoid valve does not change Repair or replace the speed change solenoid valve 3 Rear Propulsion Motor Swash Plate Stroke Cylinder The rear propulsion motor swash plate stroke cylinder is faulty Replace the rear propulsion motor 3 2 5 Vehicle does not stop completely with forward rev...

Page 210: ...ef valve is open causing the temperature of hydraulic oil in circuit to rise Measure the propulsion circuit pressure If high decrease the propulsion load 5 Suction Filter for Charge Pump The load of charge pump increases due to clogged filter causing the temperature of hydraulic oil in circuit to rise Clean or replace the suction filter 6 Charge Line Filter Charge circuit pressure increases due to...

Page 211: ...rnal leakage of solenoid valve connecting oil supply circuit with charge circuit Parking Brake Solenoid valve Speed change solenoid valve When the solenoid is not energized check if oil flows in return circuit to tank If oil flows carry out the following actions Repair or replace the solenoid valve Repair or replace the solenoid valve 4 Vibrator Solenoid Valve Vibrator pump does not discharge oil ...

Page 212: ...eakage of Vibrator Motor Vibrator motor revolutions decrease due to internal leakage of the vibrator motor Measure the drain quantity from vibrator motor If the drain quantity is larger than the standard value repair or replace the motor 5 Pressure Setting in Vibrator Circuit Relief Valve Low circuit pressure due to incorrect relief setting If the reverse phenomenon occurs when the relief valves i...

Page 213: ...rcuit pressure If high decrease the vibrator load 3 3 6 Abnormal noise from vibrator system Check point Cause Check Action 1 Oil Level of Hydraulic Oil Tank Pump suction pressure is high because oil level of hydraulic oil tank is low causing cavitation in vibrator circuit Fill the tank until the correct oil level is obtained 2 Air in Vibrator Hydraulic Circuit Cavitation is caused by air in the ci...

Page 214: ...r Steering Pump Steering pump discharge rate decreases due to clogged filter Clean or replace the suction filter 6 Steering Pump Discharging pressure is insufficient due to efficiency degradation of steering pump Measure the steering circuit pressure If low replace the steering pump 7 Steering Column Column shaft and orbitrol shaft center are misaligned Align the column shaft with orbit roll shaft...

Page 215: ...etting pressure If the load is excessively heavy the relief valve is open causing the temperature of hydraulic oil in circuit to rise Measure the steering circuit pressure If high decrease the steering load 4 Suction Filter for Steering Pump The load of steering pump increases due to clogged filter causing the temperature of hydraulic oil in circuit to rise Clean or replace the suction filter 3 4 ...

Page 216: ...replace the control valve 5 Blade Cylinder Cylinder thrust decreases due to internal leakage of the blade cylinder Repair or replace the blade cylinder 6 Steering Pump Suction Filter also used for blade circuit Steering pump discharge rate decreases due to clogged filter Clean or replace the suction filter 7 Steering Pump also used for blade circuit Discharging pressure is insufficient due to effi...

Page 217: ...erature of hydraulic oil in circuit to rise Measure the blade circuit pressure If high decrease the steering load 4 Steering Pump Suction Filter also used for blade circuit The load of steering pump increases due to clogged filter causing the temperature of hydraulic oil in circuit to rise Clean or replace the suction filter 3 5 5 Abnormal noise from blade hydraulic system Check point Cause Check ...

Page 218: ...SAKAI HEAVY INDUSTRIES LTD Head office 1 4 8 Shiba Daimon Minato ku Tokyo Japan Telephone Tokyo 03 3431 9971 Facsimile 03 3431 6212 Printed in japan 2008 10 100 H S ...

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