Sakai SV410-2 Shop Manual Download Page 201

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8-029

INSPECTION AND ADJUSTMENT

17-3. Brake Clearance Adjustment

Remove bolt (2) and lock plate (3).
Rotate adjustment pinion (4) counterclockwise to eliminate
all existing clearance between braking discs.

N•m

Rotate up to a torque of 8 to 10 N·m (5.9 to 7.4 lbf·ft)

Rotate pinion (4) clockwise to determine the required
clearance of 1 mm (0.04 in.).

Clearance change rate : 0.25 mm/turn (0.01 in./turn)

Install lock plate (3) and lock with bolt (2).

N•m

(2) Bolt : 10 to 11 N·m (7.4 to 8.1 lbf·ft)

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SV510-

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SV510-

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Summary of Contents for SV410-2

Page 1: ...SV410 2 SHOP MANUAL 3498 6404A 0 ...

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

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Page 5: ...Operating 1 004 1 9 Stopping 1 004 1 10 Maintenance 1 005 1 11 Transporting the Machine 1 007 2 SPECIFICATIONS 1 SPECIFICATION DATA 1 1 SV410D 2 2 001 1 2 SV410T 2 2 003 1 3 SV410TF 2 2 005 1 4 SV410TB 2 2 007 1 5 SV410FB 2 2 009 2 TABLE OF STANDARD VALUES 2 1 Engine 2 011 2 2 Propulsion 2 011 2 3 Hydraulic Systems 2 011 2 4 Steering Devices 2 012 2 5 Brakes 2 012 2 6 Capacities 2 012 3 FUEL AND L...

Page 6: ...ropulsion hydraulic piping Front 4 005 2 1 2 Propulsion hydraulic piping Rear 4 006 2 2 Hydraulic Component Specifications 4 007 2 2 1 Hydraulic pump assembly propulsion vibrator steering SV410D 2 T 2 TF 2 4 007 2 2 2 Hydraulic pump assembly propulsion vibrator steering SV410TB 2 TF 2 4 009 2 2 3 Propulsion hydraulic motor Front 4 011 2 2 4 Gear box 4 012 2 2 5 Propulsion hydraulic motor Rear 4 01...

Page 7: ...ttery Layout 5 004 3 2 Wiring Harness Layout Type 1 1 5 005 3 3 Wiring Harness Layout Type 1 2 5 006 3 4 Wiring Harness Layout Type 2 1 5 007 3 5 Wiring Harness Layout Type 2 2 5 008 4 WIRING HARNESSES 4 1 Main Frame Harness 5 009 4 1 1 Main frame harness type 1 only 5 009 4 1 2 Main frame harness type 2 only 5 011 4 2 Engine Harness 5 013 4 2 1 Engine harness type 1 only 5 013 4 2 2 Engine harnes...

Page 8: ...bly of Vibratory Drum 6 009 2 3 1 Disassembly of vibratory drum 6 009 2 3 2 Reassembly of vibratory drum 6 015 3 AXLE 3 1 Rear Axle SV410D 2 6 023 3 2 Rear Axle SV410T 2 TF 2 TB 2 FB 2 6 024 3 3 Rear Axle Lubrication 6 025 3 4 Rear Axle Structure 6 026 3 4 1 Center housing 6 026 3 4 2 Differential 6 027 3 4 3 Hub reduction gear 6 028 3 4 4 Brake 6 029 7 BRAKE 1 BRAKE SYSTEM 1 1 Brake Pedal 7 001 2...

Page 9: ...MENT OF PARKING BRAKE RELEASE PRESSURE 6 1 Measurement 8 010 7 MEASUREMENT AND INSPECTION OF VIBRATOR CIRCUIT PRESSURE 7 1 Measurement 8 011 7 2 Inspection 8 012 8 MEASUREMENT AND ADJUSTMENT OF VIBRATOR CHARGE CIRCUIT PRESSURE 8 013 8 1 Measurement 8 014 8 2 Adjustment 8 015 9 MEASUREMENT OF VIBRATOR HIGH LOW CHANGE CIRCUIT PRESSURE 9 1 Measurement 8 016 10 MEASUREMENT AND INSPECTION OF STEERING C...

Page 10: ...uring electrical circuit fault diagnosis 9 003 2 1 2 Inspection procedures using a tester 9 004 2 1 3 Inspection of electrical system 9 009 2 2 Engine 9 012 2 2 1 Engine will not start Starter motor does not run 1 3 9 012 2 2 1 Engine will not start Starter motor does not run 2 3 9 014 2 2 1 Engine will not start Starter motor does not run 3 3 9 016 2 2 2 Engine will not start But starter motor ru...

Page 11: ...uzzer does not sound 9 052 3 HYDRAULIC SYSTEM TROUBLESHOOTING 3 1 When Performing Hydraulic System Troubleshooting 9 053 3 2 Propulsion System 9 054 3 2 1 Machine moves neither forward nor backward 1 2 9 054 3 2 1 Machine moves neither forward nor backward 2 2 9 055 3 2 2 Machine moves in one direction only forward or backward 9 055 3 2 3 Slow machine speed or small drive force 1 2 9 055 3 2 3 Slo...

Page 12: ... 062 3 4 5 Abnormal noise from steering system 9 062 3 5 Blade SV410TB 2 FB 2 9 063 3 5 1 Blade up down operation not possible 9 063 3 5 2 Blade movement is slow or force is small 9 063 3 5 3 Blade floating operation not possible 9 064 3 5 4 Blade hydraulic system is overheating 9 064 3 5 5 Abnormal noise from blade hydraulic system 9 064 ...

Page 13: ...SAFETY ...

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Page 15: ...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 16: ... guidance of a skilled electrician and according to electrical engineering rules and regulations Work on the frame brakes hydraulic and steering systems must be performed by skilled personnel with 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 17: ...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 18: ...to slide or roll over Avoid any areas that may be a risk to machine stability Avoid side hill travel Always operate up and down the slope Always keep the propulsion travel control lever in low speed range when climbing or descending hills or steep grades Make sure there is sufficient clearance when crossing underpasses bridges and tunnels or when passing under overhead power lines Never allow anyo...

Page 19: ... to avoid the risk of accident Use lifting devices that are in perfect condition and of sufficient lifting capacity Never stand under suspended loads Always use the proper tools and workshop equipment in good condition when performing maintenance or repairs on the machine Always use specially designed safety ladders and working platforms when working above floor level Never use machine parts as a ...

Page 20: ...g or grinding operations Inspect hydraulic hoses at regular intervals and immediately replace if they show signs of chafing cracking brittleness deformation blistering fitting separation leakage corrosion or other damage which may affect their function or strength Do not work on hydraulic system while the engine is running and the system is under pressure The hydraulic system remains pressurized e...

Page 21: ...ake sure that the compactor does not slide off the edge of the ramp Keep the deck clear of mud oil ice or snow or other materials that can make the deck slippery Position the compactor on the trailer or transport vehicle centered from side to side and apply the brake Shut off the engine and lock all lockable compartments Block the drums or tires and lock the articulation lock bar Chain the machine...

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Page 23: ...SPECIFICATIONS ...

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Page 26: ... mm 104 in Compaction width 1 700 mm 67 in Minimum height above ground 315 mm 12 5 in Curb clearance 420 mm 16 5 in Drive speed 1st 0 to 6 km h 0 to 3 7 mph 2nd 0 to 10 km h 0 to 6 2 mph Reverse slope operation 0 to 7 km h 0 to 4 3 mph Vibration performance Frequency Low amplitude 38 Hz High amplitude 30 Hz Centrifugal force Low amplitude 93 kN 20 945 lbf High amplitude 118 kN 26 445 lbf Amplitude...

Page 27: ...haling type Electrical system Alternator 14 V 55 A Starter 12 V 2 3 kW Battery 12 V CCA 620 1 pcs 12 V Dry weight 268 kg 590 lbs Power line Transmission Type Hydrostatic transmission Speeds 2 speed shifts Reverser Switching the direction of flow delivered from the variable pump Differential Auto lock type Final drive Planetary gear Vibrating system Transmission Hydrostatic transmission Vibrator Ec...

Page 28: ...Compaction width 1 700 mm 67 in Minimum height above ground 325 mm 13 0 in Curb clearance 435 mm 17 0 in Drive speed 1st 0 to 6 km h 0 to 3 7 mph 2nd 0 to 10 km h 0 to 6 2 mph Reverse slope operation 0 to 7 km h 0 to 4 3 mph Vibration performance Frequency Low amplitude 38 Hz High amplitude 30 Hz Centrifugal force Low amplitude 103 kN 23 150 lbf High amplitude 127 kN 28 660 lbf Amplitude Low ampli...

Page 29: ...ternator 14 V 55 A Starter 12 V 2 3 kW Battery 12 V CCA 620 1 pcs 12 V Dry weight 268 kg 590 lbs Power line Transmission Type Hydrostatic transmission Speeds 2 speed shifts Reverser Switching the direction of flow delivered from the variable pump Differential Auto lock type Final drive Planetary gear Vibrating system Transmission Hydrostatic transmission Vibrator Eccentric shaft type Braking devic...

Page 30: ... Compaction width 1 700 mm 67 in Minimum height above ground 340 mm 13 5 in Curb clearance 450 mm 17 5 in Drive speed 1st 0 to 6 km h 0 to 3 7 mph 2nd 0 to 10 km h 0 to 6 2 mph Reverse slope operation 0 to 7 km h 0 to 4 3 mph Vibration performance Frequency Low amplitude 38 Hz High amplitude 30 Hz Centrifugal force Low amplitude 103 kN 23 150 lbf High amplitude 127 kN 28 660 lbf Amplitude Low ampl...

Page 31: ...V 2 3 kW Battery 12 V CCA 620 1 pcs 12 V Dry weight 268 kg 590 lbs Power line Transmission Type Hydrostatic transmission Speeds 2 speed shifts Reverser Switching the direction of flow delivered from the variable pump Differential Auto lock type Final drive Planetary gear Vibrating system Transmission Hydrostatic transmission Vibrator Eccentric shaft type Braking device Service brake Hydrostatic an...

Page 32: ... in Compaction width 1 700 mm 67 in Minimum height above ground 325 mm 13 0 in Curb clearance 425 mm 16 5 in Drive speed 1st 0 to 6 km h 0 to 3 7 mph 2nd 0 to 10 km h 0 to 6 2 mph Reverse slope operation 0 to 7 km h 0 to 4 3 mph Vibration performance Frequency Low amplitude 38 Hz High amplitude 30 Hz Centrifugal force Low amplitude 103 kN 23 150 lbf High amplitude 127 kN 28 660 lbf Amplitude Low a...

Page 33: ...ator 14 V 55 A Starter 12 V 2 3 kW Battery 12 V CCA 620 1 pcs 12 V Dry weight 268 kg 590 lbs Power line Transmission Type Hydrostatic transmission Speeds 2 speed shifts Reverser Switching the direction of flow delivered from the variable pump Differential Auto lock type Final drive Planetary gear Vibrating system Transmission Hydrostatic transmission Vibrator Eccentric shaft type Braking device Se...

Page 34: ... in Compaction width 1 700 mm 67 in Minimum height above ground 340 mm 13 5 in Curb clearance 445 mm 17 5 in Drive speed 1st 0 to 6 km h 0 to 3 7 mph 2nd 0 to 10 km h 0 to 6 2 mph Reverse slope operation 0 to 7 km h 0 to 4 3 mph Vibration performance Frequency Low amplitude 38 Hz High amplitude 30 Hz Centrifugal force Low amplitude 103 kN 23 150 lbf High amplitude 127 kN 28 660 lbf Amplitude Low a...

Page 35: ...V 2 3 kW Battery 12 V CCA 620 1 pcs 12 V Dry weight 268 kg 590 lbs Power line Transmission Type Hydrostatic transmission Speeds 2 speed shifts Reverser Switching the direction of flow delivered from the variable pump Differential Auto lock type Final drive Planetary gear Vibrating system Transmission Hydrostatic transmission Vibrator Eccentric shaft type Braking device Service brake Hydrostatic an...

Page 36: ...o 6 2 mph Reverse slope operation 0 to 7 km h 0 to 4 3 mph Rear wheel hub nut 785 N m 579 lbf ft Tire inflation pressure 137 kPa 20 psi 2 3 Hydraulic Systems Item Standard value Remarks Propulsion High pressure relief valve setting 41 8 1 0 MPa 6 061 145 psi at 1 800 min 1 Charge relief valve setting Pump 2 5 0 2 MPa 363 29 psi Front motor 2 5 0 2 MPa 363 29 psi Rear motor 2 67 MPa 387 psi at 19 L...

Page 37: ... See dimensions N o t e 1 N o t e 2 SV700 02001 Clearance between brake pedal and floorboard when pressed down 145 mm 5 7 in Note 2 See dimensions Brake disc wear limit 4 5 mm 0 18 in S SV700 02003 S 2 6 Capacities Item Standard value Remarks Engine oil pan 10 5 L 2 8 gal Fuel tank 180 L 48 gal Cooling 13 L 3 4 gal Gear box front motor 1 96 L 0 5 gal Center housing rear axle 7 3 L 1 9 gal Hub redu...

Page 38: ...r VI 140 ISO VG68 Over VI 110 ISO 3448 Grease 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 N A 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 N A Esso Gear Oil GP ...

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

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Page 41: ...ENGINE AND CONTROLS ...

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Page 43: ... 1 ENGINE 1 1 Engine Mount SV400 2 03001 3 2 6 1 A VIEW A 5 4 1 Damper 4 Damper 2 Nut M12 5 Damper 3 Damper 6 Bolt M12 100 N m 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 ...

Page 44: ...erator lubricating oil cooler 5 V belts 19 High pressure pump 6 Gearcase cover 20 Coolant feed to the cylinder head 7 Lubricating oil sump 21 Cylinder 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 ...

Page 45: ...TEM 2 1 Throttle Control 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 1 Throttle lever 6 Lock nut 2 Control cable 7 Shaft 3 Adjusting bolt Full 8 Nut 4 Lock nut 9 Rod end 5 Adjusting bolt Idle ...

Page 46: ...CTION A A 12 11 10 9 8 7 6 5 14 13 Apply grease 1 F R lever 6 Nut M16 11 Washer Apply grease 2 F R lever switch 7 Spring Fill grease 12 Washer 3 Backup buzzer switch 8 Steel ball 13 Nut 4 Control cable 9 Washer Apply grease 14 Clevis 5 Bolt M16 30 10 Bush Apply grease 15 Rod end Apply grease Lithium based grease ...

Page 47: ...on socket head bolt M10 35 3 Hub 9 Hexagon socket head bolt M12 35 4 Snap ring 10 Bolt M10 25 5 Vibrator pump 11 Bolt M14 45 6 Steering pump charge pump 12 Bolt M10 30 N m 8 Hexagon socket 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 ...

Page 48: ... M12 35 86 N m 63 lbf ft Secure flange 2 to engine flywheel with eight bolts 8 N m 8 Bolt M10 35 49 N m 36 lbf ft Secure housing 7 to engine flywheel housing with ten bolts 10 two bolts 12 and washers N m 10 Bolt M10 25 59 N m 44 lbf ft 12 Bolt M10 30 59 N m 44 lbf ft Engage hub 3 with flange 2 Secure pump 1 to housing 7 with four bolts 11 spring washers and washers N m 11 Bolt M14 45 167 N m 123 ...

Page 49: ...HYDRAULIC SYSTEMS ...

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Page 52: ...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 53: ...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...

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Page 55: ... 1 2 T1 150mesh 1 1 4 S E R V O S E R V O TIRE DIA Tire Tire TIRE SIZE 16 9 24 6PR OR 70X 35 380 ST 70X 35 380 ST Low 93 1 kN 2300vpm 9 5 ton High 117 7 kN 1800vpm 12 ton T TF Low 103 0 kN 2300vpm 10 5 ton High 127 5 kN 1800vpm 13 ton 2 67MPa A B P T Oil cooler Hydraulic oil filter 2 Suction filter 1 5 3 0 MPa 1 5 3 0 MPa Rear axle assembly Propulsion motor Rear Propulsion motor Front LO1 LOB LOP ...

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Page 57: ...VB SVA AS2 AS1 ARU ARD ALD ALU BRD BLD BRU BLU SVT SVP FDB FDA FDP FMB FMD FMA VPB PPA SBA SGB PPC SGA SBP R L P T 1200 1 2 1 2 1 2 Valve 3 8 3 8 1 2 1 4 1 4 1 4 1 2 1 2 1700 Propulsion motor Front 1 2 2 5 MPa 2 5 MPa 3 4 TOTAL i 43 72 i 6 00 i 6 00 i 7 286 ENGINE 1336 3 4 3 4 3 4 3 4 1 2 1 2 1 2 1 2 1 2 TIRE DIA TIRE SIZE 16 9 24 6PR OR BSA BST BSP BPF BV2 BV1 1 4 Orbitrol 1 4 3 8 3 8 Bypass valv...

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Page 59: ...nnection and the direction of the flow of the oil Hydraulic oil tank RBM VBB T2 FMA FMB FMD Propulsion motor Front Gear box Hose VBB FMA Hose RBM FMB Propulsion motor Rear Hose FMD T2 A DETAIL A 2 PROPULSION HYDRAULIC SYSTEM 2 1 Propulsion Hydraulic Piping 2 1 1 Propulsion hydraulic piping Front 4 005 HYDRAULIC SYSTEMS ...

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Page 61: ...se RMD PD1 Hose PPB RBP Coupling High pressure gauge port Coupling High pressure gauge port SECTION B B SECTION C C Hose PDC CS Hose CO T6 T6 BV2 BV1 CO CS RMD PDC C C A A A A B B D Hose BVX BV1 Hose RBB BV2 Hose VBA RMA Hydraulic oil tank Hose PPA VBP Hose PDC CS Propulsion pump PPA Bypass valve RMA Propulsion motor Rear Oil cooler RBB RBP PD1 PPB SGB SGA Hose SBA SGB Hose SGA SBP SBP SBA Servo b...

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Page 64: ...n vibrator steering SV410D 2 T 2 TF 2 SV410 2 04006 3 2 1 2 2 2 2 5 3 1 2 6 1 5 1 6 1 7 1 8 2 7 1 12 2 11 2 8 2 9 2 10 1 10 1 7 1 6 1 12 1 9 1 5 2 2 2 9 3 2 2 11 2 13 2 4 3 1 2 8 1 8 1 2 1 3 1 11 B N A 1 13 2 10 2 3 1 9 1 11 1 14 1 13 2 12 2 13 3 2 2 4 2 3 1 4 1 3 1 1 1 2 1 VIEW A Pump circuit diagram A ...

Page 65: ... Vibrator pump 2 1 High pressure relief valve For port A2 2 2 Drain port VD1 1 5 16 12UN 2 3 Servo pressure gauge port 9 16 18UNF 2 4 Charge pressure gauge port 9 16 18UNF 2 5 High pressure relief valve For port B2 2 6 Solenoid valve b Low amplitude 2 7 Solenoid valve a High amplitude 2 8 Port B2 VPB 1 1 16 12UN 2 9 Drain port VD2 1 5 16 12UN 2 10 Servo pressure gauge port 9 16 18UNF 2 11 Port A2 ...

Page 66: ...g SV410TB 2 TF 2 SV410 2 04007 3 2 1 2 2 2 2 5 3 1 2 6 1 5 1 6 1 7 1 8 2 7 1 12 2 11 2 8 2 9 2 10 1 10 1 7 1 6 1 12 1 9 1 5 2 2 2 9 3 2 2 11 2 13 2 4 3 1 2 8 1 8 1 2 1 3 1 11 B N A 1 13 2 10 2 3 1 9 1 11 1 14 1 13 2 12 2 13 3 2 2 4 2 3 1 4 1 3 1 1 1 2 1 VIEW A Pump circuit diagram A ...

Page 67: ...63 psi 2 Vibrator pump 2 1 High pressure relief valve For port A2 2 2 Drain port VD1 1 5 16 12UN 2 3 Servo pressure gauge port 9 16 18UNF 2 4 Charge pressure gauge port 9 16 18UNF 2 5 High pressure relief valve For port B2 2 6 Solenoid valve b Low amplitude 2 7 Solenoid valve a High amplitude 2 8 Port B2 VPB 1 1 16 12UN 2 9 Drain port VD2 1 5 16 12UN 2 10 Servo pressure gauge port 9 16 18UNF 2 11 ...

Page 68: ... 3 Control pressure gauge port 9 16 18UNF 9 Port A Reverse FMA SAE 3 4 4 Drain port FMD 1 1 16 12UN 10 Speed pickup 5 Servo pressure gauge port min 9 16 18UNF 11 Gauge port For Port A 7 8 14UNF 6 Drain port 1 1 16 12UN 12 Gauge port For Port B 7 8 14UNF Motor specifications Displacement max 60 0 cm3 rev 3 66 cu in rev min 26 0 cm3 rev 1 59 cu in rev Charge relief valve pressure setting 2 5 MPa 363...

Page 69: ...4 012 HYDRAULIC SYSTEMS 2 2 4 Gear box SV410 2 04002 MA DE IN ITA LY TY P CO D pla ne tar y dr ive s co m er in du st rie s 1 1 Gear box Specifications Reduction ratio 1 47 00 Weight 90 kg 198 lbs ...

Page 70: ... Plug 9 16 18UNF 1 2 Hub 1 19 Cover 1 3 Spacer 1 20 Pad 1 4 Plate 1 21 Shim 1 5 Snap ring 1 22 Bolt M10 120 1 6 Housing 1 23 Cover 1 7 Bearing nut M190 1 24 Sun gear 1 8 Ring gear 1 25 Snap ring 1 9 Plug 1 26 Bearing washer 1 10 Needle bearing 1 27 Planetary gear 1 11 Snap ring 1 28 Needle 1 12 Planetary gear 1 29 Bearing washer 1 13 O ring 1 30 Snap ring 1 14 Taper bearing 1 31 Carrier 1 15 Coupl...

Page 71: ... 9 16 18UNF 7 Port B Reverse RMB SAE 1 3 Drain port RMD 1 1 16 12UN 8 Port A Forward RMA SAE 1 4 Servo pressure gauge port 9 16 18UNF 9 Drain port 1 1 16 12UN 5 Speed change solenoid valve Motor specifications Displacement max 75 cm3 rev 4 58 cu in rev min 35 cm3 rev 2 14 cu in rev Charge relief valve pressure setting 2 67 MPa 387 psi at 19 L min Allowable motor case pressure 0 3 MPa 43 5 psi or l...

Page 72: ...ic circuit diagram 7 8 1 3 4 5 6 7 6 8 2 1 Solenoid 2 O ring 1B P14 3 Spool K 4 Body 5 Spring 6 Port T 9 16 18UNF 2B 7 Port A SBA 9 16 18UNF 2B 8 Port P SBP 9 16 18UNF 2B Specifications Rated pressure 4 9 MPa 710 psi 6 7 0 5 MPa 72 5 psi 8 Rated flow 30 L min 7 9 gal min Weight 1 5 kg 3 3 lbs ...

Page 73: ...A A SECTION B B VIEW C Hose VD1 LS2 VD2 Hose FVD T1 LO2 VD1 LS2 VPA VD2 T1 T5 Hydraulic oil filter 2 Vibrator motor FVD Coupling High pressure Coupling High pressure PDV VD1 VPB Hose VD2 PDV Hose VPA FVB Hose VPB FVA Hose FVD T1 Hose VD1 LS2 Hose VPB FVA Hose VPA FVB Hose LO2 T5 A A B B C B B Hose VPA FVB Hose VPB FVA FVA FVB 3 VIBRATOR HYDRAULIC SYSTEM 3 1 Vibrator Hydraulic Piping 4 016 HYDRAULI...

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Page 75: ...ation 1 2 Counterclockwise rotation Hydraulic circuit diagram Flow of oil 1 Port B FVB 1 1 16 12UN 2 Port A FVA 1 1 16 12UN 3 Drain port FVD 7 8 14UNF 4 Drain port 7 8 14UNF 5 Drain port 7 8 14UNF Specifications Displacement 35 0 cm3 rev 2 1 cu in Working pressure 34 5 MPa 5 003 psi Allowable motor case pressure 0 17 MPa 24 7 psi Weight 11 kg 24 3 lbs ...

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Page 77: ...aulic oil tank SCS Hose R SRR Hose SCD P Hose SCD P Hose Hydraulic oil tank SCS Steering charge pump Coupling charge pressure Hose LOP PPC Hose SRL SLB Hose L SLL Hose T LSO Hose T LSO Hose L SLL Steering cylinder L Steering cylinder R Hydraulic oil tank Hose R SRR Hose SLR SRB SRB SECTION F F SECTION D D SECTION A A VIEW B Orbitrol SECTION C C A A B C C C C D C D D D F F E E 4 STEERING SYSTEM 4 1...

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Page 79: ...A P Hose SCD FDP Hose Hydraulic oil tank SCS Steering charge pump Coupling charge pressure Hydraulic oil filter 1 Hose LOP PPC Hose SRL SLB Hose L SLL Hose T LSO Hose FDA P Hose T LSO Hose L SLL Steering cylinder L Steering cylinder R Hydraulic oil tank Hose R SRR Hose SLR SRB SRB SECTION F F VIEW G SECTION D D SECTION A A Orbitrol SECTION C C A A C C C C D D D D F F FDP Suction filter SECTION E E...

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Page 81: ... VIEW A A 0404 32804 021754 Ａ 1 Column shaft 6 Bolt M10 30 2 Nut M12 P 1 25 7 Bracket 3 Steering wheel 8 Bolt M 8 12 4 Nut M10 9 Orbitrol 5 Damper N m 2 Nut M12 P 1 25 35 N m 26 lbf ft 4 Nut M10 49 N m 36 lbf ft 6 Bolt M10 30 49 N m 36 lbf ft 8 Bolt M 8 12 23 N m 17 lbf ft ...

Page 82: ... Orbitrol SV510 04010 1 2 3 3 4 4 1 2 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 400 cm3 rev 24 4 cu in rev Relief valve pressure setting 15 0 MPa 2 175 psi Weight 7 kg 15 lbs ...

Page 83: ...aulic circuit diagram 1 2 8 1 2 3 4 5 6 7 8 1 Port A FDA G1 2 2 Port B FDB G1 2 3 Body 4 Spool 5 Cover 6 Spring 7 O ring 8 Port P FDP G3 4 Specifications Rated pressure 29 4 MPa 4 263 psi Standard flow 60 L min 16 gal min Flow division ratio A B 2 1 Weight 5 kg 11 lbs ...

Page 84: ...4 1 Bolt M16 60 5 Swing bearing 9 Roller bearing 2 Bolt M16 80 6 Yoke 10 Bracket upper 3 Nut M20 7 Bolt M16 45 11 Bracket lower 4 Bolt M20 100 8 Cover 12 O ring N m 1 Bolt M16 60 265 N m 195 lbf ft 2 Bolt M16 80 265 N m 195 lbf ft 3 Nut M20 539 N m 398 lbf ft 7 Bolt M16 45 265 N m 195 lbf ft ...

Page 85: ... BLD Hose SVB AS2 ARU ALU AS1 ALD AS2 ARD BLD BLU Blade cylinder L BRD BRU Blade cylinder R UP T5 Neutral Floating Down Hose SVP FDB Hose SVT T5 Valve C A VIEW D The letters and figures such as SVT and T5 show each port and the arrow symbols show the hose connection and the direction of the flow of the oil 5 BLADE SYSTEM SV410TB 2 FB 2 5 1 Blade Hydraulic Piping 4 024 HYDRAULIC SYSTEMS ...

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Page 87: ...c circuit diagram 1 Relief valve 4 Pressure gauge port Rc 1 4 2 Port T SVT G3 4 5 Port B SVB G1 2 3 Port P SVP G3 4 6 Port A SVA G1 2 Specifications Rated flow 70 L min 18 gal min Maximum working pressure 20 6 MPa 2 987 psi Relief valve pressure setting 13 7 MPa 1 987 psi at 30 L min 7 9 gal min Weight 7 1 kg 15 7 lbs ...

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Page 89: ...ELECTRICAL SYSTEM ...

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Page 91: ...50 Corrugate Ǟ70 GB 100 CB104 58X 2F 200 Ǟ13 770 63 CorrugateǞ10 Brw 9 GB 63 LY 38 SWP 4㧲 Mark S Starter relay harness P 5 017 J P 5 005 BrR GL Fuel sensor Wire color Reference page Marking Reference page 24 1 25 BR Wire color AVS wire size Wire number 7 28 LgW R2 BR R1 C B ACC 24 1 25BR 4 26 Lg STARTER SWITCH 26 Lg 5G 5BY The pin or socket layout of mating connectors are symmetrical either vertic...

Page 92: ...stripe GY Green Yellow stripe GB Green Black stripe GL Green Blue stripe Gy Gray GyR Gray Red stripe Y Yellow YR Yellow Red stripe YB Yellow Black stripe YG Yellow Green stripe YL Yellow Blue stripe YW Yellow White stripe GyL Gray Blue stripe Br Brown BrW Brown White stripe BrR Brown Red stripe BrY Brown Yellow stripe BrB Brown Black stripe BrG Brown Green stripe BrL Brown Blue stripe Sb Sky blue ...

Page 93: ... 2 1 5 3 26 2Lg LAMP CHECK RELAY R4 X B 32 BY 29 LgB 28 LgW 2 3 5 1 X B X B 9 YR 8 YL 19 L 19 L 19 L 8 YL 19 L 8 YL 10 YB 95E41R N100 B BATTERY AV60 COM NO X 2B BATTERY RELAY F L 65A F L 65A F L 45A 4 5BY 3 5R 23 3RG BR C B ACC STARTER SWITCH 32 BY 38 GR 21 YG 21 YG 25 2BW 16 2W 35 YW 39 L 30 1 25RY 12 R 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A FUSE BOX 1 ST OFF C BR ACC B ON R C...

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Page 95: ...404 09813 0 11629 4 SECTION A A A A 2 3 5 8 7 1 6 From battery To starter motor 1 Cord Pump housing Ground 5 Cord Battery Ground 2 Backup buzzer 6 Battery 3 Cord Battery relay NO Starter motor terminal 30 7 Starter motor 4 Cord Battery Battery relay COM 8 Battery relay ...

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Page 97: ...k H Mark P Thermo unit Rear motor solenoid harness Front motor solenoid harness B B T D J U A C M P 5 006 H P 5 006 E P 5 006 Hydraulic oil filter switch 2 Y Hydraulic oil filter harness Rear motor solenoid Tachometer sensor Hydraulic oil filter switch 1 Y Parking brake solenoid LY B G P 5 006 G YB B Fuel unit Foot brake switch COM R NO LgR F R lever switch COM R NC W Backup buzzer switch COM R NO...

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Page 99: ...harness B D W W Travel mode select switch harness Travel mode select switch Mark B Mark E Mark C Parking brake switch harness Parking brake switch Starter switch Starter switch harness Horn switch Lg Diode unit YR YB Br W GW L YL Fuse box Mark K Parking interlock relay R2 BrY BW B LgR Hydraulic pump neutral holding relay R6 LY GW B R Horn relay R3 RY LgW Lg RY Lamp check relay R4 LgW B LgB BY Trav...

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Page 101: ...raulic oil filter harness Rear motor solenoid Tachometer sensor Hydraulic oil filter switch 1 Y G P 5 008 G YB B Fuel unit Foot brake switch COM R NO LgR Fuse 10A F R lever switch COM R NC W Backup buzzer switch COM R NO GB F R lever vibration switch 1 Br 2 G P 5 008 75A 75A 65A 65A 45A Mark G Mark R Mark T Mark P Mark A Mark A Mark R L P 5 022 P 5 015 F R lever vibration switch Horn LgW B P 5 028...

Page 102: ......

Page 103: ...C Parking brake switch harness Parking brake switch Starter switch Starter switch harness Horn switch Lg Diode unit YR YB Br W GW L YL Fuse box Mark K Parking interlock relay R2 BrY BW B LgR Hydraulic pump neutral holding relay R6 LY GW B R Horn relay R3 RY LgW Lg RY Lamp check relay R4 LgW B LgB BY Travel mode relay R7 G B LR LW Interlock relay R1 W LgR B Lg Servo bypass relay R5 BrW LY B GW W 2 ...

Page 104: ... LY 66 X SWP 2F Parking brake solenoid B LW 60 16 2W 23 3RG 58X 2M LW Corrugate 19 1500 Corrugate 15 850 Corrugate 7 600 Corrugate 19 1150 Corrugate 7 Rear motor solenoid harness P 5 025 SWP 2F B X 50 R 450 50 Corrugate 7 X Y 50 LCR RL 1B LCR RL 1B 22 CB104 Hydraulic oil filter harness P 5 023 LA205 Starter relay 2 HI LA104 GB 50 A Corrugate 15 300 300 B 50 NEG LA104 C o r r u g a t e 1 5 60 5R 10...

Page 105: ...r relay YR 2 A P L 2 A P Y 2 A Hydraulic oil filter harness NO SIZE COLOR CONTACT POINTS CONNECTION 3RG 2 A Fusible link 45A BR 2 A Battery relay BR LgB 2 A P LW 2 A R 8W 4 P 2 Fusible link 75A 2 WB 2 A P BrR 2 A P LgY 2 A P LY 3 A Parking brake solenoid Servo bypass solenoid 8WY 4 Battery relay NO 2 Fusible link 75A 2 3G 2 Battery relay NO Fusible link 45A 5WR 2 Battery relay NO Fusible link 65A ...

Page 106: ...58Y 2M Engine harness type 2 only P 5 015 63 BrR LgY 64 YB YR 9 YL WB YR 29 LgB LY 66 X SWP 2F Parking brake solenoid B LW 60 16 2W 23 3RG 58X 2M LW Corrugate 19 1500 Corrugate 15 850 Corrugate 7 600 Corrugate 19 1150 Corrugate 7 Rear motor solenoid harness P 5 025 SWP 2F B X 50 R 450 50 Corrugate 7 X Y 50 LCR RL 1B LCR RL 1B 22 CB104 Hydraulic oil filter harness P 5 023 2 GB 50 A Corrugate 15 300...

Page 107: ...5RB 2 P Starter relay 2W 2 A Starter relay YR 2 A P L 2 A P NO SIZE COLOR CONTACT POINTS CONNECTION Y 2 A Hydraulic oil filter harness 3RG 2 A Fusible link 45A BR 2 A Battery relay BR LgB 2 A P LW 2 A R 8W 4 P 2 Fusible link 75A 2 WB 2 A P BrR 2 A P LgY 2 A P LY 3 A Parking brake solenoid Servo bypass solenoid 8WY 4 Battery relay NO 2 Fusible link 75A 2 3G 2 Battery relay NO Fusible link 45A 5WR 2...

Page 108: ...ate 15 400 Corrugate 15 Corrugate 15 100 Corrugate 7 600 600 Corrugate 7 Vibrator solenoid harness P 5 022 SWP 4F 50 SWP 2M SWP 8M 58Y 2F 8W 61 8W 61 B X L 19 62 WB 29 LgB BrR 63 17 YR 10 YB 64 LgY YR 9 YL 8 P YR B B YB X X 10 9 H 2 1 Concentrate connector 1 3 5 7 9 2 4 6 8 10 64 Tachometer sensor 50 LgY BrR 63 L 19 LgB 29 YL 8 62 WB B X 61 61 17 750 Corrugate 15 150 250 250 Marking Marking 5 013 ...

Page 109: ...oncentrate connector YR 2 P H YB 2 P H YR 2 P Thermo unit L 2 P Concentrate connector NO SIZE COLOR CONTACT POINTS CONNECTION LgB 2 P Concentrate connector 8W 4 P 2 Alternator 2 WB 2 P Concentrate connector BrR 2 P Tachometer sensor LgY 2 P Tachometer sensor 5 014 ELECTRICAL SYSTEM ...

Page 110: ...ator solenoid harness P 5 022 SWP 4F 50 LCT RL 1B LCT RL 1A SWP 2M SWP 8M 58Y 2F 8W 61 8W 61 B X L 19 62 WB 29 LgB BrR 63 17 YR 10 YB 64 LgY YR 9 YL 8 P YR B B YB X X 10 9 H 15 14 15 14 2 1 Concentrate connector 1 3 5 7 9 2 4 6 8 10 64 Tachometer sensor 50 LgY BrR 63 L 19 LgB 29 YL 8 62 WB B X 61 61 17 5 R 2 0 0 5 R B 2 0 0 Starter motor 30 LA308 50 LA304 5RB 100 5R 100 350 Corrugate 15 100 150 15...

Page 111: ... P H YB 2 P H 5R 2 P Starter motor 50 5RB 2 P Starter motor 30 YR 2 P Thermo unit NO SIZE COLOR CONTACT POINTS CONNECTION L 2 P Concentrate connector LgB 2 P Concentrate connector 8W 4 P 2 Alternator 2 WB 2 P Concentrate connector BrR 2 P Tachometer sensor LgY 2 P Tachometer sensor 5 016 ELECTRICAL SYSTEM ...

Page 112: ...27 SWP 6F SWP 6M SWP 6F SWP 8F Combination meter Vibration select switch harness P 5 026 SWP 6F BR 28 1 25LgW 26 24 LCR RL 1B 4 2Lg E Backup buzzer switch F R lever vibration switch 2 CB104 1 CB104 Tape 150 Tape 100 250 Tape Tape 70 Br 31 YG 21 RY YW YB B 42 35 6 X YR YW 17 35 YL BY 32 8 GR 22 38 Y 50 LW L 39 Travel mode select switch harness P 5 029 SWP 2F K COM CB104 NC CA104 F R lever switch CO...

Page 113: ... Combination meter Control box Y 2 A Combination meter 3RG 2 A Fuse box BR 2 A E 2BW 2 Fuse box 10 Relay box R2 2Lg 2 E Relay box R1 NO SIZE COLOR CONTACT POINTS CONNECTION 1 25LgW LgW 3 E Relay box R4 Fuse 10A LgB 2 A Relay box R4 1 25RY RY 4 B Fuse box 8 Relay box R3 2 Br 2 Combination meter Diode unit BY 2 Relay box R4 Combination meter Lg 2 Relay box R3 Horn switch LgW 2 Relay box R3 Horn YW 5...

Page 114: ...t switch harness P 5 026 SWP 6F BR 28 1 25LgW 26 24 LCR RL 1B 4 5BY 70 70 2Lg E Backup buzzer switch F R lever vibration switch 2 CB104 1 CB104 Tape 150 Tape 100 80 5 0 110 250 Tape Tape 70 Br 31 YG 21 RY YW YB B 42 35 6 X YR YW 17 35 YL BY 32 8 GR 22 38 Y 50 LW L 39 Travel mode select switch harness P 5 029 SWP 2F K COM CB104 NC CA104 F R lever switch COM CB104 NO CA104 12 13 12 2 11 81 W 50 R 50...

Page 115: ... Combination meter Control box Y 2 A Combination meter 3RG 2 A Fuse box BR 2 A E 2BW 2 Fuse box 10 Relay box R2 2Lg 2 E Relay box R1 NO SIZE COLOR CONTACT POINTS CONNECTION 1 25LgW LgW 3 E Relay box R4 Fuse 10A LgB 2 A Relay box R4 1 25RY RY 4 B Fuse box 8 Relay box R3 2 Br 2 Combination meter Diode unit BY 2 Relay box R4 Combination meter Lg 2 Relay box R3 Horn switch LgW 2 Relay box R3 Horn YW 5...

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Page 117: ...ape 70 1 25LgW 70 LA105 ACC 5BY 70 LA305 B BR 70 LA105 BR LCT RL 1A 5BY 70 2Lg 70 LA205 C 70 4 4 24 26 28 Dashboard harness P 5 017 019 Starter switch Marking NO SIZE COLOR CONTACT POINTS CONNECTION 5BY 2 E Starter switch B BR 2 E Starter switch BR 2Lg 2 E Starter switch C 2LgW 2 E Starter switch ACC ...

Page 118: ...9 10 SWP 4M LA103 LA103 Vibrator solenoid b Vibrator solenoid a LA103 LA103 Corrugate 7 Corrugate 7 Y B 7 0 B 7 0 B 50 YR 50 250 250 Main frame harness P 5 009 011 Marking NO SIZE COLOR CONTACT POINTS CONNECTION B 4 H 2 Vibrator solenoid a b YR 2 H Vibrator solenoid a YB 2 H Vibrator solenoid b ...

Page 119: ...Filter Harness SV410 2 05015 22 22 22 CA104 Main frame harness P 5 009 011 Tape Y 100 50 LE105 50 Tape Hydraulic oil filter switch LE105 Tape Y 100 100 NO SIZE COLOR CONTACT POINTS CONNECTION Y 3 Main frame harness Hydraulic oil filter switch 2 ...

Page 120: ... Starter relay 2100 Tape X LA308 2B 100 LA210 Ground bolt X 2B 200 200 Tape 5RB 100 15 5R 100 14 LA308 LA205 LA308 30 LA304 50 14 5R 100 15 5RB 100 NO SIZE COLOR CONTACT POINTS CONNECTION 2B 2 Starter relay Ground bolt 5R 2 Starter relay Starter motor 50 5RB 2 Starter relay Starter motor 30 ...

Page 121: ...lenoid Harness SV410 2 05008 Rear motor solenoid B 50 LW 50 LA103 LA103 Corrugate 7 200 B LW 50 X R SWP 2M X 50 Main frame harness P 5 009 011 Marking NO SIZE COLOR CONTACT POINTS CONNECTION B 2 R Rear motor solenoid LW 2 R Rear motor solenoid ...

Page 122: ... 11 11 11 30 81 RY 150 RG 150 Y 150 11 Y 9 10 YR YB 30 RY 81 RG Tape 150 Y 150 Y 150 B YB 150 YR 150 5 2 1 4 2 1 3 Marking NO SIZE COLOR CONTACT POINTS CONNECTION YR 2 B Vibration select switch 5 YB 2 B Vibration select switch 2 Y 4 B Vibration select switch 1 4 Vibration mode change switch 2 RY 2 B Vibration mode change switch 1 RG 2 B Vibration mode change switch 3 ...

Page 123: ... 36 5 4 3 2 1 Parking brake switch SWP 6M B 150 Tape 150 GR 150 BrW 150 BrY 150 LgR 150 Dashboard harness P 5 017 019 Marking NO SIZE COLOR CONTACT POINTS CONNECTION B 2 C Parking brake switch 5 BrY 2 C Parking brake switch 2 LgR 2 C Parking brake switch 1 BrW 2 C Parking brake switch 3 GR 2 C Parking brake switch 4 ...

Page 124: ...Harness SV410 2 05007 X B 53 WR B 50 WR 50 X LA103 LA103 53 2700 T SWP 2F Corrugate 7 Front motor solenoid Travel mode select switch harness P 5 029 Marking NO SIZE COLOR CONTACT POINTS CONNECTION B 2 T Front motor solenoid WR 2 T Front motor solenoid ...

Page 125: ...IL COM NO T 1 1 Pin position Corrugate 7 Corrugate 7 Travel mode select switch Front motor solenoid harness P 5 028 Dashboard harness P 5 017 019 Orbitrol mounting bolt Travel mode relay Tape Tape Tape Marking NO SIZE COLOR CONTACT POINTS CONNECTION B 3 T R7 Orbitrol mounting bolt L 3 K Travel mode select switch 1 4 LW 3 K R7 Travel mode select switch 5 G 2 R7 Travel mode select switch 2 LR 2 R7 T...

Page 126: ...ode change switch Travel mode select switch YW RY R BW Combination meter Engine warning lamp Control box Horn relay Parking interlock relay W Starter relay 10 9 8 7 6 5 4 3 2 1 F R lever switch Backup buzzer switch Propulsion pump neutral holding relay Foot brake switch Harness color codes W White RY Red Yellow stripe R Red RG Red Green stripe L Blue YW Yellow White stripe BW Black White stripe ...

Page 127: ...VIBRATORY DRUM REAR AXLE ...

Page 128: ......

Page 129: ...ther substances 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 pin...

Page 130: ...g life coolant 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 131: ...t allow the rear wheel tires to leave the ground The tires must support the vehicle s body weight too Rear lift weight SV410D 2 3 800 kg 8 377 lbs SV410T 2 3 770 kg 8 311 lbs SV410TF 2 3 730 kg 8 223 lbs SV410TB 2 3 670 kg 8 091 lbs SV410FB 2 3 620 kg 7 981 lbs When lifting the vehicle use an appropriate hoist of sufficient strength Confirm that the surrounding area is safe and work in a natural u...

Page 132: ...0FB 2 470 kg 1 036 lbs When 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 pres...

Page 133: ...posite 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 S...

Page 134: ...RY DRUM REAR AXLE 8 Place chock blocks at the front and rear of the removed drum assembly 11 to prevent the drum assembly from moving SV400 2 06009 Chock block Chock block 11 SV400 2 06009 Chock block Chock block 11 ...

Page 135: ...alling 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 leakage Start t...

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Page 137: ... O ring 36 Housing 37 Bolt M16 50 38 Disc 39 Bolt M20 90 40 Bolt M16 50 41 Holder 42 Damper 43 Bolt M12 40 44 Bolt M12 40 45 Propulsion motor 46 Vibrator motor 47 Ring 48 Bolt M16 50 49 Bolt M22 70 50 Gear box 51 Bolt M8 16 52 Plug 0404 43802 0 11846 0 Propulsion motor side SECTION A A Vibrator motor side Vibrator mode is Low with motor rotating clockwise Vibrator mode is High with motor rotating ...

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Page 139: ...ear 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 SV410D 2 2 665 kg 5 875 lbs SV410T 2 2 865 kg 6 316 lbs SV410TF 2 4 205 kg 9 2...

Page 140: ... 16 Attach 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 14 135 kg 298 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 0...

Page 141: ...t 150 kg 331 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 eccentric shaft 4 Then lift with a crane and remove Eccentric shaft 135 kg 298 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 ha...

Page 142: ...ng area is safe and work in a natural unstrained posture 10 Remove the seventeen bolts 40 As shown in the figure on the right attach the lifting bolt nut 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 38 145 kg 320 lbs 11 Remove the eighteen bolts 48 Remove the propulsion motor SUBASSY Propulsion motor SUBASSY 145 kg 320 lbs ...

Page 143: ...ht shows 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 SV410 2 06004 34 36 SV410 2 06004 34 36 SV400 2 06024 SV400 2 06024 SV400 2 06025 22 29 SV400 2 06025 22 29 ...

Page 144: ...the cover 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 145: ...le shaft 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 Axle shaft subassembly 90 kg 198 lbs Lightly apply gear oil to the press fitting surface of the roller bearing Attach the inner race of the roller bearing 13 SV400 2 06028 1...

Page 146: ...shims 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 ...

Page 147: ... at dimension 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 mu...

Page 148: ...6 Axle shaft 100 kg 220 lbs Vibrator bearing 10 kg 22 lbs 10 Install the O ring 35 to the housing 36 Lightly apply grease to the entire circumference of the O ring 35 Using the sixteen bolts 34 and washers firmly secure the housing 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 work...

Page 149: ...ed parts 41 42 and 38 145 kg 320 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 SV410D 2 2 225 kg 4 905 lbs SV410T 2 2 425 kg 5 346 lbs SV410TF 2 3 765 kg 8 300 lbs SV410TB 2 2 425 kg 5 346 lbs SV410FB 2 3 765 kg 8 300 lbs Inverting the drum can be dangerous work Therefore be very careful confirm tha...

Page 150: ...lower 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 150 kg 331 lbs 16 Using the sixteen bolts 9 and washers firmly secure the axle shaft subassembly to the drum NOTE When attachi...

Page 151: ... 30 18 and 14 135 kg 298 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...

Page 152: ...embly 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 fil...

Page 153: ... lubrication 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 630 kg 1 389 lbs Tire assembly weight 130 kg 287 lbs 0404 27805 0 11495 0 9...

Page 154: ......

Page 155: ...rication 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 660 kg 1 455 lbs Tire assembly weight 145 kg 320 lbs 0404 27804 0 11494 A 9 10 ...

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Page 157: ... 3 1 2 1 2 1 2 Center housing differential brake Hub reduction gear Drain Supply Drain 1 Filler port 2 Level gauge 3 Drain port Change oil Gear oil API grade GL4 SAE90 See recommended lubrication Change oil quantity Center housing 6 8 L 1 8 gal Hub reduction gear 0 75 L 2 0 2 gal 2 ...

Page 158: ...LE 3 4 Rear Axle Structure 3 4 1 Center housing 1 O ring 5 Vent 9 Snap ring 2 Cover 6 Housing 10 Magnet plug 3 Bolt 7 Plug 4 Seal washer 8 Plug SV201 1 06095 2 1 1 2 1 1 3 8 10 9 6 7 5 4 SV201 1 06095 2 1 1 2 1 1 3 8 10 9 6 7 5 4 ...

Page 159: ... differential 11 Spacer 2 Ring nut 7 Bolt 12 Shim 3 Taper roller bearing 8 Bevel gear set 13 Shim 4 Cylinder bolt 9 Ring nut 5 Differential carrier 10 Taper roller bearing SV400 2 06053 7 10 13 12 11 10 8 4 3 5 6 9 2 1 3 2 1 SV400 2 06053 7 10 13 12 11 10 8 4 3 5 6 9 2 1 3 2 1 ...

Page 160: ...support 24 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...

Page 161: ...on 10 Lock washer 17 Intermediate brake disc 4 O ring 11 Nut 18 Disc 5 Cover 12 Adjustment bolt 19 Bolt 6 O ring 13 Hexagon bolt 20 Seal washer 7 Cylinder bolt 14 Sheet 21 Bolt SV412 06001 1 2 3 4 5 6 7 18 19 21 20 13 14 15 12 11 10 16 9 17 8 SV412 06001 1 2 3 4 5 6 7 18 19 21 20 13 14 15 12 11 10 16 9 17 8 ...

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Page 163: ...BRAKE ...

Page 164: ......

Page 165: ...01 BRAKE 1 BRAKE SYSTEM 1 1 Brake Pedal 0404 51802 0 21623 0 1 5 4 7 6 A A 3 2 SECTION A A 1 Brake pedal 5 Return spring 2 Foot brake switch 6 Stopper bolt M10 40 3 Stopper bolt M10 40 7 Nut M10 4 Nut M10 ...

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Page 167: ...L RBR LOB Hydraulic oil filter 1 Propulsion motor Rear Parking brake solenoid valve Hose BSA RBL Hose RBL RBR Brake Brake Axle assembly Hydraulic oil tank The letters and figures such as BA and BL show each port and the arrow symbols show the hose connection and the direction of the flow of the oil 7 002 BRAKE ...

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Page 169: ...e switch Brake OFF condition Servo bypass relay R5 Hydraulic pump neutral holding relay R6 Charge pump Parking brake solenoid valve when brake is ON without solenoid excited The arrow symbol shows the direction of the hydraulic oil flow Brake Brake ON condition Rear axle Parking brake solenoid valve when brake is OFF with solenoid excited 1 4 3 5 2 1 3 5 2 1 3 5 2 ...

Page 170: ... 8 1 3 4 5 6 Hydraulic circuit diagram 7 8 6 2 1 Solenoid 2 O ring 1B P14 3 Spool J 4 Body 5 Spring 6 Port P BSP 9 16 18UNF 2B 7 Port A BSA 9 16 18UNF 2B 8 Port T BST 9 16 18UNF 2B Specifications Rated pressure 4 9 MPa 710 psi 6 7 0 5 MPa 72 5 psi 8 Rated flow 30 L min 7 9 gal min Weight 1 5 kg 3 3 lbs ...

Page 171: ...INSPECTION AND ADJUSTMENT ...

Page 172: ......

Page 173: ...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 174: ...uge port Forward 1 High pressure gauge port Reverse 2 Pressure gauge 0 to 50 MPa 0 to 7 250 psi Set propulsion travel mode select switch to Start the engine and set throttle lever to Full Establish a condition in which machine propulsion load becomes maximum Pressure does not build up unless propulsion load is applied With propulsion load at maximum slowly move F R lever to the side to be measured...

Page 175: ... 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 circuit pressure range N m 1 Nut...

Page 176: ... operation to ensure that oil does not escape to the charge relief valve on vibrator pump side Loosen nut 1 from charge relief valve 2 12 on vibrator pump side Tighten adjustment screw 2 by 1 2 complete turns Adjustment screw turned clockwise Pressure rise Adjustment screw turned counterclockwise Pressure drop Pressure change rate 0 54 MPa 1 2 turn 78 3 psi 1 2 turn The number 2 12 appearing in ab...

Page 177: ... M16 Adapter for hose ⓢ M16 P 2 0 Pressure gauge connector ⓤ M16 G3 8 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 Then read pressure indicated by pressure gauge Standard charge relief valve setting 2 5 0 2 MPa 363 29 psi SV412 08004 1 Hydraulic oil filter 1 SV412 08004 1 Hydraulic oil filter 1 s ...

Page 178: ... 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 pressure reaches standard charge re...

Page 179: ...e 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 Operate F R lever and then read pressure indicated by pressure gauge With parking brake ON measured pressures of 1 and 2 are the same With parking brake OFF measured pressures of 1 and 2 are different Standard charge relief pressure setting 2 5 0 2 MPa 363 29 psi SV...

Page 180: ...he adapter ⓗ Adapter ⓗ 9 16 18UNF Servo pressure gauge port Low 1 Servo pressure gauge port High 2 Pressure gauge 0 to 5 MPa 0 to 725 psi Apply parking brake by pressing parking brake switch button Set propulsion travel mode select switch to or Start the engine and set throttle lever to Full Then read pressure indicated by pressure gauge Standard charge relief valve setting 2 5 0 2 MPa 363 29 psi ...

Page 181: ...ssure gauge port Low 1 Servo pressure gauge port High 2 Pressure gauge 0 to 5 MPa 0 to 725 psi Apply parking brake by pressing parking brake switch button Set propulsion travel mode select switch to or Start the engine and set throttle lever to Full Then read pressure indicated by pressure gauge Standard charge relief valve setting 2 67 0 2 MPa 387 29 psi SV505 08001 1 2 Propulsion motor Rear SV50...

Page 182: ...essure gauge through adapter ⓦ Adapter ⓦ 4 4LOHL6G5TP Parker part number Pressure gauge 0 to 5 MPa 0 to 725 psi Confirm that F R lever is N properly Apply parking brake by pressing parking brake switch button Start the engine and set throttle lever to Full Release parking brake by pressing parking brake switch button Then read brake release pressure indicated by pressure gauge Brake release pressu...

Page 183: ...apter for hose ⓢ M16 P 2 0 Pressure gauge connector ⓤ M16 G3 8 High pressure gauge port 1 Low amplitude High pressure gauge port 2 High amplitude Pressure gauge 0 to 50 MPa 0 to 7 250 psi Apply parking brake by pressing parking brake switch button Set vibration mode change switch to Start the engine and set throttle lever to Full Press F R lever vibration switch ON Then read pressure gauge for max...

Page 184: ...re relief valve If pressure still deviates from maximum circuit pressure range after valve is disassembled and cleaned replace high pressure relief valve After inspection measure pressure again and check that pressure reaches maximum circuit pressure range N m Plug 40 N m 30 lbf ft NOTICE Carefully disassemble and reassemble after taking steps to prevent foreign material from getting in The number...

Page 185: ... oil does not escape to the charge relief valve on propulsion pump side Loosen nut 2 from charge relief valve 1 10 on propulsion pump side Tighten adjustment screw 3 by one complete turns Adjustment screw turned clockwise Pressure rise Adjustment screw turned counterclockwise Pressure drop Pressure change rate 0 78 MPa 2 turns 113 psi 2 turns The number 1 10 appearing in above illustrations is con...

Page 186: ... M16 Adapter for hose ⓢ M16 P 2 0 Pressure gauge connector ⓤ M16 G3 8 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 Then read pressure indicated by pressure gauge Standard charge relief valve setting 2 5 0 2 MPa 363 29 psi SV412 08004 1 Hydraulic oil filter 1 SV412 08004 1 Hydraulic oil filter 1 s ...

Page 187: ...op Pressure change rate 0 27 MPa 1 4 turn 39 2 psi 1 4 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 188: ...re gauge port High 2 3 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 Set vibration select switch and then read pressure indicated by pressure gauge With vibration select switch is measured pressures of 2 3 and 2 10 are same With vibration select switch is or measured pressures of 2 3 and 2 10 are d...

Page 189: ...hose 1 or 2 from steering cylinder Attach pressure gauge through adapter ⓧ Adapter ⓧ 6 4LOHL6G5TP Parker part number Pressure gauge 0 to 25 MPa 0 to 3 625 psi Confirm that F R lever is N properly Start the engine and set throttle lever to Full Turn steering wheel to operate relief valve Then read pressure indicated by pressure gauge Standard maximum circuit pressure orbitroll relief pressure charg...

Page 190: ...d 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 preven...

Page 191: ...nder Attach pressure gauge through the adapter ⓧ Adapter ⓧ 6 4LOHL6G5TP Parker part number Pressure gauge 0 to 25 MPa 0 to 3 625 psi Confirm that F R lever is N properly Set steering wheel to a position where vibratory drum faces straight forward Start the engine and set throttle lever to FULL Move blade control lever to operate relief valve Then read pressure indicated by pressure gauge Standard ...

Page 192: ...ped 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 N m 3 Relief valve 39 2 4 N m 28 9 3 lbf ft NOTICE Carefully disassemble and reassemble after t...

Page 193: ...ge 0 to 5 MPa 0 to 725 psi Set propulsion travel mode select switch to Start the engine and set throttle lever to FULL Establish a condition in which machine propulsion load becomes maximum Pressure does not build up unless propulsion load is applied With propulsion load at maximum measure pressure when travel mode select switch is and and F R lever is N F and R respectively Allowable pump case pr...

Page 194: ...to 5 MPa 0 to 725 psi Set propulsion travel mode select switch to Start the engine and set throttle lever to Full Establish a condition in which machine propulsion load becomes maximum Pressure does not build up unless propulsion load is applied With propulsion load at maximum measure pressure when travel mode select switch is and and F R lever is N F and R respectively Allowable motor case pressu...

Page 195: ...e select switch to Start the engine and set throttle lever to Full Establish a condition in which machine propulsion load becomes maximum Pressure does not build up unless propulsion load is applied With propulsion load at maximum measure pressure when travel mode select switch is and and F R lever is N F and R respectively Allowable motor case pressure 0 3 MPa 43 5 psi or less SV505 ޓ 08005 1 Pro...

Page 196: ...drain port 1 Attach pressure gauge with adapter ⓙ Adapter ⓙ 7 8 14UNF Pressure gauge 0 to 5 MPa 0 to 725 psi Apply parking brake by pressing parking brake switch button Set vibration mode change switch to Start the engine and set throttle lever to Full Press F R lever vibration switch ON Measure pressure when vibration select switch is in and respectively Press F R lever vibration switch OFF as so...

Page 197: ...ol cable 2 to fuel injection pump s control lever Start the engine Loosen lock nut 3 Using stopper bolt 4 adjust so that standard minimum no load rotational speed is achieved Standard minimu m no load rotational speed 750 25 rpm Using lock nut 3 firmly secure stopper bolt 4 Set throttle lever 1 to FULL Loosen lock nut 5 Using stopper bolt 6 adjust so that standard maximum no load rotational speed ...

Page 198: ...in accordance with procedure described below N maximum F and maximum R positions of F R lever 1 are positioned by notches Set F R lever in N Attach both ends of control cable 2 Specified dimension a 239 mm 9 41 in Confirm the strokes of propulsion pump control lever 3 Specified dimension b 208 mm 8 19 in c 25 mm 1 0 in SV410 2 08010 1 F N R a 2 SV410 2 08010 1 F N R a 2 SV410 2 08011 b c c 2 3 SV4...

Page 199: ...press it into disc 16 Do the same with bolt on the opposite side 3 Alternately tighten bolts 25 1 4 turn each and release brake disc After bolt end makes contact with disc 16 strictly observe not tightening bolt 25 more than one complete turn SV510 ޓ 08027 24 25 SV510 ޓ 08027 24 25 SV510 ޓ 08028 16 25 24 26 SV510 ޓ 08028 16 25 24 26 SV510 ޓ 08029 25 SV510 ޓ 08029 25 ...

Page 200: ... seal washer 26 Adjust bolt 25 to the dimensions as shown on the right Similarly adjust the bolt on the opposite side Specified dimension a 30 0 5 mm 1 34 0 02 in Tighten nut 24 and firmly secure bolt 25 When tightening nut 24 make sure that bolt 25 does not move After securing bolt check the dimensions of bolt again SV510 ޓ 08030 24 25 26 SV510 ޓ 08030 24 25 26 SV510 ޓ 08031 a SV510 ޓ 08031 a 0 0...

Page 201: ...ce between braking discs N m Rotate up to a torque of 8 to 10 N m 5 9 to 7 4 lbf ft Rotate pinion 4 clockwise to determine the required clearance of 1 mm 0 04 in Clearance change rate 0 25 mm turn 0 01 in turn Install lock plate 3 and lock with bolt 2 N m 2 Bolt 10 to 11 N m 7 4 to 8 1 lbf ft SV510 ޓ 08026 2 3 4 SV510 ޓ 08026 2 3 4 SV510 ޓ 08025 4 3 2 SV510 ޓ 08025 4 3 2 ...

Page 202: ......

Page 203: ...TROUBLESHOOTING ...

Page 204: ......

Page 205: ...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 206: ...rating it Check the problem yourself 4 Identify the problem with either a mechanical hydraulic or electrical system source 5 Isolate the problem to a particular component or circuit 6 Eliminate the simplest or easiest to check possibilities first to prevent unnecessary disassembly of components 7 Following repair or replacement of any parts perform operational tests to verify that the problem has ...

Page 207: ...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 diag...

Page 208: ...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 th...

Page 209: ...rness such as broken wire 10 Ω or higher measured value 1 3 Measuring resistance of grounding wire measuring resistance between terminal 5 of equipment B and ground 1 2 3 4 5 5 1 GW750 2 10006 Connector A Harness Ohmmeter tester Main power source of equipment B Equipment B Battery Equipment B Inspection procedure Disconnect the connector of equipment B Connect the test probe to connector terminal ...

Page 210: ...ower to equipment A Equipment B Equipment B Equipment A GW750 2 10007 Inspection procedure Connect the connectors of equipment A and that of equipment B Connect the test probe to connector terminal 3 of equipment A and the test probe to connector terminal 1 of equipment A and measure the voltage Note that reversing the connector terminals between the probes and changes the result of the measuremen...

Page 211: ... 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 cable...

Page 212: ...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 213: ...f burning or of an odor investigate as described follows 2 3 How to find cause of failure when fuse blown is reproduced Turn the starter switch OFF and remove the connector from the load valve pump 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 fu...

Page 214: ...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 215: ......

Page 216: ... 1 PARKING BRAKE SWITCH 36 LgR 24 BR 14 5R 15 5RB X 2B 3 5R 16 2W STARTER RELAY 23 3RG BR E INTERLOCK RELAY R1 13 W X B 2 1 5 3 26 2Lg 95E41R N100 B BATTERY AV60 COM NO X 2B BATTERY RELAY F L 65A F L 65A F L 45A 4 5BY 3 5R BR C B ACC STARTER SWITCH 25 2BW 16 2W 12 R 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A FUSE BOX 1 ST OFF C BR ACC B ON X B 2 1 5 3 R B NC NOCOM F R LEVER SWITCH ...

Page 217: ... is continuity between connection O O If there is no continuity starter switch is faulty Replace starter switch 3 Starter Motor 1 When starter switch is ON measure voltage between starter motor terminal 30 and chassis ground Standard voltage 12 V or more 2 When starter switch is START measure voltage between starter motor terminal 50 and chassis ground Standard voltage 12 V or more If starter moto...

Page 218: ... 1 PARKING BRAKE SWITCH 36 LgR 24 BR 14 5R 15 5RB X 2B 3 5R 16 2W STARTER RELAY 23 3RG BR E INTERLOCK RELAY R1 13 W X B 2 1 5 3 26 2Lg 95E41R N100 B BATTERY AV60 COM NO X 2B BATTERY RELAY F L 65A F L 65A F L 45A 4 5BY 3 5R BR C B ACC STARTER SWITCH 25 2BW 16 2W 12 R 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A FUSE BOX 1 ST OFF C BR ACC B ON X B 2 1 5 3 R B NC NOCOM F R LEVER SWITCH ...

Page 219: ...hassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between F R lever switch terminal NC outlet wire W and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG F R lever switch is faulty Replace F R lever switch 7 Foot Brake Switch 1 When starter switch is ON measure voltage between foot brake switch terminal COM inlet wire R and c...

Page 220: ... 1 PARKING BRAKE SWITCH 36 LgR 24 BR 14 5R 15 5RB X 2B 3 5R 16 2W STARTER RELAY 23 3RG BR E INTERLOCK RELAY R1 13 W X B 2 1 5 3 26 2Lg 95E41R N100 B BATTERY AV60 COM NO X 2B BATTERY RELAY F L 65A F L 65A F L 45A 4 5BY 3 5R BR C B ACC STARTER SWITCH 25 2BW 16 2W 12 R 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A FUSE BOX 1 ST OFF C BR ACC B ON X B 2 1 5 3 R B NC NOCOM F R LEVER SWITCH ...

Page 221: ... above items 1 and 2 are OK and item 3 is NG interlock relay is faulty Replace interlock relay R1 10 Parking Interlock Relay R2 1 When starter switch is ON measure voltage between parking interlock relay terminal 1 inlet wire BrY and chassis ground Standard voltage 12 V or more 2 When starter switch is START measure voltage between parking interlock relay terminal 3 inlet wire LgR and chassis grou...

Page 222: ... 1 PARKING BRAKE SWITCH 36 LgR 24 BR 14 5R 15 5RB X 2B 3 5R 16 2W STARTER RELAY 23 3RG BR E INTERLOCK RELAY R1 13 W X B 2 1 5 3 26 2Lg 95E41R N100 B BATTERY AV60 COM NO X 2B BATTERY RELAY F L 65A F L 65A F L 45A 4 5BY 3 5R BR C B ACC STARTER SWITCH 25 2BW 16 2W 12 R 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A FUSE BOX 1 ST OFF C BR ACC B ON X B 2 1 5 3 R B NC NOCOM F R LEVER SWITCH ...

Page 223: ...faulty Repair or replace harness 2 2 3 Engine does not stop running Reference Fig 2 2 1 Check point Check Cause Action 1 Shutdown Solenoid When starter switch is OFF measure voltage between shutdown solenoid terminal 7 inlet wire WB and chassis ground There is no electricity in normal condition If electricity does not flows but engine does not stop after started shutdown solenoid is faulty Replace...

Page 224: ... 1 PARKING BRAKE SWITCH 36 LgR 24 BR 14 5R 15 5RB X 2B 3 5R 16 2W STARTER RELAY 23 3RG BR E INTERLOCK RELAY R1 13 W X B 2 1 5 3 26 2Lg 95E41R N100 B BATTERY AV60 COM NO X 2B BATTERY RELAY F L 65A F L 65A F L 45A 4 5BY 3 5R BR C B ACC STARTER SWITCH 25 2BW 16 2W 12 R 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A FUSE BOX 1 ST OFF C BR ACC B ON X B 2 1 5 3 R B NC NOCOM F R LEVER SWITCH ...

Page 225: ...s OFF and parking brake switch is released position check continuity between parking brake switch terminal 1 and 2 There is no continuity in normal condition If there is continuity parking brake switch is faulty Replace parking brake switch 2 2 6 Starting engine is difficult Reference Fig 2 2 1 Check point Check Cause Action 1 Negative Torque Control Solenoid When starter switch is START measure v...

Page 226: ... N100 B BATTERY AV60 COM NO X 2B BATTERY RELAY F L 65A F L 65A F L 45A 4 5BY 3 5R 23 3RG BR C B ACC STARTER SWITCH 39 L 12 R 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A FUSE BOX 1 ST OFF C BR ACC B ON SOL SOL 53 WR 53 WR 50 LW X B X B X B 2 1 5 TRAVEL MODE RELAY R11 FRONT MOTOR SOLENOID REAR MOTOR SOLENOID 2 52 LR 52 LR 50 LW 51 G 51 G 3 5 1 4 6 TRAVEL MODE SELECT SWITCH 3 R B B B N...

Page 227: ...l 1 inlet wire BrW and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between servo bypass terminal 3 inlet wire GW and chassis ground Standard voltage 12 V or more 3 When starter switch is ON measure voltage between servo bypass relay terminal 5 outlet wire LY and chassis ground Standard voltage 12 V or more If above items 1 and 2 are OK and item 3 is NG ...

Page 228: ... N100 B BATTERY AV60 COM NO X 2B BATTERY RELAY F L 65A F L 65A F L 45A 4 5BY 3 5R 23 3RG BR C B ACC STARTER SWITCH 39 L 12 R 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A FUSE BOX 1 ST OFF C BR ACC B ON SOL SOL 53 WR 53 WR 50 LW X B X B X B 2 1 5 TRAVEL MODE RELAY R11 FRONT MOTOR SOLENOID REAR MOTOR SOLENOID 2 52 LR 52 LR 50 LW 51 G 51 G 3 5 1 4 6 TRAVEL MODE SELECT SWITCH 3 R B B B N...

Page 229: ... Standard voltage 12 V or more If above item 1 is OK and item 2 is NG F R lever switch is faulty Replace F R lever switch 7 Foot Brake Switch 1 When starter switch is ON measure voltage between foot brake switch terminal COM inlet wire R and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between foot brake switch terminal NO outlet wire LgR and chassis gro...

Page 230: ... N100 B BATTERY AV60 COM NO X 2B BATTERY RELAY F L 65A F L 65A F L 45A 4 5BY 3 5R 23 3RG BR C B ACC STARTER SWITCH 39 L 12 R 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A FUSE BOX 1 ST OFF C BR ACC B ON SOL SOL 53 WR 53 WR 50 LW X B X B X B 2 1 5 TRAVEL MODE RELAY R11 FRONT MOTOR SOLENOID REAR MOTOR SOLENOID 2 52 LR 52 LR 50 LW 51 G 51 G 3 5 1 4 6 TRAVEL MODE SELECT SWITCH 3 R B B B N...

Page 231: ...istance is abnormal rear motor solenoid is faulty Replace rear motor solenoid 3 Travel Mode Relay R11 1 When starter switch is ON and travel mode select switch is measure voltage between travel mode relay terminal 1 inlet wire G and chassis ground Standard voltage 12 V or more 2 When starter switch is ON and travel mode select switch is measure voltage between travel mode relay terminal 3 inlet wi...

Page 232: ... N100 B BATTERY AV60 COM NO X 2B BATTERY RELAY F L 65A F L 65A F L 45A 4 5BY 3 5R 23 3RG BR C B ACC STARTER SWITCH 39 L 12 R 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A FUSE BOX 1 ST OFF C BR ACC B ON SOL SOL 53 WR 53 WR 50 LW X B X B X B 2 1 5 TRAVEL MODE RELAY R11 FRONT MOTOR SOLENOID REAR MOTOR SOLENOID 2 52 LR 52 LR 50 LW 51 G 51 G 3 5 1 4 6 TRAVEL MODE SELECT SWITCH 3 R B B B N...

Page 233: ... When starter switch is ON and travel mode select switch is measure voltage between travel mode select switch terminal wires and chassis ground Travel mode select switch terminal 3 outlet wire WR and chasiss ground Travel mode select switch terminal 6 outlet wire LR and chasiss ground Standard voltage 12 V or more 4 When starter switch is ON and travel mode select switch is measure voltage between...

Page 234: ... N100 B BATTERY AV60 COM NO X 2B BATTERY RELAY F L 65A F L 65A F L 45A 4 5BY 3 5R 23 3RG BR C B ACC STARTER SWITCH 39 L 12 R 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A FUSE BOX 1 ST OFF C BR ACC B ON SOL SOL 53 WR 53 WR 50 LW X B X B X B 2 1 5 TRAVEL MODE RELAY R11 FRONT MOTOR SOLENOID REAR MOTOR SOLENOID 2 52 LR 52 LR 50 LW 51 G 51 G 3 5 1 4 6 TRAVEL MODE SELECT SWITCH 3 R B B B N...

Page 235: ...age between parking brake switch terminal 3 outlet wire BrW and chassis ground There is no electricity in normal condition If electricity flows parking brake switch is faulty Replace parking brake switch 3 Foot Brake Switch When starter switch is ON measure voltage between foot brake switch terminal NO outlet wire LgR and chassis ground There is no electricity in normal condition If electricity fl...

Page 236: ...L 10 YB 95E41R N100 B BATTERY AV60 COM NO X 2B BATTERY RELAY F L 65A F L 65A F L 45A 4 5BY 3 5R 23 3RG BR C B ACC STARTER SWITCH 16 2W 30 1 25RY 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A FUSE BOX 1 ST OFF C BR ACC B ON 3 6 X B 30 RY 81 RG 81 RG 11 Y 11 Y 1 3 2 VIBRATION MODE CHANGE SWITCH 11 Y 11 Y 10 YB 9 YR F R LEVER VIBRATION SWITCH Type 1 1 RG Type 2 1 Br 2 Y 2 G 1 2 VIBRATION...

Page 237: ...select switch terminal 2 outlet wire YB and chassis ground Standard voltage 12 V or more 3 When starter switch is ON and vibration select switch is measure voltage between vibration select switch terminal 5 outlet wire YR and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 or 3 is NG vibration select switch is faulty Replace vibration select switch 3 Vibration Mode Ch...

Page 238: ...L 10 YB 95E41R N100 B BATTERY AV60 COM NO X 2B BATTERY RELAY F L 65A F L 65A F L 45A 4 5BY 3 5R 23 3RG BR C B ACC STARTER SWITCH 16 2W 30 1 25RY 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A FUSE BOX 1 ST OFF C BR ACC B ON 3 6 X B 30 RY 81 RG 81 RG 11 Y 11 Y 1 3 2 VIBRATION MODE CHANGE SWITCH 11 Y 11 Y 10 YB 9 YR F R LEVER VIBRATION SWITCH Type 1 1 RG Type 2 1 Br 2 Y 2 G 1 2 VIBRATION...

Page 239: ... chassis ground Standard voltage 12 V or more 2 When starter switch is ON and vibration select switch is measure voltage between vibration select switch terminal 2 outlet wire YB and chassis ground Standard voltage 12 V or more 3 When starter switch is ON and vibration select switch is measure voltage between vibration select switch terminal 5 outlet wire YR and chassis ground Standard voltage 12 ...

Page 240: ...L 10 YB 95E41R N100 B BATTERY AV60 COM NO X 2B BATTERY RELAY F L 65A F L 65A F L 45A 4 5BY 3 5R 23 3RG BR C B ACC STARTER SWITCH 16 2W 30 1 25RY 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A FUSE BOX 1 ST OFF C BR ACC B ON 3 6 X B 30 RY 81 RG 81 RG 11 Y 11 Y 1 3 2 VIBRATION MODE CHANGE SWITCH 11 Y 11 Y 10 YB 9 YR F R LEVER VIBRATION SWITCH Type 1 1 RG Type 2 1 Br 2 Y 2 G 1 2 VIBRATION...

Page 241: ...ard voltage 12 V or more If above item 1 is OK and item 2 is NG F R lever vibration switch is faulty Replace F R lever vibration switch 2 Vibration Mode Change Switch 1 When starter switch is ON measure voltage between vibration mode change switch terminal 1 inlet wire RY and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between vibration mode change swit...

Page 242: ...8 LgW 64 LgY 35 YW 35 YW 42 RY 42 RY X B TACHOMETER SENSOR 6 YB 22 Y HYDRAULIC OIL FILTER SWITCH 1 HYDRAULIC OIL FILTER SWITCH 2 22 Y 22 Y B B THERMO UNIT ENGINE WARNING LAMP THERMO UNIT DEUTZ INSTALLED 8 YL 35 YW 35 YW 75 3G 76 5WR 19 L 19 L 24 BR 61 8W 61 8W 74 8WY 74 8WY F L 75A 61 8W F L 75A 61 8W 24 BR 3 5R 8 YL 8 YL BR E 6 YB X B FUEL UNIT 17 YR LAMP CHECK RELAY R4 X B 32 BY 29 LgB 28 LgW 2 ...

Page 243: ... 1 Bulbs Check if bulbs have burned out or are poorly contacted Bulbs are faulty or poorly connected Replace bulbs 2 Combination Meter Combination meter illumination When starter switch is ON measure voltage between combination meter illumination terminal wire No 42 inlet wire RY and ground terminal wire B Standard voltage 12 V or more If above item is OK and combination meter does not turn on com...

Page 244: ...8 LgW 64 LgY 35 YW 35 YW 42 RY 42 RY X B TACHOMETER SENSOR 6 YB 22 Y HYDRAULIC OIL FILTER SWITCH 1 HYDRAULIC OIL FILTER SWITCH 2 22 Y 22 Y B B THERMO UNIT ENGINE WARNING LAMP THERMO UNIT DEUTZ INSTALLED 8 YL 35 YW 35 YW 75 3G 76 5WR 19 L 19 L 24 BR 61 8W 61 8W 74 8WY 74 8WY F L 75A 61 8W F L 75A 61 8W 24 BR 3 5R 8 YL 8 YL BR E 6 YB X B FUEL UNIT 17 YR LAMP CHECK RELAY R4 X B 32 BY 29 LgB 28 LgW 2 ...

Page 245: ...s ground There is no electricity in normal condition If above item 1 is OK and item 2 is NG lamp check relay is faulty If above items 1 and 2 are OK and item 3 is NG alternator is faulty Repair or replace lamp check relay R4 or alternator 3 Combination Meter Lamp check 1 When starter switch is ON measure voltage between combination meter battery terminal wire No 35 inlet wire YW and ground termina...

Page 246: ...8 LgW 64 LgY 35 YW 35 YW 42 RY 42 RY X B TACHOMETER SENSOR 6 YB 22 Y HYDRAULIC OIL FILTER SWITCH 1 HYDRAULIC OIL FILTER SWITCH 2 22 Y 22 Y B B THERMO UNIT ENGINE WARNING LAMP THERMO UNIT DEUTZ INSTALLED 8 YL 35 YW 35 YW 75 3G 76 5WR 19 L 19 L 24 BR 61 8W 61 8W 74 8WY 74 8WY F L 75A 61 8W F L 75A 61 8W 24 BR 3 5R 8 YL 8 YL BR E 6 YB X B FUEL UNIT 17 YR LAMP CHECK RELAY R4 X B 32 BY 29 LgB 28 LgW 2 ...

Page 247: ...o 35 inlet wire YW and ground terminal wire B Standard voltage 12 V or more If above item is OK and no abnormality found in tachometer sensor or control box combination meter is faulty Replace combination meter 4 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 repl...

Page 248: ...8 LgW 64 LgY 35 YW 35 YW 42 RY 42 RY X B TACHOMETER SENSOR 6 YB 22 Y HYDRAULIC OIL FILTER SWITCH 1 HYDRAULIC OIL FILTER SWITCH 2 22 Y 22 Y B B THERMO UNIT ENGINE WARNING LAMP THERMO UNIT DEUTZ INSTALLED 8 YL 35 YW 35 YW 75 3G 76 5WR 19 L 19 L 24 BR 61 8W 61 8W 74 8WY 74 8WY F L 75A 61 8W F L 75A 61 8W 24 BR 3 5R 8 YL 8 YL BR E 6 YB X B FUEL UNIT 17 YR LAMP CHECK RELAY R4 X B 32 BY 29 LgB 28 LgW 2 ...

Page 249: ... of harness connecting between terminals Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 2 5 6 Fuel meter is abnormal Reference Fig 2 5 1 Check point Check Cause Action 1 Fuel Unit Disconnect harness and measure resistance of fuel unit Standard resistance 10 Ω with float in F 90 Ω with float in E If resistance is abnormal fuel unit is faulty R...

Page 250: ...8 LgW 64 LgY 35 YW 35 YW 42 RY 42 RY X B TACHOMETER SENSOR 6 YB 22 Y HYDRAULIC OIL FILTER SWITCH 1 HYDRAULIC OIL FILTER SWITCH 2 22 Y 22 Y B B THERMO UNIT ENGINE WARNING LAMP THERMO UNIT DEUTZ INSTALLED 8 YL 35 YW 35 YW 75 3G 76 5WR 19 L 19 L 24 BR 61 8W 61 8W 74 8WY 74 8WY F L 75A 61 8W F L 75A 61 8W 24 BR 3 5R 8 YL 8 YL BR E 6 YB X B FUEL UNIT 17 YR LAMP CHECK RELAY R4 X B 32 BY 29 LgB 28 LgW 2 ...

Page 251: ...esistance of harness connecting between terminals Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 2 5 8 Engine oil pressure warning lamp remains ON Reference Fig 2 5 1 Check point Check Cause Action 1 Engine Oil Pressure Switch Disconnect engine oil pressure switch and check continuity between its terminals There is continuity in normal condit...

Page 252: ...SWITCH SOL HIGH LOW VIBRATOR SOLENOID X B 4 1 2 5 a b 37 BrW 2 36 LgR 38 GR X B 5 3 4 1 PARKING BRAKE SWITCH 38 GR STARTER SWITCH AV60 AV60 D I H F E C A DIODE UNIT B G I D C B E A H G F 35 YW 42 RY 42 RY X B 35 YW 35 YW 75 3G 76 5WR 24 BR 74 8WY 74 8WY F L 75A 61 8W F L 75A 61 8W 24 BR 3 5R BR E 95E41R N100 B BATTERY AV60 COM NO X 2B BATTERY RELAY 77 5BW F L 65A F L 65A F L 45A 4 5BY 4 5BY 3 5R 2...

Page 253: ...hassis ground Standard voltage 12 V or more If above items 1 and 2 are OK and item 3 is NG diode unit is faulty Replace diode unit 3 Combination Meter Vibration indicator lamp 1 When starter switch is ON measure voltage between combination meter battery terminal wire No 35 inlet wire YW and ground terminal wire B Standard voltage 12 V or more 2 When starter switch is ON vibration mode change switc...

Page 254: ...SWITCH SOL HIGH LOW VIBRATOR SOLENOID X B 4 1 2 5 a b 37 BrW 2 36 LgR 38 GR X B 5 3 4 1 PARKING BRAKE SWITCH 38 GR STARTER SWITCH AV60 AV60 D I H F E C A DIODE UNIT B G I D C B E A H G F 35 YW 42 RY 42 RY X B 35 YW 35 YW 75 3G 76 5WR 24 BR 74 8WY 74 8WY F L 75A 61 8W F L 75A 61 8W 24 BR 3 5R BR E 95E41R N100 B BATTERY AV60 COM NO X 2B BATTERY RELAY 77 5BW F L 65A F L 65A F L 45A 4 5BY 4 5BY 3 5R 2...

Page 255: ...dicator lamp 1 When starter switch is ON measure voltage between combination meter battery terminal wire No 35 inlet wire YW and ground terminal wire B Standard voltage 12 V or more 2 When starter switch is ON and parking brake is applied measure voltage between combination meter parking brake terminal wire No 38 outlet wire GR and chassis ground Standard voltage 12 V or more If above items 1 and ...

Page 256: ... RELAY R3 5 3 1 2 30 RY 30 1 25RY X B 30 1 25RY 12 R STARTER SWITCH AV60 AV60 75 3G 76 5WR 24 BR 74 8WY 74 8WY F L 75A 61 8W F L 75A 61 8W 24 BR 3 5R BR E 95E41R N100 B BATTERY AV60 COM NO X 2B BATTERY RELAY 77 5BW F L 65A F L 65A F L 45A 4 5BY 4 5BY 3 5R 23 3RG 23 3RG BR C B ACC STARTER SWITCH 20A 15A 15A 15A 15A 15A 20A 20A 20A 10 9 8 7 6 5 4 3 2 20A FUSE BOX 1 ST OFF C BR ACC B ON TO ALTERNATOR...

Page 257: ...nals 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 5 12 Backup buzzer does not sound Reference Fig 2 5 3 Check point Check Cause Action 1 Backup Buzzer Disconnect backup buzzer and directly connect battery positive terminal to backup buzzer terminal wire GB side and negative termin...

Page 258: ...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 259: ...y circuit with charge circuit Parking brake solenoid valve Rear motor 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 ...

Page 260: ...nkage F R lever linkage 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...

Page 261: ...ve 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 Travel mode cannot be switched Check point Cause Check Action 1 Front Motor Solenoid Valve Travel mode does not change because spool of front motor solenoid valve does not c...

Page 262: ...rise Measure propulsion circuit pressure If high decrease propulsion load 5 Suction Filter for Steering Charge Pump Load of steering 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 1 Charge circuit pressure increases due to clogged filter Clean hydraulic oil filter 1 or replac...

Page 263: ...hift Repair vibrator solenoid valve or replace them if necessary 4 Suction Filter for Steering Charge Pump Steering charge pump flow is reduced due to clogged filler Clean suction filter or replace it if necessary 5 Vibrator Circuit Pressure Circuit does not obtain required pressure because setting pressure of high pressure check relief is low Measure vibrator circuit pressure If low check and cle...

Page 264: ...asure vibrator motor inlet pressure If low check and clean high pressure relief valve or replace it if necessary Vibrator circuit pressure is not held in vibrator motor case If pressure in vibrator motor case is not within allowable range repair vibrator motor or replace it if necessary Decrease in vibrator motor rpm due to internal leakage in vibrator motor Measure drain quantity from vibrator mo...

Page 265: ...vy relief valve opens causing temperature of hydraulic oil in circuit to rise Measure vibrator circuit pressure If high decrease vibration load 4 Suction Filter for Steering Charge Pump Load of steering charge pump increases due to clogged filter causing temperature of hydraulic oil in circuit to rise Clean suction filter or replace it if necessary 5 Hydraulic Oil Filter 2 Charge circuit pressure ...

Page 266: ...ng cylinder Repair steering cylinder or replace it if necessary 5 Suction Filter for Steering Charge Pump Steering charge pump discharge rate decreases due to clogged filter Clean suction filter or replace it if necessary 6 Steering Charge Pump Discharging pressure is insufficient due to efficiency degradation of steering charge pump Measure steering circuit pressure If low replace steering charge...

Page 267: ... 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 Steering Charge Pump Load of steering 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 4 5 Abnormal noise from ste...

Page 268: ...eplace stack valve 5 Blade Cylinder Cylinder thrust decreases due to internal leakage of blade cylinder Repair blade cylinder or replace it if necessary 6 Suction Filter for Steering Charge Pump Steering charge pump discharge rate decreases due to clogged filter Clean suction filter or replace it if necessary 7 Steering Charge Pump Discharging pressure is insufficient due to efficiency degradation...

Page 269: ...circuit to rise Measure blade circuit pressure If high decrease blade load 3 Suction Filter for Steering Charge Pump Load of steering 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 5 5 Abnormal noise from blade hydraulic system Check point Cause Check Action 1 Oil Level of Hydraulic Oil Tank Pump...

Page 270: ...Printed in Japan 2013 07 50 0 H S 0404 99027 0 31649 F 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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Sakai SV410-2, Shop Manual

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