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Sakai SV414, Shop Manual

The Sakai SV414 Shop Manual is a comprehensive user guide designed specifically for this heavy-duty construction equipment. With user-friendly instructions and detailed diagrams, this manual allows you to effortlessly navigate through the machine's features and functionalities. Download it for free from our website and get valuable insights into operating your Sakai SV414.

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9-021

TROUBLESHOOTING

Fig.: 2-3-1

SV414-09003

A

R

THROTTLE SWITCH

CONNECTION

1-3,4-5

1-3,4-6

1-2,4-6

FULL

MID

IDLE

ENGINE SPEED

F

R

B

CC

B

C

STARTER SWITCH

OFF

ON

ST

72

B

112   15B

112 15B

112 15B

11

10

9

8

7

6

5

4

3

2

1

AV40

3WB

78

3WL

86

24

BL

GROUND

LW

3

5R

3

5R

4 

BY

25

12

R

30

4

5

3

1

2

4

5

1

2

3

1

5

4

2

3

4

5

2

3

GROUND

5BW

140

B

6

RY

B

97

1

4

3

5

BW

30

94

97 RW

93 WG

93

RW

WG

WL

91

X

92

2

4

6

BATTERY(-)

BATTERY(-)

BATTERY(-)

79 2B

79 2B

79 2B

1(+)

3(+)

5(+)

BATTERY

BATTERY

BATTERY

2WB

AV

30

AV

40

AV20

AV20

AV20

86 3WL

79 3B

108 GB

7  WG

108

107 LgY

108 GB

107

7 

94

91

92

GB

WG

LgY

BW

LW

WL

5R

14

BrW

37

AV100

B+

L

31

57

9

BL

78

2WB

78

2WB

78

98

18 2RW

29 1.25LB

2W

16

AV100

GROUND

B

S

43

39

61

INTAKE AIR )

ECM RETURN(GENERAL)

STARTER LOCKOUT

ECM RETURN(SWITCHES)

ISC 1 SW(FULL)

ISC 2 SW(MID)

15 KEY SW. SIGNAL

R

B

13 W

4

24

5BY

BR

15 5RB

AV100

68

67

B

X

25

BrY

2BW

26

2Lg

26 2Lg

2

R
12

67

BrY

LgR

36

38 GR

B

X

  5

  3

4

1

LgR

36

NC NO COM

STOP

24

BR

24 BR

BR

5R

5RB

2B

2RW

14

18

15

X

3 8R

76 8WR

4 5BY

77 5BW

W

13

X

2LgR

68 2LgR

B

RC:185MIN
CCA:1000A

B

+

-

AV60

AV60

COM

NO

E

F.L. 65A

F.L. 75A

BR

C

B

ACC

STARTER

SWITCH

NC NO COM

12

13

R

W

2W

98

16

BR

2B

W

1.25R

Y

2

1

TO LAMP

CHECK

RELAY(A9)

5

3

2

1

FUSE

GRID HEATER

RELAY

GRID HEATER

ALTERNATOR(120A)

FUSE

BATTERY

GROUND

STARTER MOTOR

STARTER

RELAY 

BATTERY

RELAY

STARTER LOCKOUT

RELAY(A5)

THROTTLE

SWITCH

THROTTLE

RELAY(A6)

FUSE BOX

F-R LEVER

SWITCH

TO PUMP

NEUTRAL

RELAY(A3)

TO COMBINATION

METER

PARKING BRAKE

SWITCH

FOOT BRAKE

SWITCH

PARKING

INTERLOCK

RELAY (A2)

INTERLOCK

RELAY(A1)

ENGINE ECM.(CM2880B)

J2(94PIN)

30A

5A

5A

20A

15A

15A

15A

15A

15A

20A

20A

20A

125A

Summary of Contents for SV414

Page 1: ...SV414 SHOP MANUAL 3498 64214 0 ...

Page 2: ......

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...

Page 4: ......

Page 5: ...ing 1 004 1 8 Operating 1 004 1 9 Stopping 1 004 1 10 Maintenance 1 005 1 11 Transporting the Machine 1 007 2 SPECIFICATIONS 1 SPECIFICATION DATA 1 1 SV414D 2 001 1 2 SV414T 2 003 1 3 SV414TF 2 005 1 4 Common Specifications 2 007 2 TABLE OF STANDARD VALUES 2 1 Engine 2 008 2 2 Propulsion 2 008 2 3 Hydraulic System 2 008 2 4 Steering 2 009 2 5 Brakes 2 009 2 6 Capacities 2 009 3 FUEL AND LUBRICANTS...

Page 6: ...ydraulic Component Specifications 4 006 2 2 1 Hydraulic pump ASSY propulsion vibrator steering charge 4 006 2 2 2 Propulsion hydraulic motor F 4 008 2 2 3 Gear box 4 010 2 2 4 Propulsion hydraulic motor R 4 012 2 2 5 Speed change solenoid valve F 4 014 2 2 6 Block 1 4 015 2 2 7 Block 2 4 016 2 3 Description and Operation of Propulsion System 4 018 3 VIBRATOR HYDRAULIC SYSTEM 3 1 Vibrator Hydraulic...

Page 7: ...ut 1 5 004 3 2 Wiring Harness Layout 2 5 005 4 WIRING HARNESSES 4 1 Frame Harness 1 5 006 4 2 Frame Harness 2 5 008 4 3 Panel Harness 5 010 4 4 Fuse Relay Box Assembly 5 012 4 5 Battery Relay Harness 5 014 4 6 Stater Switch Harness 5 016 4 7 Control Switch Harness 5 017 4 8 Throttle Switch Harness 5 018 4 9 Vibration Switch Harness 5 019 4 10 Control Harness 5 020 4 11 F R Lever Vibration Switch H...

Page 8: ...Lubrication 6 039 4 3 Rear Axle Structure 6 040 4 3 1 Center housing 6 040 4 3 2 Differential 6 041 4 3 3 Hub reduction gear 6 042 4 3 4 Brake 6 043 7 BRAKE 1 BRAKE PEDAL 7 001 2 BRAKE HYDRAULIC PIPING 7 002 3 BRAKE SYSTEM 3 1 Description and Operation of Brake Circuit 7 003 4 HYDRAULIC COMPONENT SPECIFICATIONS 4 1 Parking Brake Solenoid Valve 7 004 4 2 Servo Bypass Solenoid Valve 7 005 8 INSPECTI...

Page 9: ... 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 CIRCUIT PRESSURE 10 1 Measurement 8 017 10 2 Inspection 8 018 11 MEASUREMENT OF PROPULSION PUMP CASE PRESSURE 11 1 Measur...

Page 10: ...motor does not run 3 3 9 026 2 3 2 No charging 9 028 2 3 3 Grid heater dose not work Engine starting performance is bad in cold weather 9 028 2 3 4 Starter motor runs even when F R lever is not at N and parking brake is not applied 9 030 2 3 5 Engine speed cannot be switched 9 030 2 4 Propulsion 9 032 2 4 1 Machine moves neither forward nor backward 1 2 9 032 2 4 1 Machine moves neither forward no...

Page 11: ...9 3 2 2 Machine moves in one direction only forward or backward 9 069 3 2 3 Slow machine speed or small drive force 1 2 9 069 3 2 3 Slow machine speed or small drive force 2 2 9 070 3 2 4 Machine speed cannot be switched 9 070 3 2 5 Machine does not stop completely with F R lever in N 9 070 3 2 6 Propulsion system is overheating 9 071 3 2 7 Abnormal noise from propulsion system 9 071 3 3 Vibrator ...

Page 12: ......

Page 13: ...SAFETY ...

Page 14: ......

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...

Page 22: ......

Page 23: ...SPECIFICATIONS ...

Page 24: ......

Page 25: ......

Page 26: ...Load on rear axle with operating weight 3 600 kg 7 935 lbs Dimensions Overall length 5 035 mm 198 in Overall width 1 905 mm 75 in Overall height with ROPS 2 810 mm 111 in without ROPS 2 075 mm 82 in Wheelbase 2 655 mm 105 in Compaction width 1 700 mm 67 in Front drum outer shell width dia thickness 1 700 mm 1 220 mm 22 mm 67 in 48 in 0 9 in Front drum inner shell width dia thickness N A N A Front ...

Page 27: ... pressure Front drum Operating weight 201 N cm 115 lbf in Rear drum Operating weight N A N cm N A lbf in Dynamic linear pressure Front drum Operating weight Low amplitude 748 N cm 425 lbf in High amplitude 895 N cm 510 lbf in Rear drum Operating weight Low amplitude N A N cm N A lbf in High amplitude N A N cm N A lbf in Traveling speed Number of speed shift 3 speed Speed range 1st 0 to 4 km h 0 to...

Page 28: ...h operating weight 3 600 kg 7 935 lbs Dimensions Overall length 5 035 mm 198 in Overall width 1 905 mm 75 in Overall height with ROPS 2 830 mm 111 in without ROPS 2 095 mm 82 in Wheelbase 2 655 mm 105 in Compaction width 1 700 mm 67 in Front drum outer shell width dia thickness N A N A Front drum inner shell width dia thickness 1 700 mm 1 120 mm 16 mm 67 in 44 in 0 6 in Front drum pad foot height ...

Page 29: ... linear pressure Front drum Operating weight N A N cm N A lbf in Rear drum Operating weight N A N cm N A lbf in Dynamic linear pressure Front drum Operating weight Low amplitude N A N cm N A lbf in High amplitude N A N cm N A lbf in Rear drum Operating weight Low amplitude N A N cm N A lbf in High amplitude N A N cm N A lbf in Traveling speed Number of speed shift 3 speed Speed range 1st 0 to 4 km...

Page 30: ...ht 3 600 kg 7 935 lbs Dimensions Overall length 5 035 mm 198 in Overall width 1 905 mm 75 in Overall height with ROPS 2 840 mm 112 in without ROPS 2 100 mm 83 in Wheelbase 2 655 mm 105 in Compaction width 1 700 mm 67 in Front drum outer shell width dia thickness 1 700 mm 1 320 mm 19 mm 67 in 52 in 0 7 in Front drum inner shell width dia thickness 1 700 mm 1 120 mm 16 mm 67 in 44 in 0 6 in Front dr...

Page 31: ...c linear pressure Front drum Operating weight 272 N cm 155 lbf in Rear drum Operating weight N A N cm N A lbf in Dynamic linear pressure Front drum Operating weight Low amplitude 819 N cm 465 lbf in High amplitude 966 N cm 550 lbf in Rear drum Operating weight Low amplitude N A N cm N A lbf in High amplitude N A N cm N A lbf in Traveling speed Number of speed shift 3 speed Speed range 1st 0 to 4 k...

Page 32: ...er forced circulation Cooling fan type Inhale Electrical system Alternator 12 V 120 A Starter 12 V 3 0 kW Battery 12 V CCA1000 1 pcs 12 V Dry weight 244 kg 538 lbs Drive system Transmission Type Hydrostatic Speed 3 speed shifts Reverser Switching the direction of flow delivered from the variable pump Differential type Front N A Rear Non spin Final drive Front Planetary gear Rear Planetary gear Vib...

Page 33: ...V414TF 0 to 10 km h 0 to 6 2 mile h 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 2 5 0 2 MPa 363 29 psi Flushing relief valve setting Front motor 1 6 MPa 232 psi at 10 L min Rear motor 2 67 MPa 387 psi at 19 L min Case pressure Pump 0 3 MPa 43 5 psi or less Front motor 0 3 MPa 4...

Page 34: ...th 140 mm 5 5 in Note 1 See dimensions SV520 02001 N o t e 1 N o t e 2 73 mm 2 9 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 8 2 L 2 2 gal Fuel tank 145 L 38 3 gal Coolant 16 L 4 2 gal Gear box front 2 0 L 0 53 gal Center housing rear axle 7 3 L 1 9 gal Hub reduction gear case rear left and right 1 3 L 2 0 ...

Page 35: ...nti wear ISO VG32 ISO VG46 ISO VG68 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 CJ4 Gear oil API GL 5 Hydraulic oil ISO VG 46 Grease NLGI 2 CHEVRON DELO 400 LE Rando HDZ 46 Multifak EP 2 BP BP Energear HYPO U Bartran HV 46 BP Energrease LS EP 2 CASTROL Tection Extra EPX GEAR OILS Castrol Hyspin AW...

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

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

Page 38: ......

Page 39: ... 8 13 12 16 15 14 9 1 Bracket 7 Plate 12 Bolt M16 140 2 Bracket 8 Damper 13 Plate 3 Engine 9 Shim 14 Damper 4 Bracket 10 Nut M16 15 Nut M16 5 Bracket 11 Bolt M12 30 16 Bolt M12 30 6 Bolt M16 140 N m 10 Nut M16 265 N m 195 lbf ft 11 Bolt M12 30 108 N m 80 lbf ft 15 Nut M16 265 N m 195 lbf ft 16 Bolt M12 30 108 N m 80 lbf ft ...

Page 40: ...3 002 ENGINE AND CONTROLS 2 FUEL SYSTEM 0421 02801 0 10002 B 1 2 IN OUT 3 B B 4 5 IN OUT 6 7 8 9 10 11 12 OUT IN A A ...

Page 41: ... 1 Fuel coller 11 Drain plug 2 Hose Fuel return engine Fuel coller IN 12 Hose Main filter OUT Fuel suction engine 3 Pre filter 13 Fuel suction tank 4 Hose Pre filter OUT Main filter IN 14 Fuel gauge unit 5 Fuel tank 15 Fuel return tank 6 Main filter 16 Hose Fuel supply 7 Hose Fuel coller OUT Fuel return tank 17 Strainer 8 Fuel suction engine 18 Fuel supply port 9 Fuel return engine 19 Filler cap 1...

Page 42: ...6 8 9 10 11 12 5 13 DETAIL B F R 1 2 3 A A B 7 Apply grease 1 F R lever switch 8 Rod end Apply grease 2 Backup buzzer switch 9 Bolt M16 30 3 F R lever 10 Nut M16 4 Control cable 11 Spring Fill grease 5 Bush Apply grease 12 Steel ball 6 Nut M12 13 Rod end Apply grease 7 Washer Apply grease Lithium based grease ...

Page 43: ...3 A A A SECTION A A 1 2 7 8 9 6 3 4 5 1 Bolt M10 25 6 Housing 2 Bolt M10 35 7 Bolt M14 45 3 Retaining ring 8 Pump 4 Hub 9 Bolt M12 35 5 Flange N m 1 Bolt M10 25 59 N m 44 lbf ft 2 Bolt M10 35 49 N m 36 lbf ft 7 Bolt M14 45 167 N m 123 lbf ft 9 Bolt M12 35 86 N m 63 lbf ft ...

Page 44: ... Secure flange 5 to engine flywheel with eight bolts 2 N m 2 Bolt M10 35 49 N m 36 lbf ft NOTICE Check for direction of flange 5 Bolt 2 is treated with thread locking fluid Use new thread locking fluid treated bolt for installation Secure housing 6 to flywheel housing with twelve bolts 1 N m 1 Bolt M10 25 59 N m 44 lbf ft NOTICE Bolt 1 is treated with thread locking fluid Use new thread locking fl...

Page 45: ...HYDRAULIC SYSTEMS ...

Page 46: ......

Page 47: ......

Page 48: ...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 49: ...es providing various flow path options for the fluid The multiple square moves to represent how flow paths change when the valving element is shifted within the compo nent Valves with infinite posi tioning between certain limits are symbolized with lines parallel to the squares Methods of Operation DESCRIPTION SYMBOL Spring Manual Pressure compensated Reversing motor Pilot pressure Internal supply...

Page 50: ......

Page 51: ... PPC PPA PD1 PD2 PDV PDC PPB VD2 VD1 VPA VPB SCD SCS SBA SBP LOP LOB LO1 LS1 LS2 LO2 T P R L SRR SRL SRB SLL SLR SLB BSP BST BSA BPL BPS SPB SPR STB ST5 SCT SCP SCA RB1 RB2 RB3 RA1 RA3 RA2 FMA FMB FMC FMD BV2 BV1 RMB RMA RMP RMD FVA VDM VDT FVB T1 T3 T2 T5 T6 CS CO RBL RBR TBR TVB Hydraulic oil filter 1 Hydraulic oil filter 2 Bypass valve Steering cylinder R Orbitrol Steering cylinder L Propulsion...

Page 52: ......

Page 53: ...se Hose ST5 T5 SCA FMC VDM FMD VDM Hose RMP SCA FMC Hose SECTION B B SPR D D B B SECTION D D F F E E E E SECTION F F SECTION E E C VIEW C Hose SCA FMC SCP Speed change solenoid valve F RB2 RA2 Block 1 P 4 015 Block 2 P 4 016 RA2 FMB Hose Hose RB2 FMA SPR RMP Hose Hose RA2 FMB Hose RB2 FMA SCA FMC Hose FMD VDM Hose Hose RB2 FMA RA2 FMB Hose FMD VDM Hose SCA FMC Hose Hose BPS SPB SPB BPS Parking bra...

Page 54: ......

Page 55: ...on of the flow of the oil VIEW E SECTION A A SECTION B B PD1 PPB Propulsion pump PPA Coupling High pressure gauge port PDC CS CO Hose PDC CS Hose PPA RB1 Hose CO T6 Hose RB3 BV2 BV2 BV1 Hose RA3 BV1 RB3 RB1 RA3 RA1 Hose PPB RA1 C C T6 SECTION C C RMD Hose RMD PD1 Hose RMD PD1 Hose PPB RA1 Hose PPA RB1 Hose RMD PD1 Hose PDC CS Hose PPA RB1 A A B B Hose PPB RA1 Oil cooler D Coupling High pressure ga...

Page 56: ......

Page 57: ......

Page 58: ...opulsion vibrator steering charge SV412 04001 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 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 59: ... 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 VPA 1 1 16 12U...

Page 60: ...DRAULIC SYSTEMS 2 2 2 Propulsion hydraulic motor F SV414 04001 9 1 1 4 2 2 3 11 9 11 VIEW A A Motor circuit diagram 6 3 7 5 5 4 8 7 6 VIEW B Flow of oil 3 6 Clockwise rotation 6 3 Counterclockwise rotation 10 B ...

Page 61: ... SAE 3 4 7 Servo pressure gauge port Low 9 16 18UNF 8 Loop flushing shuttle valve 9 Gauge port For Port B 7 8 14UNF 10 Loop flushing relief valve 11 Gauge port For Port A 7 8 14UNF Motor specifications Displacement max 60 0 cm3 rev 3 66 cu in rev min 28 0 cm3 rev 1 71 cu in rev Loop flushing relief valve pressure setting 1 6 MPa 232 psi Allowable motor case pressure 0 3 MPa 43 5 psi or less Weight...

Page 62: ...4 010 HYDRAULIC SYSTEMS 2 2 3 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 63: ... 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 64: ...4 012 HYDRAULIC SYSTEMS 2 2 4 Propulsion hydraulic motor R SV505 04003 2 4 4 3 6 7 8 9 6 2 9 3 7 8 1 5 9 Motor ciruit diagram Flow of oil 8 7 Clockwise rotation 7 8 Counterclockwise rotation ...

Page 65: ... solenoid valve R 6 Servo pressure gauge port 9 16 18UNF 7 Port B Forward RMB SAE 1 8 Port A Reverse RMA SAE 1 9 Drain port 1 1 16 12UN Motor specifications Displacement max 75 cm3 rev 4 58 cu in rev min 35 cm3 rev 2 14 cu in rev Flushing relief valve pressure setting 2 67 MPa 387 psi at 19 L min Allowable motor case pressure 0 3 MPa 43 5 psi or less Weight 55 kg 121 lbs ...

Page 66: ......

Page 67: ...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 SCP 9 16 18UNF 2B 7 Port A SCA 9 16 18UNF 2B 8 Port T SCT 9 16 18UNF 2B Specifications Rated flow 30 L min 7 9 gal min Rated pressure 4 9 MPa 710 psi 6 7 0 5 MPa 72 5 psi 8 Weight 1 5 kg 3 3 lbs ...

Page 68: ...6 Block 1 R2 4 04006 A 1 3 4 5 A SECTION A A 2 1 From propulsion pump port B PPB RA1 1 1 16 12UNF 2 Body 3 To propulsion motor F port B FMB RA2 1 1 16 12UNF 4 To bypass valve RA3 3 4 16UNF 5 To propulsion motor R port A RMA φ24 9 ...

Page 69: ...7 Block 2 SV414 04002 A 1 3 4 5 A SECTION A A 2 1 From propulsion pump port A PPA RB1 1 1 16 12UNF 2 Body 3 To propulsion motor F port A FMA RB2 1 1 16 12UNF 4 To bypass valve RB3 3 4 16UNF 5 To propulsion motor R port B RMB φ24 9 ...

Page 70: ...e pump Propulsion motor R Speed change solenoid valve Flushing valve Low pressure relief valve Rear axle ASSY Differential Final drives Tires Brake Speed change solenoid valve F Parking brake solenoid valve Bypass valve Orbitrol Relief valve Hydraulic oil filter 1 Oil cooler Suction filter Drum Gear box Propulsion motor F Speed change valve Flushing valve Low pressure relief valve Servo bypass sol...

Page 71: ... such as a and b Operation of the F R lever forward puts pump control valve a into function Servo piston c tilts the pump swashplate in the forward travel direction Propulsion pump 3 discharges oil from its port B1 Then the oil flow branches into two lines one line connecting to forward travel port A of propulsion motor R 6 and the other line to forward travel port B of propulsion motor F 17 The o...

Page 72: ...tor pump Steering charge pump Propulsion motor R Speed change solenoid valve Flushing valve Low pressure relief valve Rear axle ASSY Differential Final drives Tires Brake Speed change solenoid valve F Parking brake solenoid valve Bypass valve Orbitrol Relief valve Hydraulic oil filter 1 Oil cooler Suction filter Drum Gear box Propulsion motor F Speed change valve Flushing valve Low pressure relief...

Page 73: ...r s station energizes parking brake solenoid valve 9 The oil under pressure is fed via parking brake solenoid valve 9 into the brake cylinders This moves the brake pistons against the compression spring load releasing the brake Circuit protection against high pressure High pressure relief valves d built in propulsion pump 3 open to relieve the pressure if the system pressure exceeds the setting of...

Page 74: ......

Page 75: ...TION A A T1 AD2 AD1 SECTION C C SECTION B B VDT T1 Hose Hose VPA AD1 Hose VPB AD2 Hose Hose VD1 LS2 Hose VPA AD1 SECTION D D Hose Hose VD1 LS2 Hose C C D D The letters and numbers in the figure such as VPB and AD2 show each port Arrow symbols show the hose connection and the direction of the flow of the oil VPB AD2 VPB AD2 VPA AD1 Vibrator pump P 4 005 PDC PD2 PDV VDM P 4 004 3 VIBRATOR HYDRAULIC ...

Page 76: ......

Page 77: ...ion 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 VDM 7 8 14UNF 4 Drain port 7 8 14UNF 5 Drain port VDT 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 ...

Page 78: ...P B A A B Engine Coupling Propulsion pump Vibrator pump Amplitude select valve Charge relief valve High pressure relief valves Check valves Steering charge pump Vibrator motor Vibrator Orbitrol Hydraulic oil filter 1 Hydraulic oil filter 2 Oil cooler Suction filter a b c d 1 2 3 4 5 6 7 8 9 10 11 12 ...

Page 79: ...NOTE Because the vibrator system also uses a closed circuit HST like the propulsion circuit every time the amplitude election is changed from low amplitude to high or vice versa the function of the pump inlet and outlet is reversed with each other Circuit protection against high pressure High pressure relief valves c built in the vibrator pump 4 relieve pressure to protect the circuit when the pre...

Page 80: ......

Page 81: ...ank Steering cylinder L Steering cylinder R A A SECTION A A Hose LOP PPC Hose T3 SCS LOP LS1 Hose T LS1 Hose L SLL Hose SLR SRB Hose R SRR C C Hose R SRR Hose L SLL Hose SCD P Hose T LS1 SECTION C C D D E E Suction filter SECTION D D SECTION E E Hose SCD P Hose T3 SCS Hose LOP PPC Hose SCD P Hose T3 SCS Hose LOP PPC F LO1 Steering charge pump Coupling Charge pressure gauge port T3 L T P R Orbitrol...

Page 82: ......

Page 83: ...4 026 HYDRAULIC SYSTEMS 4 2 Steering Wheel 0418 62813 0 12540 B 1 2 3 5 4 1 Steering wheel 4 Nut M12 P 1 25 2 Bolt M10 30 5 Orbitrol 3 Column shaft N m 4 Nut M12 P 1 25 35 N m 26 lbf ft ...

Page 84: ... ORB SD 04150 1 2 3 3 4 4 1 2 Hydraulic circuit diagram 5 1 Port L L 3 4 16UNF 4 Port P P 3 4 16UNF 2 Port R R 3 4 16UNF 5 Relief valve 3 Port T T 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 85: ......

Page 86: ...uit SV414 04005 1 2 3 4 5 7 6 8 9 a b c T P R L Engine Coupling Propulsion pump Vibrator pump Steering charge pump Orbitrol Relief valve Check valve Steering cylinders Piston rods Hydraulic oil filter 1 Suction filter a b c 1 2 3 4 5 6 7 8 9 7 ...

Page 87: ...harge pump 5 enters Orbitrol 6 and a certain quantity of oil that matches the handle turning direction and speed is supplied to steering cylinders 7 The oil that enters the steering cylinder shifts piston rod c to operate it while the oil pushed out of the port on the opposite side returns to orbitrol 6 flowing into the charge circuit of propulsion pump 3 through hydraulic oil filter 1 8 For the C...

Page 88: ... oil groove of spool 1 is not aligned with the oil hole of sleeve 2 completely stopping the oil flow into the steering cylinder When the steering wheel is operated the oil groove of spool 1 is aligned with the oil hole of sleeve 2 to open the circuit allowing the oil to flow into the steering cylinder Rotor section The rotor is a kind of internal gear functioning as a hydraulic motor when the valv...

Page 89: ...hen the steering wheel is operated All the ports of the valve section are closed when Orbitrol is in the neutral position The oil in the rotor has been sealed up and rotor 4 is fixed Sleeve 2 is coupled with rotor 4 via cross pin 7 and drive shaft 5 and it is fixed also When the steering wheel is operated the turning force is applied to spool 1 contracting centering spring 6 that has been set in t...

Page 90: ...owing the rotation of the spool This phenomenon permits the spool to rotate continuously permitting the steering wheel to turn and the vehicle to swing continuously When the steering wheel operation is stopped the spool stops rotation immediately but the oil flows into Orbitrol if the displacement angle exists between the spool and sleeve permitting the rotor to rotate continuously This rotation a...

Page 91: ... force is used simply to overcome the sliding resistance of sleeve 2 and the rotor permitting the steering wheel to rotate easily When the hydraulic pump discharge is insufficient the displacement angle between spool 1 and sleeve 2 reaches the maximum reducing the quantity of oil flowing from the hydraulic pump into the rotor even if the hydraulic circuit opens widely causing the rotor to rotate s...

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Page 93: ...ELECTRICAL SYSTEM ...

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Page 95: ...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 96: ...rown 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 L Blue LW Blue White stripe LR Blue Red stripe LY Blue Yellow stripe LB Blue Black stripe LG Blue Green stripe P Pink PB Pink Black stripe Lg Light green LgR Light green Red stripe LgY Light green Yellow stripe LgB Light green Black stripe LgW Light green W...

Page 97: ...WATER IN FUEL KEY SW SIGNAL 87 70 44 CAN A CAN A ECM RETURN SENSOR COOLANT LEVEL SIGNAL SENSOR SUPPLY POWER B W R B 38 Br YW RG GR 41 RG 41 RG YB Y 22 Y 22 Y B B 3 6 YW 31 38 35 GB B 2 X 13 35 31 W YW Br W 4 24 5BY BR 24 BR 15 5RB AV100 Br 65 13 31 68 67 B X 25 BrY 2BW 26 2Lg 26 2Lg 2 R 12 67 BrY LgR 36 38 GR B X 5 3 4 1 SOL LgR 36 NC NO COM STOP 24 BR 24 BR BR 5R 5RB 2B 2RW 14 18 15 X 23 3RG 23 3...

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Page 99: ...C W F R lever switch Not in use R Insulation protection POW Sub power 12V 120W Terminating resistor Speed change solenoid harness Speed change solenoid R Battery Lg Horn switch P 5 020 Control harness 8M3 Mark 7M2 Mark 6M1 Mark 5D2 Mark 4D1 Mark 3C Mark 2C Mark 1 1 Mark Not in use P 5 020 Control harness CAP SWP 2M CAP SWP 2M 1 2 Mark Not in use 5D6 Mark 4D5 Mark 3D4 Mark 2D3 Mark P 5 006 Frame ha...

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Page 101: ...016 Stater switch harness P 5 027 Backup buzzer harness P 5 014 Battery relay harness P 5 014 Battery relay harness Grid heater relay P 5 014 Battery relay harness DETAIL M DETAIL G DETAIL H DETAIL N Battery relay Starter relay B R RB RW Alternator 120A BW WL COM B Ground Ground B GB Backup buzzer BR BR G WR NO R 12V Ground Ground Terminal B Fuel sensor Fuel filter B RB RW T Mark B Mark P Mark E M...

Page 102: ... pair cable with shield 2D3 5D6 3D4 6M1 7M2 58X 4M gray SWP 14M 82 G 83 L 2Lg 2B X 26 5BY 4 6 YB 24 BR 50 LW 87 B 94 BW SWP 6M 58Y 2M black 3RG 23 2Lg 26 3 5R 3 5R 18 2RW X 2B Marking tape color blue 8M3 Engine harness LA310 5BW 50 200 250 9 10 X X YB B B YR SWP 4F 150 H 50 50 50 50 50 50 B 50 LA108 200 50 LY 66 X B LW 950 500 250 SWP 2F B X 50 R 150 50 Parking brake solenoid 350 50 100 133 134 Tw...

Page 103: ...olenoid F No SIZE COLOR CONTACT POINTS CONNECTION 1 2 66 LY 3 8M3 Servo bypass solenoid Parking brake solenoid 72 B 2 4 Ground 78 2WB 3WB 4 2 Engine ECM 1 3 5 79 2B 3B 4 Ground Engine ECM 2 4 6 82 G 3 5D6 Terminating resistor Engine ECM 84 83 L 3 5D6 Terminating resistor Engine ECM 62 87 B 2 3D4 Ground 91 LW 2 8M3 Engine ECM 39 92 WL 2 8M3 Engine ECM 61 94 BW 2 3D4 Engine ECM 43 98 BL 2 8M3 Engine...

Page 104: ...3 6 5 4 3 2 1 78 2WB 78 2WB 78 2WB 79 2B 79 2B 79 2B 98 BL 133 GL 134 BrR 130 BR 131 LgR 132 RW 82 G 83 L 92 WL 91 LW 94 BW 107 LgY 108 GB 7 WG Twist pair cable with shield AVSSCS 0 75 Twist cable DETAIL A 4 2 Frame Harness 2 5 008 ELECTRICAL SYSTEM ...

Page 105: ...olenoid F No SIZE COLOR CONTACT POINTS CONNECTION 1 2 66 LY 3 8M3 Servo bypass solenoid Parking brake solenoid 72 B 2 4 Ground 78 2WB 3WB 4 2 Engine ECM 1 3 5 79 2B 3B 4 Ground Engine ECM 2 4 6 82 G 3 5D6 Terminating resistor Engine ECM 84 83 L 3 5D6 Terminating resistor Engine ECM 62 87 B 2 3D4 Ground 91 LW 2 8M3 Engine ECM 39 92 WL 2 8M3 Engine ECM 61 94 BW 2 3D4 Engine ECM 43 98 BL 2 8M3 Engine...

Page 106: ...B 50 LgW 50 Horn PB104 34 X LA108 500 Foot brake switch LgR 50 R 50 36 12 Tape 200 CA104 NO CB104 COM 1 5 0 T a p e LA210 2B 50 Lg 200 Tape Horn switch CB104 J X 33 100 Tape Ground 100 B Lg B X 96 E G 82 G B 87 L 83 H D A J F C Data link interface connector HD14 9 1939P with HDC16 9 1 25WR 118 5 0 0 L G 83 82 B X C B A 100 Tape Terminating resistor DT06 3S E008 with DT04 3P P006 Twist pair cable w...

Page 107: ...nation meter 2 22 36 LgR 2 P Foot brake switch NO 37 BrW 2 4D1 P 38 GR 2 P Combination meter 14 No SIZE COLOR CONTACT POINTS CONNECTION 39 L 2 5D2 P 41 RG 2 4D1 Combination meter 30 50 LW 2 3D4 P 51 G 2 5D2 P 52 BrR 2 5D2 P 53 WR 3 3D4 5D2 P 54 LR 2 5D2 P 67 BrY 2 4D1 P 70 WR 2 4D1 Combination meter 1 81 RG 2 5D2 B 82 G 4 5D6 Combination meter 11 Data link interface connector C Terminating resisto...

Page 108: ...30 LgW 33 Lg 1 25RY RY BY 4 2W 16 5R 3 T a p e 1 5 0 6M1 50 58Y 2F black SWP 16F SWP 6F 2 GB 11 Y 12 R 13 W 81 RG 50 50 50 Tape 80 T a p e 1 2 0 50 4D1 8M3 SWP 8F 43 1 25RG 5D2 3C 43 1 25RG Marking tape color blue 50 RG 41 L 39 1 25RY 30 WR 70 5R 3 123 98 24 2BW 25 R 12 YW 35 2YB 122 3RG 23 2RG 43 BL BR 2Br LW WG LY 66 2BW 2LgR 2LgR 2Lg 51 G LR 54 52 B WR 53 BrR 31 Br YR 9 YB 10 65 GW W 13 Diode u...

Page 109: ...Diode unit 32 BY 2 4D1 Lamp check relay A9 33 Lg 2 5D2 Horn relay A8 34 LgW 2 5D2 Horn relay A8 35 YW 2 4D1 Fuse box 6 No SIZE COLOR CONTACT POINTS CONNECTION 37 BrW 2 4D1 Relay box A3 39 L 2 5D2 Fuse box 5 41 RG 2 4D1 Fuse box 3 43 1 25RG 2RG 3 1 1 2 Fuse box 1 51 G 2 5D2 Relay box A7 52 BrR 2 5D2 Relay box A7 53 WR 2 5D2 Relay box A7 54 LR 2 5D2 Relay box A7 65 GW 3 Diode unit Relay box A3 A4 66...

Page 110: ...rid heater relay Tape 120 118 86 10A 1 25WL 50 1 25WR 50 Tape 120 T a p e 1 0 0 7 0 50 50 SWP 3M Twist cable 5 2B 2RW 18 X 2 3 1 3RG 23 140 80 3WB 50 3WL 50 30A 86 Fuse 10A Fuse 30A 45A red 65A black 75A gray 78 118 1 25WR 78 3WB 5RB 15 T a p e 50 58Y 2M black 14 5R 5RB 120 2RW 120 Starter relay 5R 120 14 LA308 LA308 LA205 15 18 LA205 X 2B 120 Fusible link 120 23 Tape 3G 3RG 75 Tape Tape 120 76 8W...

Page 111: ... 2 3 Starter relay 18 2RW 2 2 Starter relay 23 3RG 2 2 Fusible link 45A 24 BR 3 5 Battery relay BR Diode 1 72 B 3 4 Battery relay Ground Diode 2 75 3G 2 Battery relay NO Fusible link 45A 76 8WR 2 Battery relay NO Fusible link 75A 77 5BW 2 Battery relay COM Fusible link 65A 78 3WB 2 2 Fuse 30A 86 1 25WL 3WL 3 Battery relay COM Fuse 10A Fuse 30A 108 GB 2 5 Grid heater relay 118 1 25WR 2 4 Fuse 10A ...

Page 112: ...3M Tape 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 Panel harness P 5 010 Starter switch No SIZE COLOR CONTACT POINTS CONNECTION 4 5BY 2 E Starter switch B 24 BR 2 E Starter switch BR 26 2Lg 2 E Starter switch C 28 1 25LgW 2 E Starter switch ACC ...

Page 113: ...avel mode change switch LR 70 WR 70 53 2 54 1 3 50 LW 70 1 8 0 T a p e 6 52 BrR 70 P 300 Tape 50 No SIZE COLOR CONTACT POINTS CONNECTION X B 2 P Parking brake switch 5 36 LgR 2 P Parking brake switch 1 37 BrW 2 P Parking brake switch 3 38 GR 2 P Parking brake switch 4 39 L 2 P Speed select switch 4 50 LW 3 P Speed select switch 5 Travel mode change switch 3 51 G 2 P Speed select switch 3 52 BrR 2 ...

Page 114: ... 93 30 97 RW 97 BW 94 WG 93 RY 30 WG 70 3 1 BW 70 T SWP 4M 5 4 Throttle switch RY 70 RW 70 Tape 430 50 Panel harness P 5 010 No SIZE COLOR CONTACT POINTS CONNECTION 30 RY 2 T Throttle switch 4 93 WG 2 T Throttle switch 3 94 BW 2 T Throttle switch 1 97 RW 2 T Throttle switch 5 ...

Page 115: ... harness P 5 010 9 10 11 11 11 97 81 RW 70 RG 70 Y 70 81 RG 97 RW 9 YR 11 Y 10 YB Tape 250 Y 70 Y 70 B YB 70 YR 70 No SIZE COLOR CONTACT POINTS CONNECTION 9 YR 2 B Vibration select switch 5 10 YB 2 B Vibration select switch 2 11 Y 4 B Vibration mode change switch 2 Vibration select switch 1 4 81 RG 2 B Vibration mode change switch 3 97 RW 2 B Vibration mode change switch 1 ...

Page 116: ... buzzer switch R 50 GB 50 CB104 COM CA104 NO 12 2 11 81 T a p e 50 Tape 2C SWP 6M RG 81 GB 2 Y 11 R 12 W 13 150 Tape Marking tape color red Marking tape color white Corrugate 10 Corrugate 10 C o r r u g a t e 7 P 5 012 P 5 021 Fuse relay box assembly No SIZE COLOR CONTACT POINTS CONNECTION X 2B 2 2C POW 2 GB 2 3C Backup buzzer switch NO 11 Y 2 3C F R lever vibration switch harness 12 R 3 3C Backup...

Page 117: ...W 65 Br 65 F R lever vibration switch Control harness P 5 020 See Wiring Harness Layout 1 DETAIL E 635 G 65 P 5 004 PVC Tube 6 0 5 No SIZE COLOR CONTACT POINTS CONNECTION Br 2 Control harness F R lever vibration switch 1 G 2 Control harness F R lever vibration switch 2 W 2 Control harness F R lever vibration switch 3 ...

Page 118: ...noid Harness 1412 09005 0 30074 A Speed change solenoid B 50 LW 50 LA103 LA103 Corrugate 7 200 B LW 50 X R SWP 2M X 50 Frame harness 1 P 5 006 No SIZE COLOR CONTACT POINTS CONNECTION X B 2 R Speed change solenoid R 50 LW 2 R Speed change solenoid R ...

Page 119: ... YB X X 9 10 SWP 4M LA103 LA103 Vibrator solenoid a Vibrator solenoid b LA103 LA103 Corrugate 7 Corrugate 7 Y B 7 0 B 7 0 B 50 YR 50 250 250 Frame harness 1 P 5 006 No SIZE COLOR CONTACT POINTS CONNECTION X B 4 H 2 Vibrator solenoid a b 9 YR 2 H Vibrator solenoid b 10 YB 2 H Vibrator solenoid a ...

Page 120: ...tic Switch Harness 1421 09023 1 30154 A SWP 2M Diagnostic switch LA104 3 LA104 2 96 X Lg 50 B 50 Tape 150 B X 96 Lg J Panel harness P 5 010 No SIZE COLOR CONTACT POINTS CONNECTION X B 2 J Diagnostic switch 3 96 Lg 2 J Diagnostic switch 2 ...

Page 121: ...4 15 Hydraulic Oil Filter Harness 1405 09009 0 40195 0 22 LA105 200 Tube 22 CA104 Panel harness Hydraulic oil filter switch P 5 010 Y 50 No SIZE COLOR CONTACT POINTS CONNECTION 22 Y 2 Hydraulic oil filter switch Panel harness ...

Page 122: ...50 1650 Twist cable BR 130 LgR 131 RW 132 Coolant level sensor Twist cable M 130 BR 131 LgR 132 RW 29 1 25LB SWP 2F SWP 3F Frame harness 1 P 5 006 750 100 H COT Corrugate 7 H COT Corrugate 7 H COT Corrugate 7 No SIZE COLOR CONTACT POINTS CONNECTION 29 1 25LB 2 M Alternator 130 BR 2 M Coolant level sensor 131 LgR 2 M Coolant level sensor 132 RW 2 M Coolant level sensor ...

Page 123: ...ackup Buzzer Harness 1421 09044 0 30245 0 SWP 2M Backup buzzer LA104 LA104 2 X GB 50 B 50 350 50 GB 2 X B BU Frame harness 1 P 5 006 Corrugate 7 No SIZE COLOR CONTACT POINTS CONNECTION X B 2 BU Backup buzzer 2 GB 2 BU Backup buzzer ...

Page 124: ...rottle switch RY Backup buzzer switch F R lever switch Foot brake switch Pump neutral holding relay R WR BR BR Starter switch Battery relay Engine ECM BL BY Starter lockout relay A5 W 11 10 9 15A 8 7 6 5 4 3 2 1 Combination meter Battery relay COM Starter switch Harness color codes W White WR White Red stripe R Red RY Red Yellow stripe Br Brown RG Red Green stripe L Blue YW Yellow White stripe BW ...

Page 125: ...een DEF SCR Quality Red DEF Tampering Buzzer Water splay Liquid spray High beam Flood lamp Turn signal R Turn signal L Vibrator Inhibit the DPF Auto vegeneration Inhibit the SCR cleaning 7 Segments LCD Dot Matrix LCD TACHO FUEL TEMP BAT Battery 12V Ground Starter switch ACC Pull down Resistor 4 7KΩ x7 BAT System configuration diagram X 35 38 32 22 96 35 32 82 83 31 70 41 6 DESCRIPTION Battery 12V ...

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

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Page 129: ...t and other 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 pin...

Page 130: ...ng 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: ... crane Place support stands under rear frame when rear wheel tires is slightly off ground to support machine body Rear axle weight SV414D 3 600 kg 7 935 lbs SV414T 3 600 kg 7 935 lbs SV414TF 3 600 kg 7 935 lbs NOTICE Do not allow rear wheel tires to leave the ground The tires must support the machine s body weight too 3 Lift front frame with a crane Ensuring that no load is applied to bolts 2 left...

Page 132: ...s condition can cause burns Wait for the hydraulic oil to cool down before starting the work 5 Disconnecting piping 5 1 Propulsion motor piping Disconnect hydraulic hoses 5 6 7 and 8 connecting to propulsion motor NOTICE Plug both ends of the disconnected hoses or implement other actions to prevent entry of foreign matter 5 2 Vibrator motor piping Disconnect hydraulic hoses 9 10 11 and 12 connecti...

Page 133: ...3 from frame Remove bolts 2 Remove vibratory drum ASSY Vibratory drum ASSY SV414D 2 520 kg 5 556 lbs SV414T 2 495 kg 5 500 lbs SV414TF 3 785 kg 8 344 lbs 6 Put chocks or the like under removed drum 13 to prevent it from moving SV414 06086 Support stand Lift with crane 2 13 SV414 06087 13 Chock ...

Page 134: ... member 2 Upon installing vibratory drum pay particular attention to items mentioned below Fill hydraulic oil tank to specified level to make up for any oil leakage Start engine and circulate oil through piping Then check oil level again ensuring that the oil is at specified level NOTICE If the engine is run at high speed or the cylinder is operated to full stroke when the engine is started for th...

Page 135: ...0 53 Bolt M16 45 4 Ring 54 Bolt M 8 16 5 Plug 55 Propulsion motor 6 Bolt M16 50 56 Bolt M16 40 7 Vibrator bearing 57 Bolt M20 80 8 Eccentric shaft 58 Nut M20 9 Shaft 59 Holder 10 Bolt M10 40 11 Sleeve 12 Spring pin 13 Bolt M16 50 14 Plug 15 Disc 16 Bolt M12 40 17 Nut M12 18 Damper 19 Bolt M12 40 20 Nut M12 21 Holder 22 Plate 23 Bolt M20 80 24 Nut M20 25 Bolt M20 50 26 Breather 27 Cover 28 O ring 2...

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Page 137: ... 1 and drain plug 14 2 WARNING When standing the vibratory drum use wooden blocks of sufficient strength to securely support the drum Carry out the work in an unstrained posture using a work stool or the like 2 Lift vibratory drum ASSY with a crane and stand it with its vibrator motor 29 side facing up as shown on the right Vibratory drum ASSY SV414D 2 500 kg 5 512 lbs SV414T 2 470 kg 5 445 lbs SV...

Page 138: ...nstalling lifting bolts secure them with nuts 4 Install lifting bolts M20 and nuts to holders 21 and 35 5 Remove bolts 25 6 Remove disc SUBASSY Disc SUBASSY 135 kg 298 lbs SV414 06004 35 21 Lifting bolt nut SV414 06005 25 SV414 06006 Disc SUBASSY ...

Page 139: ... shaft SUBASSY using two pulling bolts M20 60 WARNING When installing lifting bolts screw in the threads fully before using 9 Install lifting bolts M20 to axle shaft SUBASSY SV414 06050 13 11 SV414 06052 Lifting bolt Axle shaft SUBASSY SV414 06051 Axle shaft SUBASSY Pulling bolt ...

Page 140: ...entric shaft end with a wooden hammer via a wooden bar during lifting Axle shaft SUBASSY 150 kg 331 lbs 11 Put axle shaft SUBASSY on wooden blocks 12 Install a lifting bolt M10 to eccentric shaft SUBASSY SV414 06053 Axle shaft SUBASSY Wooden hammer Wooden bar SV414 06054 Axle shaft SUBASSY Wooden block SV414 06007 Lifting bolt Eccentric shaft SUBASSY ...

Page 141: ... Be careful because reversing the vibratory drum involves risk Confirm that the surrounding area is safe and work in a natural unstrained posture 14 Reverse drum SUBASSY Drum SUBASSY SV414D 2 055 kg 4 530 lbs SV414T 2 045 kg 4 508 lbs SV414TF 3 325 kg 7 330 lbs 15 Remove bolts 56 Remove propulsion motor 55 55 Propulsion motor 30 kg 66 lbs SV414 06010 56 55 SV414 06008 Movable weight Eccentric shaf...

Page 142: ...DRUM REAR AXLE 16 Install lifting bolts M20 and nuts to holders 52 and 59 17 Remove bolts 53 18 Remove disc SUBASSY Disc SUBASSY 115 kg 254 lbs SV414 06014 Disc SUBASSY SV414 06013 53 SV414 06012 52 59 Lifting bolt nut ...

Page 143: ...stall lifting bolts M16 to gear box 45 Remove bolts 3 20 Remove gear box 45 45 Gear box 120 kg 265 lbs 21 Install lifting bolts M16 to housing SUBASSY Remove bolts 6 SV414 06015 3 Lifting bolt 45 SV414 06016 45 SV414 06017 6 Lifting bolt ...

Page 144: ...ASSY Housing SUBASSY 100 kg 220 lbs 23 Put housing SUBASSY on wooden blocks 24 The right illustration shows axle shaft SUBASSY removed from vibratory drum SV414 06018 Housing SUBASSY SV414 06019 Housing SUBASSY Wooden block SV414 06096 Axle shaft SUBASSY ...

Page 145: ...ts 30 Remove cover 32 Remove shim 36 27 Put a piece of wooden board on the end of axle shaft 41 and set a puller on housing 37 Separate housing SUBASSY together with roller bearing from axle shaft SUBASSY SV414 06055 34 27 SV414 06056 30 32 36 SV414 06057 41 37 Puller Wooden board ...

Page 146: ... housing SUBASSY 29 Remove housing SUBASSY Housing SUBASSY 45 kg 99 lbs 30 The right illustration shown housing SUBASSY removed from vibratory drum SV414 06059 Housing SUBASSY Axle shaft SUBASSY SV414 06058 Lifting bolt Housing SUBASSY SV414 06097 Housing SUBASSY ...

Page 147: ...6 018 VIBRATORY DRUM REAR AXLE 31 Remove bolts 54 and seal washers 32 Remove vibrator bearing 7 using long bolts M8 SV414 06020 54 SV414 06095 7 Long bolt ...

Page 148: ... posture using a work stool or the like 1 Lift vibratory drum 1 with a crane and put it in an upright position 1 Drum SV414D 1 685 kg 3 715 lbs SV414T 1 660 kg 3 660 lbs SV414TF 2 955 kg 6 515 lbs 2 Apply a coat of gear oil to vibrator bearing 7 mounting surface of housing 44 Drive vibrator bearing into housing NOTICE Take care not to damage the bearing when installing it 3 Apply grease to O ring ...

Page 149: ...UBASSY WARNING When installing lifting bolts screw in the threads fully before using 5 Install lifting bolts M16 to housing SUBASSY Lift housing SUBASSY Housing SUBASSY 100 kg 220 lbs 6 Lower housing SUBASSY on mounting surface of drum 1 NOTICE Take care not to let O ring to protrude from its groove SV414 06024 5 Housing SUBASSY 54 SV414 06025 Lifting bolt Housing SUBASSY SV414 06026 1 Housing SUB...

Page 150: ... 265 N m 195 lbf ft 8 Reassembly of gear box SUBASSY Secure ring 4 to gear box 45 with ten bolts 2 and washers N m 2 Bolts M22 70 686 N m 506 lbf ft 9 Install lifting bolts M16 to gear box 45 Lift gear box 45 Gear box 120 kg 265 lbs SV414 06091 2 4 45 SV414 06027 6 Housing SUBASSY SV414 06028 Lifting bolt 45 ...

Page 151: ...44 11 Secure gear box 45 with eighteen bolts 3 and washers N m 3 Bolts M16 50 265 N m 195 lbf ft WARNING When installing lifting bolts secure them with nuts 12 Install lifting bolts and nuts M20 to holders 52 and 59 SV414 06030 3 45 SV414 06031 59 52 Lifting bolt nut SV414 06029 45 44 ...

Page 152: ...54 lbs NOTICE Disc SUBASSY and propulsion motor mounting holes must be arranged as shown on the right 14 Secure disc SUBASSY with seventeen bolts 53 and washers N m 53 Bolts M16 45 265 N m 195 lbf ft SV414 06032 Disc SUBASSY 45 SV414 06033 Disc SUBASSY Propulsion motor mounting hole SV414 06034 53 Disc SUBASSY ...

Page 153: ...ropulsion motor 55 with two bolts 56 and washers N m 56 Bolts M16 40 265 N m 195 lbf ft WARNING Be careful because reversing the vibratory drum involves risk Confirm that the surrounding area is safe and work in a natural unstrained posture 17 Reverse drum SUBASSY Drum SUBASSY SV414D 2 055 kg 4 530 lbs SV414T 2 045 kg 4 508 lbs SV414TF 3 325 kg 7 330 lbs SV414 06088 56 55 SV510 06056 1 Wooden bloc...

Page 154: ...ING Take care not to get your fingers caught in movable weights 20 Apply a coat of gear oil to bearing mounting surface of eccentric shaft SUBASSY Install eccentric shaft SUBASSY to drum SUBASSY Eccentric shaft SUBASSY 135 kg 298 lbs NOTICE Put the movable weight at its outmost position SV414 06036 8 9 10 SV414 06037 Lifting bolt Eccentric shaft SUBASSY SV414 06038 Movable weight Eccentric shaft S...

Page 155: ...unting surface of axle shaft 41 Drive vibrator bearing into axle shaft NOTICE Take care not to damage the bearing when installing it 21 2 Reverse axle shaft SUBASSY Axle shaft SUBASSY 90 kg 198 lbs Apply a coat of gear oil to roller bearing 38 inner race mounting surface of axle shaft 41 Drive roller bearing inner race into axle shaft SV414 06060 42 41 Wooden block SV414 06061 38 Axle shaft SUBASS...

Page 156: ... race 21 4 Apply a coat of gear oil to roller bearings 38 outer race mounting surface of housing 37 Drive roller bearing outer races into housing Apply liquid packing to periphery of oil seal 39 Drive oil seal into housing Apply grease to lip of oil seal 21 5 Install lifting bolts M12 to housing SUBASSY SV414 06062 14 38 41 SV414 06063 38 38 37 39 SV414 06064 Lifting bolt Housing SUBASSY ...

Page 157: ...ft Apply sufficient amount of lithium based grease to rollers of roller bearing inner race Drive in roller bearing inner race until rollers come in contact with outer race 21 8 Preload adjustment of roller bearing Install a shim of about 1 mm 0 04 in Secure cover 32 to axle shaft 41 with four bolts 30 and washers SV414 06066 38 SV414 06067 30 32 41 Shim SV414 06065 Housing SUBASSY Axle shaft SUBAS...

Page 158: ...Tighten the bolts alternately in diagonal directions NOTICE Push in the inner race while rotating the bearing Otherwise even strongly trying to push the inner race the bearing rollers will not be pushed up and therefore bearing will not be seated Remove bolts 30 Remove cover 32 Remove shim NOTICE Do not turn the housing 37 after the cover is removed SV414 06068 30 37 41 32 Shim Gap PLA 06001 End o...

Page 159: ...m install cover 32 to axle shaft 41 with four bolts 30 and washers Using a thickness gauge measure clearance A Preload adjusting shim thickness A 0 1 mm 0 004 in Remove bolts 30 Remove cover 32 SV414 06071 A No gap SV414 06092 30 32 SV414 06070 30 32 41 ...

Page 160: ...ht bolts 30 and washers N m 30 Bolts M14 40 167 N m 123 lbf ft 21 9 Apply liquid packing to periphery of oil seal 33 Drive oil seal into cover 27 Apply grease to lip of oil seal 21 10 Secure cover 27 to housing 37 with six bolts 34 and washers N m 34 Bolts M12 40 108 N m 80 lbf ft SV414 06073 27 33 SV414 06074 34 27 37 SV414 06093 30 32 36 41 ...

Page 161: ...shown on the right 22 Install lifting bolts M16 to axle shaft SUBASSY 23 Lift axle shaft SUBASSY Axle shaft SUBASSY 150 kg 331 lbs Apply grease to O ring 40 Install O ring to axle shaft 41 SV414 06076 40 Axle shaft SUBASSY SV414 06040 Hole 1 37 Breather mounting hole 27 Hole 3 Cover mounting hole Hole 2 Cover mounting hole SV414 06075 Lifting bolt Axle shaft SUBASSY ...

Page 162: ...he vibrator bearing inner race during installation Take care not to let O ring to protrude from its groove 25 Secure axle shaft SUBASSY with sixteen bolts 13 and washers N m 13 Bolts M16 50 265 N m 195 lbf ft 26 Install a lifting bolt M10 on shaft end of eccentric shaft SUBASSY SV414 06041 Axle shaft SUBASSY Pipe SV414 06077 13 Axle shaft SUBASSY SV414 06078 Lifting bolt ...

Page 163: ...and check that there is an axial play of 1 to 3 mm 0 04 to 0 12 in 28 Install lifting bolts and nuts M20 to holders 21 and 35 29 Lower disc SUBASSY on mounting surface of housing 37 Disc SUBASSY 135 kg 298 lbs SV414 06043 Disc SUBASSY 37 SV414 06079 SV414 06042 21 35 Lifting bolt nut ...

Page 164: ...lling the disc SUBASSY the breather mounting hole in cover 27 must be perpendicular to the longer edge of the disc 15 31 Drive two spring pins 12 into sleeve 11 32 Apply grease to splined portion of sleeve 11 Fit sleeve to splined portion on eccentric shaft SUBASSY end SV414 06044 Breather mounting hole 15 27 25 SV414 06080 11 12 SV414 06045 11 ...

Page 165: ...6 Install breather to cover 27 NOTICE The vibrator motor which have ports A and B must face the same direction as the side of the breather 26 Take care not to let O ring to protrude from its groove 35 Lay vibratory drum ASSY with plugs 14 1 14 2 and 14 3 positioned as shown on the right Hold with chocks Vibratory drum ASSY SV414D 2 500 kg 5 512 lbs SV414T 2 470 kg 5 445 lbs SV414TF 3 765 kg 8 300 ...

Page 166: ...REAR AXLE 36 Remove plugs 14 1 and 14 3 Supply gear oil from oil supply port Check that oil drips from gauge port Quantity of gear oil 21 L 5 5 gal Reinstall plugs 14 1 and 14 3 SV414 06049 14 1 14 3 Supply port Gauge port ...

Page 167: ... gauge and drain 11 Parking brake release port RBR M14 P 1 5 12 Parking brake release port RBL M14 P 1 5 13 Plug differential filler and level gauge 14 Plug differential drain 15 Bolt M20 220 16 Nut M20 N m 3 Nut M22 P 1 5 785 N m 579 lbf ft 16 Nut M20 540 N m 398 lbf ft Specifications Tire size 14 9 24 8PR Tire inflation pressure 177 kPa 26 psi Tire ASSY weight D type 110 kg 243 lbs T TF type 112...

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Page 169: ... 3 1 2 1 2 1 2 Center housing differential brake Hub reduction gear Drain Supply Drain 1 Filler port 2 Level port 3 Drain gauge Change oil Gear oil API grade GL4 SAE90 See recommended lubrication Change oil quantity Center housing 7 3 L 1 9 gal Hub reduction gear 1 3 L 2 0 33 gal 2 ...

Page 170: ... VIBRATORY DRUM REAR AXLE 4 3 Rear Axle Structure 4 3 1 Center housing SV201 1K 06002 10 1 1 1 2 7 9 8 5 6 4 3 1 O ring 5 Housing 9 Magnet plug 2 Bolt 6 Plug 10 Cover 3 Seal washer 7 Plug 4 Vent 8 Snap ring ...

Page 171: ...3 2 Differential SV400 2 06053 7 10 13 12 11 10 8 4 3 5 6 9 2 1 3 2 1 1 Bolt 6 No spin differential 11 Spacer 2 Ring nut 7 Bolt 12 Shim 3 Taper roller bearing 8 Bevel gear set 13 Shim 4 Bolt 9 Ring nut 5 Differential carrier 10 Bearing ...

Page 172: ...3 24 26 1 Half shaft 10 Stud 19 Wheel nit 2 Spring washer 11 Plug 20 Stud 3 Bolt 12 Magnet plug 21 Nut 4 Seal 13 Nut 22 Circlip 5 Seal 14 Axle case 23 Planet gear 6 Bearing 15 Circlip 24 Bearing 7 Wheel stad 16 Ring gear 25 Friction washer 8 Wheel hub 17 Ring gear support 26 Planet gear carrier 9 O ring 18 Locking plate 27 Countersunk bolt ...

Page 173: ... VIBRATORY DRUM REAR AXLE 4 3 4 Brake SV201 1K 06003 1 2 8 3 4 2 5 6 7 10 11 12 13 9 1 Spring 6 Dowel 11 Nut 2 O ring 7 Brake disc 12 Bolt 3 Piston 8 Plug 13 Plug 4 O ring 9 Seal washer 5 Ring 10 Lock washer ...

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Page 175: ...BRAKE ...

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Page 177: ...7 001 BRAKE 1 BRAKE PEDAL 0418 62813 0 12540 B 1 3 4 5 2 A SECTION B B DETAIL A 7 6 B B 1 Brake pedal 5 Stopper bolt M10 50 2 Foot brake switch 6 Stopper bolt M10 50 3 Spring 7 Nut M10 4 Nut M10 ...

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Page 179: ... symbols show the hose connection and the direction of the flow of the oil VIEW A TVB TBR RBL Parking brake solenoid valve Speed change solenoid valve F Servo bypass solenoid valve SBA Hose SGA SGB BTS DETAL D SGA SBP SBA SGB VBA TVB Hose VBA TVB TBR RBR SECTION C C C C Rear axle ASSY BPF VBA SECTION B B BPF SPB BST Hose BST BTS D B B Hose P 4 004 2 BRAKE HYDRAULIC PIPING 7 002 BRAKE ...

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Page 181: ... solenoid valve 7 and close the brake indicator lamp circuit This stops feeding the fluid from parking brake solenoid valve 7 to brake 8 Springs b move pistons a toward the brake discs and plates so that they make a close contact with each other The brake is applied The indicator lamp comes on simultaneously When brake pedal is pushed down on If brake pedal is depressed foot brake switch 2 is swit...

Page 182: ...am 7 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 flow 30 L min 7 9 gal min Rated pressure 4 9 MPa 710 psi 6 7 0 5 MPa 72 5 psi 8 Weight 1 5 kg 3 3 lbs ...

Page 183: ...uit 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 flow 30 L min 7 9 gal min Rated pressure 4 9 MPa 710 psi 7 8 0 5 MPa 72 5 psi 6 Weight 1 5 kg 3 3 lbs ...

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Page 185: ...INSPECTION AND ADJUSTMENT ...

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Page 187: ...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 188: ...m that F R lever is N Set propulsion speed select switch to Start the engine and set throttle switch 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 Read pressure indicated by pressure gauge After measuring promptly return F R ...

Page 189: ... change rate 9 MPa turn 1 305 psi turn If there is no evidence of nut having loosened remove multifunction valve Check removed multifunction valve for trapped dirt and scratches on its seat If trapped dirt is present disassemble and clean multifunction valve If a scratch is found on seat replace multifunction valve After adjustment measure pressure again and check that pressure reaches maximum cir...

Page 190: ...owing 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 ...

Page 191: ...e gauge 0 to 5 MPa 0 to 725 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Start the engine and set throttle switch to Full Read pressure indicated by pressure gauge Standard charge relief valve setting 2 5 0 2 MPa 363 29 psi The number 1 2 appearing in above illustrations is consistent with lead line numbers shown in illustration of pump ASSY in 2 2 Hy...

Page 192: ...ressure drop Pressure change rate 0 39 MPa turn 57 psi turn If there is no evidence of nut having loosened remove charge relief valve Check removed charge relief valve for trapped dirt and scratches on its seat If trapped dirt is present disassemble and clean charge relief valve If a scratch is found on seat replace charge relief valve After adjustment measure pressure again and check that pressur...

Page 193: ...e gauge 0 to 5 MPa 0 to 725 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Start the engine and set throttle switch 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 pressur...

Page 194: ... Adapter ⓗ 9 16 18UNF Servo pressure gauge port High 1 Servo pressure gauge port Low 7 Pressure gauge 0 to 5 MPa 0 to 725 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Set speed select switch to 1 2 or 3 Start the engine and set throttle switch to Full Read pressure indicated by pressure gauge Standard charge relief valve setting 1 6 0 2 MPa 232 29 psi...

Page 195: ...i Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Set speed select switch to 1 2 or 3 Start the engine and set throttle switch to Full Read pressure indicated by pressure gauge Standard charge relief valve setting 2 67 0 2 MPa 387 29 psi The numbers 4 and 6 appearing in above illustrations are consistent with lead line numbers shown in illustration of propul...

Page 196: ...enoid valve Attach pressure gauge through adapter ⓜ Adapter ⓜ G1 4 Pressure gauge 0 to 5 MPa 0 to 725 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Start the engine and set throttle switch to Full Release parking brake by pressing parking brake switch button Read brake release pressure indicated by pressure gauge Brake release pressure 1 5 to 3 0 MPa 2...

Page 197: ... 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 Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Set vibration mode change switch to Start the engine and set throttle switch to Full Press F R lever vibration switch ON Read pre...

Page 198: ...irt is present disassemble and clean high pressure relief valve If pressure still deviates from maximum circuit pressure range after valve is disassembled and cleaned replace high pressure relief valve After inspection measure pressure again and check that pressure reaches maximum circuit pressure range N m 3 Plug 40 N m 30 lbf ft NOTICE Carefully disassemble and reassemble after taking steps to p...

Page 199: ...use following operation to ensure that oil does not escape to the charge relief valve on propulsion pump side Loosen nut 3 from charge relief valve 1 10 on propulsion pump side Tighten adjustment screw 4 by two complete turns Adjustment screw turned clockwise Pressure rise Adjustment screw turned counterclockwise Pressure drop Pressure change rate 0 39 MPa turn 57 psi turn The number 1 10 appearin...

Page 200: ...e gauge 0 to 5 MPa 0 to 725 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Start the engine and set throttle switch to Full Read pressure indicated by pressure gauge Standard charge relief valve setting 2 5 0 2 MPa 363 29 psi The number 1 2 appearing in above illustrations is consistent with lead line numbers shown in illustration of pump ASSY in 2 2 Hy...

Page 201: ...re drop Pressure change rate 0 54 MPa 1 2 turn 78 3 psi 1 2 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 pr...

Page 202: ...brake by pressing parking brake switch button Start the engine and set throttle switch 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 different Standard charge relief valve setting 2 5 0 2 MPa 363 29 psi The nu...

Page 203: ... 1 or 2 from steering cylinder Attach pressure gauge through adapter ⓝ Adapter ⓝ G3 8 Pressure gauge 0 to 25 MPa 0 to 3 625 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Start the engine and set throttle switch to Full Turn steering wheel to operate relief valve Read pressure indicated by pressure gauge Standard maximum circuit pressure orbitroll relie...

Page 204: ... 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 prevent...

Page 205: ...hat F R lever is N Apply parking brake by pressing parking brake switch button Set propulsion speed select switch to 1 Start the engine and set throttle switch 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 speed select switch is 1 2 and 3 and F R lever...

Page 206: ... parking brake by pressing parking brake switch button Set propulsion speed select switch to 1 Start the engine and set throttle switch 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 speed select switch is 1 2 and 3 and travel mode change switch is and ...

Page 207: ...tch button Set propulsion speed select switch to 1 Start the engine and set throttle switch 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 speed select switch is 1 2 and 3 and travel mode change switch is and F R lever is N F and R respectively Allowabl...

Page 208: ... 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 switch to Full Press F R lever vibration switch ON Measure pressure when vibration select switch is and respectively Turn F R lever vibration switch OFF as soon...

Page 209: ...smoothly make an adjustment 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 210 mm 8 27 in Confirm the strokes of propulsion pump control lever 3 Specified dimension b 212 mm 8 35 in c 25 mm 0 98 in SV414 08013 2 3 F R b c c SV414 08012 a 1 2 ...

Page 210: ...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 211: ... 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 34 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...

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Page 213: ...TROUBLESHOOTING ...

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Page 215: ...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 216: ...r full details of the trouble ask questions 3 Verify the trouble by warming up the machine and operating it Check the problem yourself 4 Identify the problem with either a mechanical hydraulic or 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 Foll...

Page 217: ...nal 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 diagnosing a circuit measuring the voltage resistance continuity and current move related wiring and connectors several times...

Page 218: ...equipment A measuring resistance between terminals 1 and 3 1 2 3 3 4 2 5 1 2 3 1 2 3 1 TS 10002 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 the tes...

Page 219: ...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 TS 10004 Connector A Harness Ohmmeter tester Main power source of equipment B Equipment B Battery Equipment B Inspection procedure Disconnect the connector of equipment B Connect the test probe to connector terminal 5 of ...

Page 220: ...A Power to equipment A Equipment B Equipment B Equipment A TS 10005 Inspection procedure Connect the connectors of equipment A and that of equipment B Connect the test probe to connector terminal 3 of equipment A and the test probe to connector terminal 1 of equipment A and measure the voltage Note that reversing the connector terminals between the probes and changes the result of the measurement ...

Page 221: ...onnected 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 a...

Page 222: ...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 so...

Page 223: ...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 224: ...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 225: ...ion Sensor 1 Circuit Voltage above normal or shorted to high source Remote accelerator will not operate 134 974 4 Remote Accelerator Pedal or Lever Position Sensor 1 Circuit Voltage below normal or shorted to low source Remote accelerator will not operate 143 100 18 Engine Oil Rifle Pressure Data Valid But Below Normal Operating Range Moderately Severe Level Possible reduced engine performance 144...

Page 226: ...g in severity from time of alert If the Engine Protection Shutdown feature is enabled the engine will shut down 30 seconds after the red STOP lamps starts flashing 187 3510 4 Sensor Supply 2 Circuit Voltage below normal or shorted to low source Possible reduced engine performance 195 111 3 Coolant Level Sensor 1 Circuit Voltage above normal or shorted to high source None on performance 196 111 4 C...

Page 227: ...ource Engine may run rough may stop running may not start or may be difficult to start 285 639 9 SAE J1939 Multiplexing PGN Timeout Error Abnormal update rate At least one multiplexed device will not operate properly 286 639 13 SAE J1939 Multiplexing Configuration Error Out of Calibration At least one multiplexed device will not operate properly 287 91 19 SAE J1939 Multiplexing Configuration Error...

Page 228: ...or Sensor Circuit Voltage below normal or shorted to low source Possible reduced engine performance 431 558 2 Accelerator Pedal or Lever Idle Validation Switch Data erratic intermittent or incorrect Engine will only idle 432 558 13 Accelerator Pedal or Lever Idle Validation Switch Circuit Out of Calibration Engine will be shut down 435 100 2 Engine Oil Rifle Pressure Data erratic intermittent or i...

Page 229: ...he engine will not start or the engine will not have starter lockout protection 585 677 4 Starter Relay Driver Circuit Voltage below normal or shorted to low source Either the engine will not start or the engine will not have starter lockout protection 599 640 14 Auxiliary Commanded Dual Output Shutdown Special Instructions Engine will be shut down 649 1378 31 Engine Oil Change Interval Condition ...

Page 230: ...ource The engine will operate in Limp Home mode 1242 91 2 Accelerator Pedal or Lever Position Sensor 1 Data erratic intermittent or incorrect Engine will only idle 1515 91 19 SAE J1939 Multiplexed Accelerator Pedal or Lever Sensor System Received Network Data In Error Engine will only idle 1539 1387 3 Auxiliary Pressure Sensor Input 1 Circuit Voltage above normal or shorted to high source None on ...

Page 231: ...t None on performance 2349 2791 5 EGR Valve Control Circuit Current Below Normal or Open Circuit Possible reduced engine performance 2351 2791 4 EGR Valve Control Circuit Voltage below normal or shorted to low source Possible reduced engine performance 2352 2791 3 EGR Valve Control Circuit Voltage above normal or shorted to high source Possible reduced engine performance 2353 2791 6 EGR Valve Cont...

Page 232: ...mance 2572 263 4 Engine Charge Air Cooler Outlet Temperature Voltage Below Normal or Shorted to Low Source None on performance 2963 110 15 Engine Coolant Temperature Data Valid But Above Normal Operating Range Least Severe Level Progressive power and or speed derate increasing in severity from time of alert If the Engine Protection Shutdown feature is enabled the engine will shut down 30 seconds a...

Page 233: ...nical system not responding or out of adjustment Possible reduced engine performance 3741 5571 0 High Pressure Common Rail Fuel Pressure Relief Valve Data valid but above normal operational range Most Severe Level Engine may run rough may stop running may not start or may be difficult to start 3765 442 3 Auxiliary Temperature Sensor Input 2 Circuit Voltage Above Normal or Shorted to High Source No...

Page 234: ...alve Driver Circuit Voltage Above Normal or Shorted to High Source None on performance 6232 741 4 Transmission 1 Forward Solenoid Valve Driver Circuit Voltage Below Normal or Shorted to Low Source None on performance 6233 4216 3 Transmission 1 Reverse Solenoid Valve Driver Circuit Voltage Above Normal or Shorted to High Source None on performance 6234 4216 4 Transmission 1 Reverse Solenoid Valve D...

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Page 236: ...HEATER ECM RETURN GENERAL STARTER LOCKOUT ECM RETURN SWITCHES ISC 1 SW FULL ISC 2 SW MID 15 KEY SW SIGNAL R B 13 W 4 24 5BY BR 15 5RB AV100 68 67 B X 25 BrY 2BW 26 2Lg 26 2Lg 2 R 12 67 BrY LgR 36 38 GR B X 5 3 4 1 LgR 36 NC NO COM STOP 24 BR 24 BR BR 5R 5RB 2B 2RW 14 18 15 X 3 8R 76 8WR 4 5BY 77 5BW W 13 X 2LgR 68 2LgR B RC 185MIN CCA 1000A B AV60 AV60 COM NO E F L 65A F L 75A BR C B ACC STARTER S...

Page 237: ...e Switch is OK if there 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 B and chassis ground Standard voltage 12 V or more 2 When starter switch is START measure voltage between starter motor terminal S and chassis ground Standard voltage 12 V or...

Page 238: ...HEATER ECM RETURN GENERAL STARTER LOCKOUT ECM RETURN SWITCHES ISC 1 SW FULL ISC 2 SW MID 15 KEY SW SIGNAL R B 13 W 4 24 5BY BR 15 5RB AV100 68 67 B X 25 BrY 2BW 26 2Lg 26 2Lg 2 R 12 67 BrY LgR 36 38 GR B X 5 3 4 1 LgR 36 NC NO COM STOP 24 BR 24 BR BR 5R 5RB 2B 2RW 14 18 15 X 3 8R 76 8WR 4 5BY 77 5BW W 13 X 2LgR 68 2LgR B RC 185MIN CCA 1000A B AV60 AV60 COM NO E F L 65A F L 75A BR C B ACC STARTER S...

Page 239: ...ure 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 Interlock Relay A1 1 When starter switch is ON measure voltage between interlock relay terminal 3 inlet wire Lg and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measur...

Page 240: ...HEATER ECM RETURN GENERAL STARTER LOCKOUT ECM RETURN SWITCHES ISC 1 SW FULL ISC 2 SW MID 15 KEY SW SIGNAL R B 13 W 4 24 5BY BR 15 5RB AV100 68 67 B X 25 BrY 2BW 26 2Lg 26 2Lg 2 R 12 67 BrY LgR 36 38 GR B X 5 3 4 1 LgR 36 NC NO COM STOP 24 BR 24 BR BR 5R 5RB 2B 2RW 14 18 15 X 3 8R 76 8WR 4 5BY 77 5BW W 13 X 2LgR 68 2LgR B RC 185MIN CCA 1000A B AV60 AV60 COM NO E F L 65A F L 75A BR C B ACC STARTER S...

Page 241: ...ire BrY and chassis ground Standard voltage 12 V or more 3 When starter switch is ON measure voltage between parking interlock relay terminal 5 outlet wire BW and chassis ground Standard voltage 12 V or more If above items 1 and 2 are OK and item 3 is NG parking interlock relay is faulty Replace parking interlock relay A2 11 Starter Lockout Relay Relay A5 1 When starter switch is ON measure voltag...

Page 242: ...HEATER ECM RETURN GENERAL STARTER LOCKOUT ECM RETURN SWITCHES ISC 1 SW FULL ISC 2 SW MID 15 KEY SW SIGNAL R B 13 W 4 24 5BY BR 15 5RB AV100 68 67 B X 25 BrY 2BW 26 2Lg 26 2Lg 2 R 12 67 BrY LgR 36 38 GR B X 5 3 4 1 LgR 36 NC NO COM STOP 24 BR 24 BR BR 5R 5RB 2B 2RW 14 18 15 X 3 8R 76 8WR 4 5BY 77 5BW W 13 X 2LgR 68 2LgR B RC 185MIN CCA 1000A B AV60 AV60 COM NO E F L 65A F L 75A BR C B ACC STARTER S...

Page 243: ...l grid heater is faulty Replace grid heater 2 Grid Heater Relay 1 When starter switch is ON measure voltage between grid heater relay terminal 3 inlet wire and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between grid heater relay terminal 1 inlet wire and chassis ground Standard voltage 12 V or more 3 When starter switch is ON measure voltage between gr...

Page 244: ...HEATER ECM RETURN GENERAL STARTER LOCKOUT ECM RETURN SWITCHES ISC 1 SW FULL ISC 2 SW MID 15 KEY SW SIGNAL R B 13 W 4 24 5BY BR 15 5RB AV100 68 67 B X 25 BrY 2BW 26 2Lg 26 2Lg 2 R 12 67 BrY LgR 36 38 GR B X 5 3 4 1 LgR 36 NC NO COM STOP 24 BR 24 BR BR 5R 5RB 2B 2RW 14 18 15 X 3 8R 76 8WR 4 5BY 77 5BW W 13 X 2LgR 68 2LgR B RC 185MIN CCA 1000A B AV60 AV60 COM NO E F L 65A F L 75A BR C B ACC STARTER S...

Page 245: ...d 6 There is continuity in normal condition 3 When throttle switch is FULL check continuity between throttle switch terminals 1 and 3 4 and 5 There is continuity in normal condition If above item 1 2 or 3 is NG throttle switch is faulty Replace throttle switch 2 Throttle Relay A6 1 When starter switch is ON and throttle switch is FULL measure voltage between throttle relay terminal 1 inlet wire RW...

Page 246: ... 2 1 50 LR 54 53 LW 50 LW WR SOL B X SOL 5 2 1 4 6 3 39 L 51 BrR G X B BrW 37 D I H F E C A B G I D C B E A H G F R B W 4 24 5BY BR 65 13 2 R 12 LgR 36 38 GR B X 5 3 4 1 SOL LgR 36 NC NO COM STOP 24 BR 24 BR BR 3 8R 76 8WR 4 5BY 77 5BW RC 185MIN CCA 1000A B AV60 AV60 COM NO E F L 65A F L 75A BR C B ACC STARTER SWITCH NC NO COM 12 13 R W L BATTERY BATTERY RELAY FUSE BOX DIODE UNIT SPEED CHANGE SOLE...

Page 247: ...age between pump neutral relay terminal 1 inlet wire BrW and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between pump neutral relay terminal 3 inlet wire GW and chassis ground Standard voltage 12 V or more 3 When starter switch is ON measure voltage between pump neutral relay terminal 5 outlet wire LY and chassis ground Standard voltage 12 V or more If ...

Page 248: ... 2 1 50 LR 54 53 LW 50 LW WR SOL B X SOL 5 2 1 4 6 3 39 L 51 BrR G X B BrW 37 D I H F E C A B G I D C B E A H G F R B W 4 24 5BY BR 65 13 2 R 12 LgR 36 38 GR B X 5 3 4 1 SOL LgR 36 NC NO COM STOP 24 BR 24 BR BR 3 8R 76 8WR 4 5BY 77 5BW RC 185MIN CCA 1000A B AV60 AV60 COM NO E F L 65A F L 75A BR C B ACC STARTER SWITCH NC NO COM 12 13 R W L BATTERY BATTERY RELAY FUSE BOX DIODE UNIT SPEED CHANGE SOLE...

Page 249: ...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 ground Standard voltage 12 V ...

Page 250: ... 2 1 50 LR 54 53 LW 50 LW WR SOL B X SOL 5 2 1 4 6 3 39 L 51 BrR G X B BrW 37 D I H F E C A B G I D C B E A H G F R B W 4 24 5BY BR 65 13 2 R 12 LgR 36 38 GR B X 5 3 4 1 SOL LgR 36 NC NO COM STOP 24 BR 24 BR BR 3 8R 76 8WR 4 5BY 77 5BW RC 185MIN CCA 1000A B AV60 AV60 COM NO E F L 65A F L 75A BR C B ACC STARTER SWITCH NC NO COM 12 13 R W L BATTERY BATTERY RELAY FUSE BOX DIODE UNIT SPEED CHANGE SOLE...

Page 251: ...d Select Switch 1 When starter switch is ON measure voltage between speed select switch terminal 1 4 inlet wire L and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between speed select switch terminal 3 outlet wire G and chassis ground Standard voltage 12 V or more 3 When starter switch is ON measure voltage between speed select switch terminal 5 outlet w...

Page 252: ... 2 1 50 LR 54 53 LW 50 LW WR SOL B X SOL 5 2 1 4 6 3 39 L 51 BrR G X B BrW 37 D I H F E C A B G I D C B E A H G F R B W 4 24 5BY BR 65 13 2 R 12 LgR 36 38 GR B X 5 3 4 1 SOL LgR 36 NC NO COM STOP 24 BR 24 BR BR 3 8R 76 8WR 4 5BY 77 5BW RC 185MIN CCA 1000A B AV60 AV60 COM NO E F L 65A F L 75A BR C B ACC STARTER SWITCH NC NO COM 12 13 R W L BATTERY BATTERY RELAY FUSE BOX DIODE UNIT SPEED CHANGE SOLE...

Page 253: ...ct switch is measure voltage between speed select switch terminal wires and chassis ground Speed select switch terminal 2 and chasiss ground Speed select switch terminal 6 outlet wire BrR and chasiss ground Standard voltage 12 V or more 3 When starter switch is ON and speed select switch is TRAVEL MODE measure voltage between speed select switch terminal wires and chassis ground Speed select switc...

Page 254: ... 2 1 50 LR 54 53 LW 50 LW WR SOL B X SOL 5 2 1 4 6 3 39 L 51 BrR G X B BrW 37 D I H F E C A B G I D C B E A H G F R B W 4 24 5BY BR 65 13 2 R 12 LgR 36 38 GR B X 5 3 4 1 SOL LgR 36 NC NO COM STOP 24 BR 24 BR BR 3 8R 76 8WR 4 5BY 77 5BW RC 185MIN CCA 1000A B AV60 AV60 COM NO E F L 65A F L 75A BR C B ACC STARTER SWITCH NC NO COM 12 13 R W L BATTERY BATTERY RELAY FUSE BOX DIODE UNIT SPEED CHANGE SOLE...

Page 255: ...nd item 3 is NG travel mode relay is faulty Replace travel mode relay A7 5 Travel Mode Change Switch 1 When starter switch is ON measure voltage between travel mode change switch terminal 1 inlet wire LR and chasiss ground Standard voltage 12 V or more 2 When starter switch is ON and travel mode change switch is measure voltage between travel mode change switch terminal 3 inlet wire LW and chassis...

Page 256: ... 2 1 50 LR 54 53 LW 50 LW WR SOL B X SOL 5 2 1 4 6 3 39 L 51 BrR G X B BrW 37 D I H F E C A B G I D C B E A H G F R B W 4 24 5BY BR 65 13 2 R 12 LgR 36 38 GR B X 5 3 4 1 SOL LgR 36 NC NO COM STOP 24 BR 24 BR BR 3 8R 76 8WR 4 5BY 77 5BW RC 185MIN CCA 1000A B AV60 AV60 COM NO E F L 65A F L 75A BR C B ACC STARTER SWITCH NC NO COM 12 13 R W L BATTERY BATTERY RELAY FUSE BOX DIODE UNIT SPEED CHANGE SOLE...

Page 257: ... is NG pump neutral relay is faulty Replace pump neutral relay A3 3 Pump Neutral Holding Relay A4 1 When starter switch is ON measure voltage between pump neutral holding relay terminal 1 inlet wire LY and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between pump neutral holding relay terminal 3 inlet wire R and chassis ground Standard voltage 12 V or mo...

Page 258: ... 2 1 50 LR 54 53 LW 50 LW WR SOL B X SOL 5 2 1 4 6 3 39 L 51 BrR G X B BrW 37 D I H F E C A B G I D C B E A H G F R B W 4 24 5BY BR 65 13 2 R 12 LgR 36 38 GR B X 5 3 4 1 SOL LgR 36 NC NO COM STOP 24 BR 24 BR BR 3 8R 76 8WR 4 5BY 77 5BW RC 185MIN CCA 1000A B AV60 AV60 COM NO E F L 65A F L 75A BR C B ACC STARTER SWITCH NC NO COM 12 13 R W L BATTERY BATTERY RELAY FUSE BOX DIODE UNIT SPEED CHANGE SOLE...

Page 259: ... and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between parking brake switch terminal 3 outlet wire BrW and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG parking brake switch is faulty Replace parking brake switch 6 Harness Connecting Between Terminals Measure resistance of harness connecting between terminals Stan...

Page 260: ... 2 1 50 LR 54 53 LW 50 LW WR SOL B X SOL 5 2 1 4 6 3 39 L 51 BrR G X B BrW 37 D I H F E C A B G I D C B E A H G F R B W 4 24 5BY BR 65 13 2 R 12 LgR 36 38 GR B X 5 3 4 1 SOL LgR 36 NC NO COM STOP 24 BR 24 BR BR 3 8R 76 8WR 4 5BY 77 5BW RC 185MIN CCA 1000A B AV60 AV60 COM NO E F L 65A F L 75A BR C B ACC STARTER SWITCH NC NO COM 12 13 R W L BATTERY BATTERY RELAY FUSE BOX DIODE UNIT SPEED CHANGE SOLE...

Page 261: ...en starter switch is ON measure voltage between pump neutral relay terminal 1 inlet wire BrW and chassis ground There is no electricity in normal condition 2 When starter switch is ON measure voltage between pump neutral relay terminal 5 outlet wire LY and chassis ground There is no electricity in normal condition If above items 1 is OK and item 2 is NG pump neutral relay is faulty Replace pump ne...

Page 262: ...3 WG 3 6 4 24 5BY BR 24 BR 24 BR BR 3 8R 76 8WR 4 5BY 77 5BW X 81 11 RG Y 1 3 2 Br G 11 Y Y 11 10 YB 9 YR 1 2 SOL HIGH LOW B X B 4 1 2 5 a b RC 185MIN CCA 1000A B AV60 AV60 COM NO E F L 65A F L 75A BR C B ACC STARTER SWITCH 1 25RY 2 BATTERY BATTERY RELAY VIBRATION SELECT SWITCH VIBRATOR SOLENOID THROTTLE SWITCH TO THROTTLE RELAY A6 TO ENGINE ECM VIBRATION MODE CHANGE SWITCH F R LEVER VIBRATION SWI...

Page 263: ...nal 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 Throttle Switch 1 When starter switch is ON measure voltage between throttle switch terminal 4 inlet wire RY and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between throttle...

Page 264: ...3 WG 3 6 4 24 5BY BR 24 BR 24 BR BR 3 8R 76 8WR 4 5BY 77 5BW X 81 11 RG Y 1 3 2 Br G 11 Y Y 11 10 YB 9 YR 1 2 SOL HIGH LOW B X B 4 1 2 5 a b RC 185MIN CCA 1000A B AV60 AV60 COM NO E F L 65A F L 75A BR C B ACC STARTER SWITCH 1 25RY 2 BATTERY BATTERY RELAY VIBRATION SELECT SWITCH VIBRATOR SOLENOID THROTTLE SWITCH TO THROTTLE RELAY A6 TO ENGINE ECM VIBRATION MODE CHANGE SWITCH F R LEVER VIBRATION SWI...

Page 265: ...ndard 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 V or more If above ...

Page 266: ...3 WG 3 6 4 24 5BY BR 24 BR 24 BR BR 3 8R 76 8WR 4 5BY 77 5BW X 81 11 RG Y 1 3 2 Br G 11 Y Y 11 10 YB 9 YR 1 2 SOL HIGH LOW B X B 4 1 2 5 a b RC 185MIN CCA 1000A B AV60 AV60 COM NO E F L 65A F L 75A BR C B ACC STARTER SWITCH 1 25RY 2 BATTERY BATTERY RELAY VIBRATION SELECT SWITCH VIBRATOR SOLENOID THROTTLE SWITCH TO THROTTLE RELAY A6 TO ENGINE ECM VIBRATION MODE CHANGE SWITCH F R LEVER VIBRATION SWI...

Page 267: ...ndard 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 RW and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between vibration mode change sw...

Page 268: ... 12V Starter switch ACC Ground Turn signal R Engine stop Over heat REV ratio SEL 1 REV ratio SEL 3 Buzzer Lamp check CAN CAN 1 2 3 4 5 6 7 8 9 10 11 12 Head lamp Parking brake Charge warning HYD oil filter warning Engine warning Fuel meter REV ratio SEL 2 REV ratio SEL 4 DTC display Hour meter Turn signal L Preheating 13 14 15 16 17 18 19 20 21 22 23 24 Water splay Flood lamp Vibrator Liquid spray...

Page 269: ...re No 41 wire RG Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 2 Combination Meter Combination meter illumination 1 When starter switch is ON measure voltage between combination meter terminal wires and ground terminal wire Continuous power terminal wire No 70 inlet wire WR and ground terminal wire No X wire B Power terminal wire No 35 inlet...

Page 270: ... 12V Starter switch ACC Ground Turn signal R Engine stop Over heat REV ratio SEL 1 REV ratio SEL 3 Buzzer Lamp check CAN CAN 1 2 3 4 5 6 7 8 9 10 11 12 Head lamp Parking brake Charge warning HYD oil filter warning Engine warning Fuel meter REV ratio SEL 2 REV ratio SEL 4 DTC display Hour meter Turn signal L Preheating 13 14 15 16 17 18 19 20 21 22 23 24 Water splay Flood lamp Vibrator Liquid spray...

Page 271: ...inuity between lamp check relay terminal 3 inlet wire BY and chassis ground There is no continuity in normal condition If above items 1 and 2 are OK and item 3 is NG lamp check relay is faulty If above item 1 is OK and item 2 is NG alternator is faulty Repair or replace lamp check relay A9 or alternator 3 Combination Meter Lamp check 1 When starter switch is ON measure voltage between combination ...

Page 272: ... 12V Starter switch ACC Ground Turn signal R Engine stop Over heat REV ratio SEL 1 REV ratio SEL 3 Buzzer Lamp check CAN CAN 1 2 3 4 5 6 7 8 9 10 11 12 Head lamp Parking brake Charge warning HYD oil filter warning Engine warning Fuel meter REV ratio SEL 2 REV ratio SEL 4 DTC display Hour meter Turn signal L Preheating 13 14 15 16 17 18 19 20 21 22 23 24 Water splay Flood lamp Vibrator Liquid spray...

Page 273: ... Fuel meter is abnormal Reference Fig 2 6 1 Check point Check Cause Action 1 Fuel Gauge Unit Disconnect harness and measure resistance of fuel gauge unit Standard resistance 13 5 Ω with float in F 80 0 Ω with float in E If resistance is abnormal fuel gauge unit is faulty Replace fuel gauge unit 2 Combination Meter Fuel meter When starter switch is ON measure voltage between combination meter termi...

Page 274: ... 12V Starter switch ACC Ground Turn signal R Engine stop Over heat REV ratio SEL 1 REV ratio SEL 3 Buzzer Lamp check CAN CAN 1 2 3 4 5 6 7 8 9 10 11 12 Head lamp Parking brake Charge warning HYD oil filter warning Engine warning Fuel meter REV ratio SEL 2 REV ratio SEL 4 DTC display Hour meter Turn signal L Preheating 13 14 15 16 17 18 19 20 21 22 23 24 Water splay Flood lamp Vibrator Liquid spray...

Page 275: ...t wire Y and chassis ground There is no continuity in normal condition If there is continuity hydraulic oil filter switch 1 or 2 is faulty Replace hydraulic oil filter switch 1 or 2 3 Combination Meter Hydraulic oil filter warning 1 When starter switch is ON measure voltage between combination meter terminal wires and ground terminal wire Continuous power terminal wire No 70 inlet wire WR and grou...

Page 276: ... 5V LDO CPU MOTOR driver LCD driver Illumination LED Engine oil pressure indicator DEF SCR Quality Green DEF SCR Quality Red DEF Tampering Buzzer Water splay Liquid spray High beam Flood lamp Turn signal R Turn signal L Vibrator Inhibit the DPF Auto vegeneration Inhibit the SCR cleaning 7 Segments LCD Dot Matrix LCD TACHO FUEL TEMP BAT Battery 12V Ground Starter switch ACC Pull down Resistor 4 7KΩ...

Page 277: ...12 V or more 2 When starter switch is ON and vibration select switch is measure voltage between diode unit terminal E inlet wire YR and chassis ground Standard voltage 12 V or more 3 When starter switch is ON measure voltage between diode unit terminal F outlet wire Br and chassis 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...

Page 278: ... 5V LDO CPU MOTOR driver LCD driver Illumination LED Engine oil pressure indicator DEF SCR Quality Green DEF SCR Quality Red DEF Tampering Buzzer Water splay Liquid spray High beam Flood lamp Turn signal R Turn signal L Vibrator Inhibit the DPF Auto vegeneration Inhibit the SCR cleaning 7 Segments LCD Dot Matrix LCD TACHO FUEL TEMP BAT Battery 12V Ground Starter switch ACC Pull down Resistor 4 7KΩ...

Page 279: ...king brake switch is faulty Replace parking brake switch 3 Combination Meter Parking brake indicator lamp 1 When starter switch is ON measure voltage between combination meter terminal wires and ground terminal wire Continuous power terminal wire No 70 inlet wire WR and ground terminal wire No X wire B Power terminal wire No 35 inlet wire YW and ground terminal wire No X wire B Standard voltage 12...

Page 280: ...B W GB B 2 X 4 24 5BY BR 24 BR 24 BR BR 3 8R 76 8WR 4 5BY 77 5BW B X HORN LgW Lg 34 33 30 30 RY 1 25RY RC 185MIN CCA 1000A B AV60 AV60 COM NO E F L 65A F L 75A BR C B ACC STARTER SWITCH N C N O C O M 12 R 1 25RY BATTERY BATTERY RELAY FUSE BOX BACKUP BUZZER BACKUP BUZZER SWITCH HORN RELAY A8 HORN SWITCH 5A 5A 20A 15A 15A 15A 15A 15A 20A 20A 20A ...

Page 281: ...resistance of harness connecting between terminals Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 2 6 9 Backup buzzer does not sound Reference Fig 2 6 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 terminal to backup b...

Page 282: ...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 283: ... circuit with charge circuit Parking brake solenoid valve Speed change solenoid valve When solenoid is energized check if oil flows in return circuit to tank If oil is flowing repair solenoid 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 284: ...kage 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 285: ...case is not within allowable range repair propulsion pump or replace it if necessary 3 2 4 Machine speed cannot be switched Check point Cause Check Action 1 Charge Circuit Pressure Insufficient steering charge pump discharge Repair steering charge pump or replace it if necessary Charge pressure decreases due to internal leakage of solenoid valve connecting oil supply circuit with charge circuit Pa...

Page 286: ...o 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 repl...

Page 287: ...shift 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 cl...

Page 288: ...nlet pressure is low Measure 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 qu...

Page 289: ...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 1 Charge circuit pressure ...

Page 290: ...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 291: ...oad 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 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 steerin...

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Page 294: ...pan 2018 02 10 0 K P 0421 99003 0 30026 0 SV414 SHOP MANUAL 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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