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Sakai SV510-III, Shop Manual

The Sakai SV510-III Shop Manual is a comprehensive user guide for this powerful construction equipment. With detailed instructions and essential maintenance tips, this manual is a must-have for operators. Download it for free from our website and unlock the full potential of your Sakai SV510-III.

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6-005

VIBRATORY DRUM • REAR AXLE

6)  Remove eight bolts (2) (left and right sides).

Lift off vibratory drum (11) from frame.

 Vibratory drum assembly 

 

SV510D-

: 4,470 kg (  9,855 lbs.)

 

 

SV510T-

: 4,810 kg (10,604 lbs.)

 

 

SV510TF-

: 7,180 kg (15,829 lbs.)

7)  Put chocks or the like under removed drum (11) to prevent 

it from moving.

•

SV510-

 

-06007

Support stand

Lift with crane.

2

11

SV510-

 

-06007

Support stand

Lift with crane.

2

11

SV510-

 

-06009

Chock

11

SV510-

 

-06009

Chock

11

Summary of Contents for SV510-III

Page 1: ...SV510 SHOP MANUAL 3498 6412A 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...

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Page 5: ...1 9 Stopping 1 004 1 10 Maintenance 1 005 1 11 Transporting the Machine 1 007 2 SPECIFICATIONS 1 SPECIFICATION DATA 1 1 SV510D Ⅲ 2 001 1 2 SV510T Ⅲ 2 003 1 3 SV510TF Ⅲ 2 005 2 TABLE OF STANDARD VALUES 2 1 Engine 2 007 2 2 Propulsion 2 007 2 3 Hydraulic System 2 007 2 4 Steering 2 008 2 5 Brakes 2 008 2 6 Capacities 2 008 3 FUEL AND LUBRICANTS SPECIFICATION 3 1 Rating 2 009 3 2 Recommended Lubrican...

Page 6: ...ydraulic pump assembly propulsion vibrator steering 4 007 2 2 2 Gear box 4 009 2 2 3 Propulsion hydraulic motor front 4 011 2 2 4 Propulsion hydraulic motor rear 4 012 3 VIBRATOR HYDRAULIC SYSTEM 3 1 Vibrator Hydraulic Piping 4 013 3 2 Hydraulic Component Specifications 4 014 3 2 1 Vibrator hydraulic motor 4 014 4 STEERING SYSTEM 4 1 Steering Hydraulic Piping 4 015 4 2 Steering Wheel 4 016 4 3 Hyd...

Page 7: ...2 Rear axle assembly type 2 6 038 3 2 Rear Axle Lubrication 6 039 3 3 Rear Axle Structure 6 040 3 3 1 Center housing 6 040 3 3 2 Differential 6 041 3 3 3 Hub reduction gear 6 042 3 3 4 Brake type 1 6 043 3 3 5 Brake type 2 6 044 3 3 6 Gearbox 6 045 7 BRAKE 1 BRAKE PEDAL 7 001 2 BRAKE HYDRAULIC PIPING 7 002 3 BRAKE SYSTEM 7 003 4 HYDRAULIC COMPONENT SPECIFICATIONS 4 1 Brake Solenoid Valve 7 004 8 I...

Page 8: ...010 7 1 Measurement 8 011 7 2 Inspection 8 012 8 MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE 8 1 Measurement 8 013 8 2 Inspection 8 014 9 MEASUREMENT OF HYDRAULIC PUMP CASE PRESSURE 9 1 Measurement of Propulsion Pump Case Pressure 8 015 9 2 Measurement of Vibrator Pump Case Pressure 8 016 10 MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE 10 1 Measurement 8 017 11 MEASUREMENT OF VIBRATOR...

Page 9: ...un 2 2 9 025 2 4 2 Engine will not start But starter motor runs 9 027 2 4 3 No charging 9 029 2 4 4 Engine speed cannot be switched 9 029 2 4 5 Starter motor runs even when F R lever is not at neutral position 9 031 2 5 Propulsion 9 033 2 5 1 Machine moves neither forward nor backward 9 033 2 5 2 Machine speed cannot be changed 9 035 2 5 3 Traction control does not work 1 3 9 037 2 5 3 Traction co...

Page 10: ...kward 9 068 3 2 3 Slow machine speed or small drive force 1 2 9 068 3 2 3 Slow machine speed or small drive force 2 2 9 069 3 2 4 Machine speed cannot be switched 9 069 3 2 5 Machine does not stop completely with F R lever in neutral position 9 069 3 2 6 Propulsion system is overheating 9 070 3 2 7 Abnormal noise from propulsion system 9 070 3 3 Vibrator System 9 071 3 3 1 No vibration 9 071 3 3 2...

Page 11: ...SAFETY ...

Page 12: ......

Page 13: ...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 14: ... 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 15: ...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 16: ...anging banks or on grades that could cause the compactor to slide or roll over Avoid any areas that may be a risk to machine stability Avoid side hill travel Always operate up and down the slope Always keep the propulsion travel control lever in low speed range when climbing or descending hills or steep grades Make sure there is sufficient clearance when crossing underpasses bridges and tunnels or...

Page 17: ...it until the machine has cooled down Use care when attaching and securing lifting tackle to individual parts and large assemblies being removed or repositioned for repair purposes to avoid the risk of accident Use lifting devices that are in perfect condition and of sufficient lifting capacity Never stand under suspended loads Always use the proper tools and workshop equipment in good condition wh...

Page 18: ...t or perform grinding on the machine unless expressly authorized as there may be a risk of fire or explosion Disconnect the battery when welding on the machine Clean the machine and its surrounding from dust or other flammable substances and make sure the area is adequately ventilated before beginning welding flame cutting or grinding operations Inspect hydraulic hoses at regular intervals and imm...

Page 19: ...idth Block the drums or tires front and rear of the hauling vehicle when loading and unloading the compactor Ensure that the haul vehicle is on level ground and approach the loading ramps squarely to make sure that the compactor does not slide off the edge of the ramp Keep the deck clear of mud oil ice or snow or other materials that can make the deck slippery Position the compactor on the trailer...

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Page 21: ...SPECIFICATIONS ...

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Page 24: ...heelbase 2 970 mm 117 in Compaction width 2 130 mm 84 in Minimum height above ground 435 mm 17 in Curb clearance 445 mm 18 in Speed 1st 0 to 6 km h 0 to 3 7 mph 2nd 0 to 10 km h 0 to 6 2 mph Vibration performance Frequency Low amplitude 36 7 Hz 2 200 vpm High amplitude 27 5 Hz 1 650 vpm Centrifugal force Low amplitude 171 5 kN 38 553 lbs High amplitude 225 4 kN 50 670 lbs Amplitude Low amplitude 1...

Page 25: ... type Electrical system Alternator 12 V 160 A Starter 12 V 4 8 kW Battery 12 V 100 Ah 2 pcs 12 V Power line Transmission Type Hydrostatic transmission Speeds 2 speed shifts Reverser Switching the direction of flow delivered from the variable pump Differential Auto lock type Final drive Planetary gear Vibrating system Transmission Hydrostatic transmission Vibrator Eccentric shaft type Braking devic...

Page 26: ... 970 mm 117 in Compaction width 2 130 mm 84 in Minimum height above ground 470 mm 19 in Curb clearance 480 mm 19 in Speed 1st 0 to 6 km h 0 to 3 7 mph 2nd 0 to 10 km h 0 to 6 2 mph Vibration performance Frequency Low amplitude 36 7 Hz 2 200 vpm High amplitude 27 5 Hz 1 650 vpm Centrifugal force Low amplitude 186 2 kN 41 858 lbs High amplitude 245 0 kN 55 076 lbs Amplitude Low amplitude 1 01 mm 0 0...

Page 27: ...2 V 160 A Starter 12 V 4 8 kW Battery 12 V 100 Ah 2 pcs 12 V Power line Transmission Type Hydrostatic transmission Speeds 2 speed shifts Reverser Switching the direction of flow delivered from the variable pump Differential Auto lock type Final drive Planetary gear Vibrating system Transmission Hydrostatic transmission Vibrator Eccentric shaft type Braking device Service brake Hydrostatic and mech...

Page 28: ...2 970 mm 117 in Compaction width 2 130 mm 84 in Minimum height above ground 475 mm 19 in Curb clearance 490 mm 19 in Speed 1st 0 to 6 km h 0 to 3 7 mph 2nd 0 to 10 km h 0 to 6 2 mph Vibration performance Frequency Low amplitude 36 7 Hz 2 200 vpm High amplitude 27 5 Hz 1 650 vpm Centrifugal force Low amplitude 186 2 kN 41 858 lbs High amplitude 245 0 kN 55 076 lbs Amplitude Low amplitude 0 76 mm 0 ...

Page 29: ...W Battery 12 V 100 Ah 2 pcs 12 V Power line Transmission Type Hydrostatic transmission Speeds 2 speed shifts Reverser Switching the direction of flow delivered from the variable pump Differential Auto lock type Final drive Planetary gear Vibrating system Transmission Hydrostatic transmission Vibrator Eccentric shaft type Braking device Service brake Hydrostatic and mechanical type Parking brake Me...

Page 30: ...0 km h 0 to 6 2 mph Rear wheel hub nut 785 N m 579 lbf ft Tire inflation pressure 137 kPa 20 psi 2 3 Hydraulic System Item Standard value Remarks Propulsion oil pressure High pressure relief valve setting 41 8 1 0 MPa 6 061 145 psi At 1 800 min 1 Charge relief valve setting 1 89 0 2 MPa 274 29 psi Motor relief valve setting 2 45 0 2 MPa 355 29 psi Motor drainage front 17 8 L min 4 7 gal min Motor ...

Page 31: ...700 02001 Clearance between brake pedal and floorboard when pressed down 145 mm 5 7 in Note 2 See dimensions Brake disc wear limit 4 5 mm 0 18 in S SV700 02003 S 2 6 Capacities Item Standard value Remarks Engine oil pan 11 6 L 3 1 gal Fuel tank 250 L 66 gal Coolant 17 L 4 5 gal Gear box front 4 7 L 1 24 gal Gear box rear 2 0 L 0 53 gal Center housing rear type 1 9 5 L 2 51 gal Center housing rear ...

Page 32: ...VI 140 ISO VG68 Over VI 110 ISO 3448 Grease Lithium type extreme pressure NLGI 2 Fuel Diesel oil ASTM D975 2D 3 2 Recommended Lubricants Lubricant Oil company Engine oil API CH 4 Gear oil API GL 4 Hydraulic oil VG 46 Grease NLGI II CALTEX N A Universal Thuban 90 Rando Oil HD 46 Martifack EP 2 BP Vanellus C Extra BP Gear Oil EP 90 BP Energol HLP 46 BP Energrease LS EP 2 ESSO N A Esso Gear Oil GP 90...

Page 33: ...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 34: ......

Page 35: ...ENGINE AND CONTROLS ...

Page 36: ......

Page 37: ... 20 2 Engine 8 Nut M16 14 Damper 3 Bracket 9 Bolt M10 20 15 Nut M16 4 Bracket 10 Damper 16 Bolt M12 40 5 Bracket 11 Bolt M10 20 6 Bracket 12 Bolt M16 100 N m 1 Bolt M10 100 43 N m 32 lbf ft 12 Bolt M16 100 265 N m 195 lbf ft 7 Bolt M16 100 265 N m 195 lbf ft 13 Bolt M10 20 59 N m 44 lbf ft 9 Bolt M10 20 59 N m 44 lbf ft 16 Bolt M12 40 108 N m 80 lbf ft 11 Bolt M10 20 59 N m 44 lbf ft ...

Page 38: ......

Page 39: ...emperature sensor Coolant outlet Intake manifold pressure temperature sensor Air intake inlet Electronic control module ECM Ambient air pressure sensor Dipstick oil level sensor Oil pan drain plug Fan or PTO drive flange mounting Turbocharger exhaust outlet Starter Turbocharger compressor inlet Starter mounting location Coolant inlet Water pump Belt tensioner Flywheel Flywheel housing Crankcase br...

Page 40: ......

Page 41: ...trol 0412 12801 0 10007 A SECTION B B DETAIL A VIEW C 8 7 9 1 R N F 11 12 4 6 A C 5 2 10 Fill grease B B 3 1 F R lever 7 Steel ball 2 Backup buzzer switch 8 Nut M16 3 F R lever switch 9 Bolt M16 30 4 Control cable 10 Spring 5 Pump lever 11 Clevis 6 Rod end 12 Nut M12 ...

Page 42: ...2 0 SECTION A A A A 3 2 1 7 6 5 4 9 8 1 Bolt M10 30 6 Housing 2 Bolt M10 38 7 Bolt M14 45 3 Retaining ring 8 Pump 4 Hub 9 Bolt M12 35 5 Flange N m 1 Bolt M10 30 59 N m 44 lbf ft 2 Bolt M10 38 49 N m 36 lbf ft 7 Bolt M14 45 167 N m 123 lbf ft 9 Bolt M12 35 120 N m 89 lbf ft ...

Page 43: ... hub N m 9 Bolt M12 35 120 N m 89 lbf ft Install housing 6 to pump 8 and tighten with four bolts 7 and spring washers and washers N m 7 Bolt M14 45 167 N m 123 lbf ft Install flange 5 on engine flywheel and tighten eight bolts 2 N m 2 Bolt M10 38 49 N m 36 lbf ft Ensure engagement of flange 5 with hub 4 and install pump 8 in engine Tighten twelve bolts 1 and washers N m 1 Bolt M10 30 59 N m 44 lbf...

Page 44: ......

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...

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Page 51: ...tal i 65 36 1 89 MPa SERVO SERVO 41 8 MPa 41 8 MPa 2 34 MPa SERVO SERVO 245 0 kN 1650 vpm 225 4 kN 1650 vpm 2 45 MPa at 11L min S E R V O i 63 49 Drum S E R V O n 25 MPa 25 MPa IN LS2 LO2 OUT IN LS1 LO1 OUT VMA FMT RA2 RBR RBL VMT VMB FA FB PB1 VT1 VT2 PT1 PT2 PB2 PA2 PP PS PA1 Tire dia Tire size Propulsion motor Front Vibrator motor Suction filter Vibratory system Propulsion motor Rear Reduction ...

Page 52: ......

Page 53: ...ow symbols show the hose connection and the direction of the flow of the oil SECTION B B SECTION C C SECTION A A Hose FMT Hydraulic oil tank RA1 A A B B B B Gear box Hose RA1 FB Hose RB1 FA Hose FMT Hydraulic oil tank Hose RA1 FB Hose RB1 FA Hose RA1 FB Hose RB1 FA Hose FMT Hydraulic oil tank 2 PROPULSION HYDRAULIC SYSTEM 2 1 Propulsion Hydraulic Piping 2 1 1 Propulsion hydraulic piping front type...

Page 54: ......

Page 55: ...A1 FB Hose RB1 FA Hose FMT Hydraulic oil tank B B B B C C A A SECTION A A SECTION B B SECTION C C FA FMT FB Hydraulic oil tank RA1 RB1 Gear box Propulsion motor Front Propulsion motor Rear Hose FMT Hydraulic oil tank Hose RA1 FB Hose FMT Hydraulic oil tank Hose RA1 FB Hose FMT Hydraulic oil tank Hose RA1 FB Hose RB1 FA 2 1 2 Propulsion hydraulic piping front type 2 4 005 HYDRAULIC SYSTEMS ...

Page 56: ......

Page 57: ... SECTION A A SECTION B B PT1 PA1 PB1 Propulsion motor Rear Propulsion pump Hydraulic oil tank CS PT2 Bypass valve RB2 CO A1 RMT B1 RB3 RA3 Oil cooler RA2 VIEW C A A B B The letters and figures such as PT2 and CS show each port and the arrow symbols show the hose connection and the direction of the flow of the oil 2 1 3 Propulsion hydraulic piping rear 4 006 HYDRAULIC SYSTEMS ...

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Page 59: ......

Page 60: ... 8 1 1 2 4 2 3 3 2 2 1 Pump circuit diagram 1 7 2 8 1 2 1 3 2 7 2 6 2 2 1 4 2 11 2 10 2 12 1 12 3 1 3 1 2 13 1 13 1 10 1 9 1 11 2 5 2 9 A VIEW A 1 10 2 13 2 6 1 7 1 12 2 3 2 2 2 7 2 1 2 10 2 5 3 1 3 2 1 13 1 5 1 11 1 8 1 6 1 3 1 2 75 0 cc rev 45 9 35 cc rev 24 9 cc rev 1 89 MPa SERVO SERVO 41 8 MPa 41 8 MPa 2 34 MPa SERVO SERVO 25 MPa 25 MPa 2 ...

Page 61: ...t For Port A2 9 16 18UNF 2 2 High pressure gauge port For Port B2 9 16 18UNF 2 3 Port B2 High amplitude PB2 1 5 16 12UN 2 4 High pressure relief valve For Port B2 2 5 Servo pressure gauge port 9 16 18UNF 2 6 Drain port VT2 1 1 16 12UN 2 7 Port A2 Low amplitude PA2 1 5 16 12UN 2 8 Solenoid valve a Low amplitude 2 9 Solenoid valve b High amplitude 2 10 Servo pressure gauge port 9 16 18UNF 2 11 Charg...

Page 62: ...4 009 HYDRAULIC SYSTEMS 2 2 2 Gear box SV510 04004 1 1 Gear box Specifications Reduction ratio 1 63 49 Weight 168 kg 370 lbs ...

Page 63: ... shaft coupling subassembly 1 10 Bolt 1 2 Hub spindle subassembly 1 11 Intermediate carrier subassembly 1 3 Dowel pin 1 12 Sun gear 1 4 Output planetary subassembly 1 13 Input carrier subassembly 1 5 External retaining ring 1 14 Sun gear 1 6 Thrust spacer 1 15 O ring 1 7 Magnetic pipe plug 1 16 Thrust washer 1 8 O ring 1 17 Cover subassembly 1 9 Ring gear 1 18 Bolt ...

Page 64: ...n port FMT 1 1 16 12UN 10 Port B Forward FB SAE 1 4 Speed pickup 11 High pressure gauge port For Port A 9 16 18UNF 5 Drain port 1 1 16 12UN 12 High pressure gauge port For Port B 9 16 18UNF 6 Charge pressure relief valve 13 Servo pressure max angle gauge port 9 16 18UNF 7 Loop flushing shuttle valve 14 Supply pressure shuttle valve 9 16 18UNF Motor specifications Displacement max 80 7 cm3 rev 4 92...

Page 65: ... A Forward RA SAE 1 3 Speed pickup 9 Port B Reverse RB SAE 1 4 Drain port 1 1 16 12UN 10 High pressure gauge port For Port A 9 16 18UNF 5 Charge pressure relief valve 11 High pressure gauge port For Port B 9 16 18UNF 6 Loop flushing shuttle valve 12 Servo pressure max angle gauge port 9 16 18UNF Motor specifications Displacement max 80 7 cm3 rev 4 92 cu in rev min 32 0 cm3 rev 1 95 cu in rev Charg...

Page 66: ......

Page 67: ... Hydraulic oil tank VMT Hose PB2 VMB Hose PA2 VMA Hose Hose PA2 VMA Hose VMB PB2 Hose PB2 VMB Hose VMA PA2 Hose VT1 LS2 SECTION A A SECTION B B SECTION C C PT2 The letters and figures such as VMB and PB2 show each port and the arrow symbols show the hose connection and the direction of the flow of the oil VIEW D Hydraulic oil tank VMT Hydraulic oil tank 3 VIBRATOR HYDRAULIC SYSTEM 3 1 Vibrator Hyd...

Page 68: ......

Page 69: ...3 4 Flow of oil 1 2 Clockwise rotation 2 1 Counterclockwise rotation SV510 04008 1 Port A VMA SAE 3 4 2 Port B VMB SAE 3 4 3 Drain port L VMT 7 8 14UNF 4 Drain port L1 7 8 14UNF Specifications Displacement 44 5 cm3 rev 2 72 cu in rev Working pressure 28 MPa 4 060 psi Allowable pump case pressure 0 3 MPa 43 5 psi Weight 17 kg 37 lbs ...

Page 70: ......

Page 71: ...R RC1 Hose L LC1 Hose T LS1 Hose LO1 PC Hose Hydraulic oil tank PS Hose RC1 LC2 Hose Hose R RC1 Hose PP P Hose PP P Hose L LC1 Hose LS1 T Hose Hydraulic oil tank PS Steering Charge pump Hose LO1 PC P PP The letters and figures such as LO1 and PC show each port and the arrow symbols show the hose connection and the direction of the flow of the oil B B C C 4 STEERING SYSTEM 4 1 Steering Hydraulic Pi...

Page 72: ......

Page 73: ...21754 Ａ 1 Column shaft 6 Bolt M10 30 2 Nut M12 P 1 25 7 Bracket 3 Steering wheel 8 Bolt M8 12 4 Nut M10 9 Orbitrol 5 Damper N m 2 Nut M12 P 1 25 35 N m 26 lbf ft 4 Nut M10 49 N m 36 lbf ft 6 Bolt M10 30 49 N m 36 lbf ft 8 Bolt M8 12 23 N m 17 lbf ft Steering wheel assembly weight 17 kg 37 lbf ft ...

Page 74: ... Orbitrol SV510 04010 1 2 3 3 4 4 1 2 Hydraulic circuit diagram 1 Port L L 3 4 16UNF 2 Port R R 3 4 16UNF 3 Port T T 3 4 16UNF 4 Port P P 3 4 16UNF Specifications Displacement 400 cm3 rev 24 4 cu in rev Relief valve pressure setting 15 0 MPa 2 175 psi Weight 7 kg 15 lbs ...

Page 75: ...4 1 Bolt M16 60 5 Swing bearing 9 Roller bearing 2 Bolt M16 80 6 Yoke 10 Bracket upper 3 Nut M20 7 Bolt M16 45 11 Bracket lower 4 Bolt M20 110 8 Cover 12 O ring N m 1 Bolt M16 60 265 N m 196 lbf ft 2 Bolt M16 80 265 N m 196 lbf ft 3 Nut M20 539 N m 398 lbf ft 7 Bolt M16 45 265 N m 196 lbf ft ...

Page 76: ......

Page 77: ...ELECTRICAL SYSTEM ...

Page 78: ......

Page 79: ...J1939 SHIELD 46 SAE J1939 25 DEC CRUISE SET SW 34 SW RETURN 24 INC CRUISE RESUME SW 2 DIAGNOSTIC SW 39 KEY SW SIGNAL ISC2 SW 16 ISC1 SW 4 44 WARNING LAMP 43 STOP LAMP 4 BATTERY 3 BATTERY ENGINE ECM 72 2BrY 72 2BrY 70 8W 70 71 8BW G X AV100 STARTER RELAY 2 GB 2 GB 12 R 40 1 25G 40 G 30 RY 30 RY 34 LgW 36 LgR 38 GR 37 BrW X B X B FRONT MOTOR PROPORTIONAL SOLENOID SOL X B 53 WG 56 GR 60 GB 68 Lg 69 L...

Page 80: ......

Page 81: ...uzzer Battery Fuel unit Vibrator solenoid b Vibrator solenoid a Hydraulic oil filter switch 1 Hydraulic oil filter switch 2 F R lever switch Horn Rear motor proportional solenoid Front motor proportional solenoid Backup buzzer switch Foot brake switch Rear motor rotation sensor Engine ECM Tachometer sensor F R lever vibration switch 2 ELECTRICAL COMPONENTS 2 1 Electrical Component Layout 1 5 002 E...

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Page 83: ...tch Combination meter Engine stop lamp Warning lamp Throttle switch Starter switch Lamp check relay Fuse box Oil pressure relay Diode unit Throttle relay Interlock relay Parking brake switch Speed change switch Traction control box Vibration mode change switch A C B D D Diagnostic switch INC DEC switch Tachometer sensor control box Horn relay 2 2 Electrical Component Layout 2 5 003 ELECTRICAL SYST...

Page 84: ......

Page 85: ... Starter relay Alternator Battery relay F R lever switch Backup buzzer switch Foot brake switch Throttle switch Horn relay Combination meter Engine ECM Speed change switch Traction control box Combination meter BW RW R RG R RY YW G RY Harness color codes RG Red Green stripe BW Black White stripe RW Red White stripe YW Yellow White stripe RY Red Yellow stripe G Green R Red ...

Page 86: ......

Page 87: ...VIBRATORY DRUM REAR AXLE ...

Page 88: ......

Page 89: ...ther substances from getting in Before removing piping for hydraulic oil or coolant or removing related parts satisfactorily release internal pressure 2 Precautions for installation work Tighten bolts and nuts sleeve nuts to the specified torque screw tightening torque table When installing hoses do not twist them or allow them to interfere with other parts Replace gaskets O rings split cotter pin...

Page 90: ...g life coolant to the specified level Start the engine and allow the coolant to circulate through the piping Then add coolant again to the specified level If hydraulic equipment has been removed and reinstalled fill with hydraulic oil to the specified level Start the engine and allow the oil to circulate through the piping Then add oil again to the specified level ...

Page 91: ...ar end of rear frame NOTICE Do not allow rear wheel tires to leave the ground The tires must support the machine s body weight too Rear axle weight SV510D 4 910 kg 10 825 lbs SV510T 4 920 kg 10 850 lbs SV510TF 4 890 kg 10 780 lbs 3 Lift front frame with a crane Ensuring that no load is applied to eight bolts 2 left and right sides place support stands at right and left sides of front frame Firmly ...

Page 92: ...ore starting the work 5 Disconnecting piping 5 1 Propulsion motor piping Disconnect hydraulic hoses 5 6 and 7 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 8 9 and 10 connecting to vibrator motor NOTICE Plug both ends of the disconnected hoses or imple...

Page 93: ... Vibratory drum assembly SV510D 4 470 kg 9 855 lbs SV510T 4 810 kg 10 604 lbs SV510TF 7 180 kg 15 829 lbs 7 Put chocks or the like under removed drum 11 to prevent it from moving SV510 06007 Support stand Lift with crane 2 11 SV510 06007 Support stand Lift with crane 2 11 SV510 06009 Chock 11 SV510 06009 Chock 11 ...

Page 94: ...ory drum 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 t...

Page 95: ...ric shaft 6 Shaft 7 Bolt M12 40 8 Sleeve 9 Spring pin 10 Bolt M20 60 11 Plug 12 Housing 13 Oil seal 14 Roller bearing 15 Disc 16 Bolt M12 40 17 Bolt M20 60 18 Bolt M12 40 19 Damper 20 Holder 21 Bolt M20 90 22 Plate 23 Breather 24 Cover 25 Bolt M14 40 26 Vibrator motor 27 O ring 28 Bolt M14 40 29 Cover 30 Plate 31 Oil seal 32 Bolt M12 40 33 Shim 34 Holder 35 Axle shaft 36 O ring 37 Vibrator bearing...

Page 96: ......

Page 97: ...ING 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 with a crane and stand it with its vibrator motor 26 side facing up as shown on the right Vibratory drum assembly SV510D 4 470 kg 9 855 lbs SV510T 4 810 kg 10 604 lbs SV510TF 7 180 kg 15 829 lbs 3...

Page 98: ...0 to holders 20 and 34 5 Remove sixteen bolts 17 6 Lift holders 20 34 dampers 19 and disc 15 together with a crane and remove them Total weight of parts to be lifted 150 kg 331 lbs SV510 06013 Lifting bolt Nut 34 20 SV510 06013 Lifting bolt Nut 34 20 SV510 06014 17 SV510 06014 17 SV510 06008 34 15 19 20 SV510 06008 34 15 19 20 ...

Page 99: ...two pulling bolts M20 60 WARNING When attaching lifting bolts screw in the threads fully before using 9 Install lifting bolts M20 to axle shaft subassembly 35 SV510 06015 10 8 SV510 06015 10 8 SV510 06021 35 Pulling bolt SV510 06021 35 Pulling bolt SV510 06016 35 Lifting bolt SV510 06016 35 Lifting bolt ...

Page 100: ... with a wooden hammer via a wooden bar during lifting 35 Axle shaft subassembly 240 kg 529 lbs 11 Put removed axle shaft subassembly 35 on wooden blocks 12 Install a lifting bolt M10 to the end of eccentric shaft subassembly 5 SV510 06017 35 Wooden hammer Wooden bar SV510 06017 35 Wooden hammer Wooden bar SV510 06018 35 Wooden block SV510 06018 35 Wooden block SV510 06019 5 Lifting bolt SV510 0601...

Page 101: ...m that the surrounding area is safe and work in a natural unstrained posture 14 Lift vibratory drum with a crane and reverse it Then stand drum with its propulsion motor 47 side facing up Total weight of parts to be lifted SV510D 3 790 kg 8 355 lbs SV510T 4 120 kg 9 083 lbs SV510TF 6 255 kg 13 790 lbs 15 Remove two bolts 46 Remove propulsion motor 47 47 Propulsion motor 35 kg 77 lbs SV510 06020 5 ...

Page 102: ...ove twenty bolts 45 18 Lift holders 42 51 dampers 41 and disc 2 together with a crane and remove them Total weight of parts to be lifted 230 kg 507 lbs SV510 06024 42 51 Nut Lifting bolt SV510 06024 42 51 Nut Lifting bolt 45 SV510 06025 45 SV510 06025 SV510 06026 2 41 42 51 SV510 06026 2 41 42 51 ...

Page 103: ... Remove sixteen bolts 44 20 Lift gearbox subassembly 48 with a crane and remove it Total weight of parts to be lifted 220 kg 485 lbs 21 Remove sixteen bolts 39 SV510 06027 44 48 Lifting bolt SV510 06027 44 48 Lifting bolt SV510 06028 48 SV510 06028 48 SV510 06029 39 SV510 06029 39 ...

Page 104: ... M20 60 23 Install lifting bolts M20 on axle shaft 43 24 Lift axle shaft 43 with a crane and remove it 43 Axle shaft 235 kg 518 lbs SV510 06031 Pulling bolts 43 SV510 06031 Pulling bolts 43 SV510 06098 Lifting bolts 43 SV510 06098 Lifting bolts 43 SV510 06030 43 SV510 06030 43 ...

Page 105: ... on wooden blocks 26 The right illustration shows axle shaft subassembly 35 removed from vibratory drum 27 Remove six bolts 32 Remove cover 24 24 Cover 10 kg 22 lbs SV510 06038 43 SV510 06038 43 SV510 06032 35 SV510 06032 35 SV510 06033 32 24 SV510 06033 32 24 ...

Page 106: ...f axle shaft 35 and set a puller on housing 12 Separate housing 12 together with roller bearing from axle shaft 35 30 Install lifting bolts M12 to housing 12 SV510 06034 25 29 33 SV510 06034 25 29 33 SV510 06035 Puller 35 12 Wooden board SV510 06035 Puller 35 12 Wooden board SV510 06036 Lifting bolt 12 SV510 06036 Lifting bolt 12 ...

Page 107: ...d separate it from axle shaft 35 12 Housing subassembly 45 kg 99 lbs 32 The right illustration shows axle shaft 43 removed from vibratory drum 33 Remove bolts 3 from axle shaft 43 SV510 06037 12 35 SV510 06037 12 35 SV510 06038 43 SV510 06038 43 SV510 06039 3 43 SV510 06039 3 43 ...

Page 108: ...steel bar through bolt holes and alternately strike each side on outer race of vibrator bearing 4 Remove vibrator bearing 4 from axle shaft 43 SV510 06040 Round steel bar Strike on outer ring 43 4 SV510 06040 Round steel bar Strike on outer ring 43 4 ...

Page 109: ...d put it in an upright position 1 Vibratory drum SV510D 3 060 kg 6 746 lbs SV510T 3 385 kg 7 463 lbs SV510TF 5 755 kg 12 687 lbs 2 Apply a thin coat of gear oil to axle shaft 43 on its surface where vibrator bearing 4 will be press fitted Drive in vibrator bearing 4 NOTICE Take care not to damage the bearing when installing it 3 Apply grease to entire periphery of O ring 40 Install O ring 40 on ax...

Page 110: ...ully before using 5 Install lifting bolts M20 to axle shaft 43 6 Lift axle shaft 43 with a crane and lower it on mounting surface of vibratory drum 1 43 Axle shaft 235 kg 518 lbs NOTICE When installing axle shaft take care not to allow the O ring to protrude from the fitting groove SV510 06043 3 43 SV510 06043 3 43 SV510 06044 Lifting bolt 43 SV510 06044 Lifting bolt 43 SV510 06046 43 1 SV510 0604...

Page 111: ...8 with twenty bolts 38 and spring washers N m 38 Bolts M20 80 P 1 5 588 N m 434 lbf ft 9 Lift gearbox subassembly 48 with a crane and reverse it 48 Gearbox subassembly 220 kg 485 lbs Install lifting bolts M20 P 1 5 to gearbox subassembly 48 SV510 06047 1 43 39 SV510 06047 1 43 39 SV510 06048 38 49 48 SV510 06048 38 49 48 SV510 06049 Lifting bolt 48 SV510 06049 Lifting bolt 48 ...

Page 112: ... 44 and washers N m 44 Bolts M20 70 539 N m 398 lbf ft WARNING When installing lifting bolts secure them with nuts 12 Install lifting bolts and nuts M20 on a subassembly of holders 42 51 dampers 41 and disc 2 as shown on the right SV510 06050 43 48 SV510 06050 43 48 SV510 06051 44 48 SV510 06051 44 48 SV510 06052 Nut 2 Lifting bolt 42 51 41 SV510 06052 Nut 2 Lifting bolt 42 51 41 ...

Page 113: ...E When installing the disc subassembly the imaginary line passing through both propulsion motor mounting bolt hole centers must be parallel to the longer edge of the disc 15 Secure propulsion motor 47 with two bolts 46 and washers 47 Propulsion motor 35 kg 77 lbs N m 46 Bolts M20 40 P 1 5 588 N m 434 lbf ft SV510 06053 2 48 SV510 06053 2 48 SV510 06054 2 45 Propulsion mounting bolt hole SV510 0605...

Page 114: ...ith its propulsion motor side facing down 1 Vibratory drum SV510D 3 790 kg 8 355 lbs SV510T 4 120 kg 9 083 lbs SV510TF 6 255 kg 13 790 lbs 17 Secure shaft 6 to eccentric shaft 5 with six bolts 7 and spring washers N m 7 Bolts M12 40 108 N m 80 lbf ft 18 Install a lifting bolt M10 to the end of eccentric shaft subassembly 5 SV510 06056 1 Wooden block SV510 06056 1 Wooden block SV510 06073 5 6 7 SV5...

Page 115: ...g the eccentric shaft put the movable weights at their outmost position 20 Insert eccentric shaft subassembly 5 into vibrator bearing 4 while taking care not to tilt vibrator bearing inner race installed on axle shaft 43 21 Reassembly of axle shaft subassembly 35 21 1 Fix axle shaft 35 with wooden blocks SV510 06075 5 Movable weight SV510 06075 5 Movable weight SV510 06076 5 4 43 Inner race SV510 ...

Page 116: ...e it 35 Axle shaft 180 kg 397 lbs Apply a thin coat of gear oil to roller bearing 14 inner race on its surface to be press fitted Press fit roller bearing 14 inner race 21 4 Apply grease to O rings for plugs 11 Install three plugs 11 Apply sufficient amount of lithium based grease to rollers of roller bearing 14 inner race SV510 06058 Wooden block 37 35 SV510 06058 Wooden block 37 35 SV510 06059 W...

Page 117: ...stall oil seal 13 Apply a thin coat of grease to lip of oil seal 13 21 6 Install lifting bolts M12 to housing subassembly 12 21 7 Lift housing subassembly 12 with a crane and install it on axle shaft subassembly 35 12 Housing subassembly 40 kg 88 lbs SV510 06061 14 14 12 13 SV510 06061 14 14 12 13 SV510 06062 Lifting bolt 12 SV510 06062 Lifting bolt 12 SV510 06063 12 35 SV510 06063 12 35 ...

Page 118: ...orque of 108 N m 80 lbf ft again Repeat this work several times until tightening torque of bolts no longer fluctuates NOTICE Tighten four of the eight bolts 25 alternately in the 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 SV510 0...

Page 119: ...reload adjusting shim thickness A 0 1 mm 0 04 in Remove four bolts 25 Remove cover 29 Install a shim of preload adjusting shim 33 thickness A 0 1 mm and reinstall cover 29 Then secure cover with eight bolts 25 and washers N m 25 Bolts M14 40 170 N m 125 lbf ft SV510 06067 25 29 33 SV510 06067 25 29 33 SV510 06068 There must be no gap 25 29 A SV510 06068 There must be no gap 25 29 A SV510 06069 33 ...

Page 120: ...0 108 N m 80 lbf ft NOTICE The four holes in housing 12 breather mounting hole in cover 24 and vibrator motor mounting bolt holes must be arranged as shown on the right SV510 06070 24 31 SV510 06070 24 31 SV510 06071 32 24 12 SV510 06071 32 24 12 SV510 06072 12 24 Hole 4 Hole 3 Hole 2 Hole 1 Breather mounting hole Vibrator motor mounting bolt hole SV510 06072 12 24 Hole 4 Hole 3 Hole 2 Hole 1 Brea...

Page 121: ...ccentric shaft subassembly 5 with a pipe or the like align center of vibrator bearing inner race to that of shaft 35 Axle shaft subassembly 240 kg 529 lbs NOTICE Install the axle shaft taking care not to tilt the vibrator bearing When installing the axle shaft take care not to allow the O ring to protrude from the fitting groove SV510 06077 Lifting bolt 35 SV510 06077 Lifting bolt 35 SV510 06078 3...

Page 122: ... M20 60 539 N m 398 lbf ft 26 Install a lifting bolt M8 on shaft end of eccentric shaft 5 27 Slowly lift eccentric shaft with a crane and check that there is an axial play of 1 to 3 mm 0 04 to 0 12 in SV510 06080 10 35 SV510 06080 10 35 SV510 06081 Lifting bolt SV510 06081 Lifting bolt SV510 06082 SV510 06082 ...

Page 123: ...50 kg 331 lbs 30 Secure disc subassembly 15 with sixteen bolts 17 and washers N m 17 Bolts M20 60 539 N m 398 lbf ft NOTICE When installing the disc subassembly the breather mounting hole in cover 24 must be perpendicular to the longer edge of the disc SV510 06083 Lifting bolt 34 20 15 19 Nut SV510 06083 Lifting bolt 34 20 15 19 Nut SV510 06084 15 12 SV510 06084 15 12 SV510 06085 Breather mounting...

Page 124: ...Apply molybdenum based grease to splined portion of sleeve 8 Fit sleeve 8 to splined shaft on eccentric shaft end 33 Apply grease to O ring 27 Install O ring 27 to vibrator motor 26 SV510 06086 8 9 SV510 06086 8 9 SV510 06087 8 SV510 06087 8 SV510 06088 26 27 SV510 06088 26 27 ...

Page 125: ...h a crane and lay it with plugs positioned as shown on the right Hold with chocks Vibratory drum assembly SV510D 4 470 kg 9 855 lbs SV510T 4 810 kg 10 604 lbs SV510TF 7 180 kg 15 829 lbs NOTICE Make sure that the drum is placed on level ground 36 Remove plugs 11 1 and 11 3 Supply gear oil from oil supply port Check that oil drips from gauge port Quantity of gear oil 34 L 9 0 gal Reinstall plugs 11...

Page 126: ......

Page 127: ...ake 10 Differential 11 Gearbox 12 Valve 13 Plug hub reduction gear filler level gauge and drain 14 Bolt brake adjustment 15 Parking brake release port RBL G1 4 16 Parking brake release port RBR G1 4 17 Plug differential filler 18 Plug differential filler and level gauge 19 Plug differential drain 20 Bolt M20 250 N m 2 Nut M22 P 1 5 785 N m 579 lbf ft 19 Bolt M20 250 540 N m 398 lbf ft Specificatio...

Page 128: ......

Page 129: ...lug hub reduction gear component filler level gauge and drain 14 Parking brake release port RBL G1 4 15 Parking brake release port RBR G1 4 16 Plug differential filler 17 Plug differential filler and level gauge 18 Plug differential drain 19 Bolt M20 250 N m 2 Nut M22 P 1 5 785 N m 579 lbf ft 19 Bolt M20 250 540 N m 398 lbf ft Specifications Tire inflation pressure 170 kPa 25 psi Tire assembly wei...

Page 130: ......

Page 131: ...reduction gear Drain Drain Supply Drain 2 2 2 1 2 1 3 1 3 1 3 1 3 2 1 Filler port 2 Drain port 3 Level gauge Change oil Gear oil API grade GL4 SAE90 See recommended lubrication Change oil quantity Gearbox 2 0 L 0 53 gal Center housing type 1 9 5 L 2 51 gal type 2 11 0 L 2 90 gal Hub reduction gear 1 75 L 2 0 46 gal 2 ...

Page 132: ...IBRATORY DRUM REAR AXLE 3 3 Rear Axle Structure 3 3 1 Center housing 2 2 3 5 10 8 9 4 7 6 1 1 1 1 SV510 ޓ 06093 1 O ring 5 Bolt 9 Snap ring 2 Cover 6 Seal washer 10 Magnet plug 3 Vent 7 Plug 4 Housing 8 Cover ...

Page 133: ... 7 11 12 13 14 15 16 5 9 4 8 6 10 1 1 SV510 ޓ 06101 1 Bolt 7 Bevel gear set 13 Shim 2 Ring nut 8 Nospin differential 14 Seal 3 Taper roller bearing 9 Spacer 15 Spacer 4 Bolt 10 Bolt 16 Shim 5 Spring washer 11 Ring nut 6 Differential carrier 12 Taper roller bearing ...

Page 134: ...3 12 11 1 Half shaft 10 O ring 19 Snap ring 2 Seal 11 Stud 20 Planet gear 3 Spring washer 12 Plug 21 Bearing 4 Bolt 13 Nut 22 Planet gear carrier 5 Seal 14 Magnet plug 23 Stud 6 Bearing 15 Axle case 24 Locking plate 7 Wheel stud 16 Circlip 25 Nut 8 Wheel hub 17 Ring gear 26 Friction washer 9 Wheel nut 18 Ring gear support 27 Countersunk bolt ...

Page 135: ...6 2 3 4 5 6 7 10 11 9 8 12 13 14 15 16 17 21 20 19 18 1 1 Spring 8 Cover 15 O ring 2 O ring 9 O ring 16 Lock plate 3 Piston 10 Disc 17 Bolt 4 O ring 11 Cylinder bolt 18 Plate 5 Bolt 12 Brake disc 19 Lock washer 6 Seal washer 13 Ring 20 Nut 7 Bolt 14 Pinion 21 Bolt ...

Page 136: ...6 044 VIBRATORY DRUM REAR AXLE 3 3 5 Brake type 2 SV700 06094 1 2 3 4 5 2 6 7 8 9 10 11 12 1 Spring 7 Brake disc 2 O ring 8 Plug 3 Piston 9 Bolt 4 O ring 10 Nut 5 Ring 11 Lock washer 6 Dowel 12 Plug ...

Page 137: ...97 1 12 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 1 Vent 7 Cover 13 Gear 2 Housing 8 Cylinder bolt 14 Plug 3 Ball bearing 9 O ring 15 Spring washer 4 Circlip 10 Intermediate cover 16 Bolt 5 Spacer 11 Cylinder bolt 17 Magnet plug 6 Gear 12 Bolt 18 Cylinder bolt ...

Page 138: ......

Page 139: ...BRAKE ...

Page 140: ......

Page 141: ...nit 9 Rod 17 Rod 2 Shaft 10 Nut M10 Left hand thread 18 Stopper bolt M10 40 3 Brake pedal 11 Ball joint Left hand thread 19 Nut M10 4 Clevis 12 Rod 20 Return spring 5 Nut M10 13 Nut M12 21 Nut M10 6 Foot brake switch 14 Rod end 22 Stopper bolt M10 40 7 Ball joint 15 Ball joint Left hand thread 8 Nut M10 16 Nut M10 Left hand thread ...

Page 142: ......

Page 143: ...d valve Hose BT Hydraulic oil tank Hose LO1 BP Hose BA RBL RBL Hydraulic oil filter 1 Hose RBL RBR Brake right Brake left BA LO1 BP BT The letters and figures such as BA and RBL show each port and the arrow symbols show the hose connection and the direction of the flow of the oil 7 002 BRAKE ...

Page 144: ......

Page 145: ...r 15A Fuse Parking brake switch Brake OFF condition 1 4 3 5 Steering charge pump Parking brake solenoid valve when brake is ON without solenoid excited The arrow symbol shows the direction of the hydraulic oil flow Brake Brake ON condition Rear axle Parking brake solenoid valve when brake is OFF with solenoid excited ...

Page 146: ...ction diagram 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 BP G1 4 7 Port A BA G1 4 8 Port T BT G1 4 Specifications Rated pressure 4 9 MPa 710 psi 6 7 0 5 MPa 72 5 psi 8 Rated flow 30 L min 7 9 gal min Weight 1 5 kg 3 3 lbs ...

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

Page 148: ......

Page 149: ...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 150: ... 50 MPa 0 to 7 250 psi Apply parking brake by pressing parking brake switch button Set propulsion speed change switch to position Start the engine and set throttle switch to Full position Slowly move F R lever to the side to be measured Then read pressure indicated by pressure gauge After measuring promptly return F R lever to Neutral position Maximum circuit pressure high pressure relief valve se...

Page 151: ...e is no evidence of nut having loosened remove multifunction valve Check removed multifunction valve for trapped dirt and scratches on its seat If trapped dirt is present disassemble and clean multifunction valve If a scratch is found on seat replace multifunction valve After adjustment measure pressure again and check that pressure reaches maximum circuit pressure range N m 1 Nut 41 N m 30 lbf ft...

Page 152: ... adapter ⓗ Adapter ⓗ 9 16 18UNF Pressure gauge 0 to 5 MPa 0 to 725 psi Apply parking brake by pressing parking brake switch button Start the engine and set throttle switch to Full position Then read pressure indicated by pressure gauge Standard charge relief valve setting 1 89 0 2 MPa 274 29 psi The number 1 3 appearing in above illustrations is consistent with lead line numbers shown in illustrat...

Page 153: ...turn 57 psi turn If there is no evidence of nut having loosened remove charge relief valve Check removed charge relief valve for trapped dirt and scratches on its seat If trapped dirt is present disassemble and clean charge relief valve If a scratch is found on seat replace charge relief valve After adjustment measure pressure again and check that pressure reaches standard charge relief valve sett...

Page 154: ... pressure min angle gauge port 2 4 2nd speed Pressure gauge 0 to 5 MPa 0 to 725 psi Apply parking brake by pressing parking brake switch button Set propulsion speed change switch to or position Start the engine and set throttle switch to Full position Then read pressure indicated by pressure gauge Standard motor relief valve setting 2 45 0 2 MPa 355 29 psi SV510 ޓ 08024 1 2 Propulsion motor Front ...

Page 155: ...brake solenoid valve Attach pressure gauge through adapter ⓜ Adapter ⓜ G 1 4 Pressure gauge 0 to 5 MPa 0 to 725 psi Confirm that F R lever is in Neutral position Apply parking brake by pressing parking brake switch button Start the engine and set throttle switch to Full position Release parking brake by pressing parking brake switch button Then read brake release pressure indicated by pressure gau...

Page 156: ...uge port 2 2 High amplitude Pressure gauge 0 to 50 MPa 0 to 7 250 psi Apply parking brake by pressing parking brake switch button Set vibration mode change switch to position Start the engine and set throttle switch to Full position Press F R lever vibration switch ON Then read pressure gauge for maximum value of vibrator circuit pressure Turn F R lever vibration switch OFF as soon as measurement ...

Page 157: ...ve If pressure still deviates from maximum circuit pressure range after valve is disassembled and cle aned replace high pressure relief valve After inspection measure pressure again and check that pressure reaches maximum circuit pressure range N m 2 4 to 2 12 High pressure relief valve 176 N m 130 lbf ft NOTICE Carefully disassemble and reassemble after taking steps to prevent foreign material fr...

Page 158: ...ue use following operation to ensure that oil does not escape to the charge relief valve on propulsion pump side Loosen nut 2 from charge relief valve 1 9 on propulsion pump side Tighten adjustment screw 3 by two complete turns Pressure change rate 0 39 MPa turn 57 psi turn The number 1 9 appearing in above illustrations is consistent with lead line numbers shown in illustration of vibrator pump i...

Page 159: ...pressing parking brake switch button Start the engine and set throttle switch to Full position Then read pressure indicated by pressure gauge Standard charge relief valve setting 2 34 0 2 MPa 339 29 psi The number 1 3 appearing in above illustrations is consistent with lead line numbers shown in illustration of vibrator pump in 2 2 Hydraulic Component Specifications page 4 007 SV510 ޓ 08006 Propul...

Page 160: ... deviates from standard charge pressure setting range after valve is disassembled and cleaned replace charge relief valve After inspection measure pressure again and check that pressure reaches standard charge relief pressure setting range N m 2 11 Charge relief valve 108 N m 80 lbf ft NOTICE Carefully disassemble and reassemble after taking steps to prevent foreign material from getting in The nu...

Page 161: ... 1 from steering charge pump Attach the pressure gauge through the adapter ⓟ Adapter ⓟ G1 2 Pressure gauge 0 to 25 MPa 0 to 3 625 psi Confirm that F R lever is in Neutral positio n properly Start the engine and set throttle switch to Full position Turn steering wheel to operate relief valve Then read pressure indicated by pressure gauge Standard maximum circuit pressure orbitroll relief pressure c...

Page 162: ... 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 163: ...king brake switch button Start the engine and set throttle switch to Full position Measure pressure when speed change switch is in and positions and F R lever in neutral forward and reverse positions respectively Allowable pump case pressure 0 3 MPa 43 5 psi or less The number such as 1 12 appearing in above illustrations is consistent with lead line numbers shown in illustration of propulsion pum...

Page 164: ...ure gauge through adapter ⓟ Adapter ⓟ G 1 2 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 position Start the engine and set throttle switch to Full position Press F R lever vibration switch ON Measure pressure when vibration amplitude selector switch is in and positions respectively Turn F R lever vibration sw...

Page 165: ...si Apply parking brake by pressing parking brake switch button Start the engine and set throttle switch to Full position Measure pressure when speed change switch is in and positions and F R lever in neutral forward and reverse positions respectively Allowable motor case pressure 0 3 MPa 43 5 psi or less SV510 ޓ 08020 Propulsion motor front 1 SV510 ޓ 08020 Propulsion motor front 1 SV510 ޓ 08021 Pr...

Page 166: ...ressure 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 position Start the engine and set throttle switch to Full position Press F R lever vibration switch ON Measure pressure when vibration amplitude selector switch is in and positions respectively Turn F R lever vibrati...

Page 167: ...side are positioned by notches Firmly secure the F R lever in neutral position Firmly secure both ends of control cable 2 Specified dimension of control cable ends a 238 mm 9 37 in Specified dimension of control cable ends b 210 mm 8 27 in Confirm the stroke of control lever 3 on propulsion pump side Specified dimension of control lever c 25 mm 1 0 in SV510 ޓ 08019 2 a 1 N F R SV510 ޓ 08019 2 a 1 ...

Page 168: ...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 169: ... 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...

Page 170: ...learance between braking discs N m Rotate up to a torque of 8 to 10 N m 5 9 to 7 4 lbf ft Rotate pinion 4 clockwise to determine the required clearance of 1 mm 0 04 in Clearance change rate 0 25 mm turn 0 010 in turn Install lock plate 3 and lock with bolt 2 N m 2 Bolt 10 to 11 N m 7 4 to 8 1 lbf ft SV510 ޓ 08026 2 3 4 SV510 ޓ 08026 2 3 4 SV510 ޓ 08025 4 3 2 SV510 ޓ 08025 4 3 2 ...

Page 171: ...TROUBLESHOOTING ...

Page 172: ......

Page 173: ...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 174: ...ecting surfaces on the connector side Wire number wire size and wire color are shown as above in electrical circuit diagrams 100 3 BW Wire color AVS wire size Wire number SW880 11020 B Black BW Black White stripe BY Black Yellow stripe BR Black Red stripe BG Black Green stripe BL Black Blue stripe O Orange YO Yellow Orange stripe W White WR White Red stripe WB White Black stripe WL White Blue stri...

Page 175: ...internally Since connectors are not numbered be sure to affix alignment marks so that you can restore them to their original condition Before making a diagnosis check related connectors for faulty connections Check by disconnecting and reconnecting related connectors several times Before proceeding to the next step be sure to return the disconnected connectors to their original condition When diag...

Page 176: ...equipment A measuring resistance between terminals 1 and 3 1 2 3 3 4 2 5 1 2 3 1 2 3 1 GW750 2 10004 Equipment A Connector Harness Equipment A Ohmmeter tester Equipment B Main power source of equipment B Signal from equipment A Power to equipment A Ground of equipment A Inspection procedure Disconnect the connector of equipment A Connect the test probe to connector terminal 1 of equipment A and th...

Page 177: ...rness such as broken wire 10 Ω or higher measured value 1 3 Measuring resistance of grounding wire measuring resistance between terminal 5 of equipment B and ground 1 2 3 4 5 5 1 GW750 2 10006 Connector A Harness Ohmmeter tester Main power source of equipment B Equipment B Battery Equipment B Inspection procedure Disconnect the connector of equipment B Connect the test probe to connector terminal ...

Page 178: ...ower to equipment A Equipment B Equipment B Equipment A GW750 2 10007 Inspection procedure Connect the connectors of equipment A and that of equipment B Connect the test probe to connector terminal 3 of equipment A and the test probe to connector terminal 1 of equipment A and measure the voltage Note that reversing the connector terminals between the probes and changes the result of the measuremen...

Page 179: ... connected in position contact the tester probes to the terminals without disconnecting the connector The following methods are available Measurement using a test harness Prepare the test harness for the measurement Measurement from the backside of connector Insert a wire from the backside of the connector Measurement on a lead cable Remove the bundling tape from the harness to separate each cable...

Page 180: ...on procedure Disconnect the connector of equipment A and connect the test harness Connect the test probe to connector terminal 1 harness side of equipment A and the test probe to connector terminal 1 equipment side of equipment A and measure the current Note that reversing the connector terminals between the probes and changes the result of the measurement Be sure to connect the probe to the power...

Page 181: ...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 182: ...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 183: ... is not currently active The ENGINE STOP light is red and indicates the need to stop the engine as soon as it can be safely done The engine must remain shutdown until the fault can be repaired The WARNING light is orange and indicates the need to repair the fault at the first available opportunity Maintenance type fault codes will flash the orange warning light for 30 seconds after the starter swi...

Page 184: ...e will flash in ENGINE STOP red There will be a one or two second pause between each number When the number has finished flashing in red an orange light will appear again 3 The lights flash each fault code out three times before advancing to the next code To skip to the next fault code move the INC DEC switch momentarily to the increment position You can go back to the previous fault code by momen...

Page 185: ...he engine protection warning limit None on performance 144 Orange Engine coolant temperature 1 sensor circuit Voltage above normal or shorted to high source High signal voltage or open circuit detected at engine coolant temperature circuit Possible white smoke Fan will stay ON if controlled by ECM No engine protection for engine coolant temperature 145 Orange Engine coolant temperature 1 sensor ci...

Page 186: ...one on performance 197 Orange Coolant level Data valid but below normal operation range Moderately severe level Low engine coolant level detected None on performance 221 Orange Barometric pressure sensor circuit Voltage above normal or shorted to high source High signal voltage detected at barometric pressure circuit Engine power derate 222 Orange Barometric pressure sensor circuit Voltage below n...

Page 187: ...it at all One or more multiplexed devices will not operate properly One or more symptoms will occur 286 Orange SAE J1939 multiplexing configuration error Out of calibration The ECM expected information from a multiplexed device but only received a portion of the necessary information At least one multiplexed device will not operate properly 287 Orange SAE J1939 multiplexed accelerator pedal or lev...

Page 188: ...performance 343 Orange Electronic control module warning internal hardware failure Bad intelligent device or component No performance effects or possible severe power derate 351 Orange Injector power supply Bad intelligent device or component The ECM measured injector boost voltage is low Possible smoke low power engine misfire and or engine will not start 352 Orange Sensor supply 1 circuit Voltag...

Page 189: ... metering rail 1 pressure sensor circuit Voltage above normal or shorted to high source High signal voltage detected at the rail fuel pressure sensor circuit Power and or speed derate 452 Orange Injector metering rail 1 pressure sensor circuit Voltage below normal or shorted to low source Low signal voltage detected at the rail fuel pressure sensor circuit Power and or speed derate 488 Orange Inta...

Page 190: ...o noticeable performance effects or engine dying or hard starting Fault information trip information and maintenance monitor data may be inaccurate 1376 Maintenance Engine camshaft speed position sensor Data erratic intermittent or incorrect The ECM has detected an error in the engine camshaft speed position signal Possible poor starting Engine power derate 1383 Orange Intake manifold 1 pressure s...

Page 191: ...vel The ECM has detected that fuel pressure is lower than commanded pressure Possibly hard to start low power or engine smoke 2261 Maintenance Fuel pump delivery pressure Data valid but above normal operation range Least severe level Fuel pump supply pressure high Low power or engine smoke 2262 Maintenance Fuel pump delivery pressure Data valid but below normal operation range Least severe level F...

Page 192: ...ittent synchronization Possible low power 2377 Orange Fan control circuit Voltage above normal or shorted to high source No action taken by the ECM 2555 Orange Intake air heater 1 circuit Voltage above normal or shorted to high source High voltage detected at the intake air heater signal circuit The intake air heater may be ON or OFF all the time 2556 Orange Intake air heater 1 circuit Voltage bel...

Page 193: ...corrected After the error has been corrected the traction control box will indicate the next error code if one is present The traction control system will not operate properly with active error codes The error codes are assigned a number ranging from 1 to 99 The error codes show up with a four blink burst to indicate the start of an error code This is followed by long blinks representing the tens ...

Page 194: ...3W BATTERY 1 BATTERY 2 ALTERNATOR 95A PHASE IGNITION INDICATOR BATTERY GROUND 47 SAE J1939 37 SAE J1939 SHIELD 46 SAE J1939 25 DEC CRUISE SET SW 34 SW RETURN 24 INC CRUISE RESUME SW 2 DIAGNOSTIC SW 39 KEY SW SIGNAL ISC2 SW 16 ISC1 SW 4 44 WARNING LAMP 43 STOP LAMP 4 BATTERY 3 BATTERY ENGINE ECM 72 2BrY 72 2BrY 70 8W 70 71 8BW G X AV100 STARTER RELAY 25 1 25BW 12 R 30 1 25RY 20 1 25RW 3 5R 23 5RG 1...

Page 195: ... Switch Check continuity between O O according to starter switch connection table 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 30 and chassis ground Standard voltage 12 V or more 2 When starter switch is START measure vol...

Page 196: ...3W BATTERY 1 BATTERY 2 ALTERNATOR 95A PHASE IGNITION INDICATOR BATTERY GROUND 47 SAE J1939 37 SAE J1939 SHIELD 46 SAE J1939 25 DEC CRUISE SET SW 34 SW RETURN 24 INC CRUISE RESUME SW 2 DIAGNOSTIC SW 39 KEY SW SIGNAL ISC2 SW 16 ISC1 SW 4 44 WARNING LAMP 43 STOP LAMP 4 BATTERY 3 BATTERY ENGINE ECM 72 2BrY 72 2BrY 70 8W 70 71 8BW G X AV100 STARTER RELAY 25 1 25BW 12 R 30 1 25RY 20 1 25RW 3 5R 23 5RG 1...

Page 197: ...chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between F R lever switch terminal NC outlet wire W and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG F R lever switch is faulty Replace F R lever switch 7 Interlock Relay 1 When starter switch is ON measure voltage between interlock relay terminal 2 inlet wire W and chassi...

Page 198: ...t mounted on engine 3 ECM cooling plate 4 To fuel supply pump 5 To fuel filter 6 Fuel filter head 7 Fuel filter 8 To high pressure pump 9 High pressure pump 10 To fuel rail 11 Fuel rail 12 To injectors 13 High pressure connector 14 Injector 15 Fuel return from injectors and fuel rail to fuel filter head 16 Fuel return from high pressure pump to fuel filter head 17 Fuel return manifold 18 To fuel t...

Page 199: ...in tank with an appropriate one 2 Fuel Prefilter with sedimenter Fuel Filter Check that water in sedimenter is not above upper limit If amount of water exceeds limit engine does not start Drain water Check filter for clogging Insufficient supply of proper fuel due to clogging of filter NOTICE Priming should be performed whenever filter is replaced Replace filter Bleed filter 3 Fuel Supply Pump Dis...

Page 200: ...3W BATTERY 1 BATTERY 2 ALTERNATOR 95A PHASE IGNITION INDICATOR BATTERY GROUND 47 SAE J1939 37 SAE J1939 SHIELD 46 SAE J1939 25 DEC CRUISE SET SW 34 SW RETURN 24 INC CRUISE RESUME SW 2 DIAGNOSTIC SW 39 KEY SW SIGNAL ISC2 SW 16 ISC1 SW 4 44 WARNING LAMP 43 STOP LAMP 4 BATTERY 3 BATTERY ENGINE ECM 72 2BrY 72 2BrY 70 8W 70 71 8BW G X AV100 STARTER RELAY 25 1 25BW 12 R 30 1 25RY 20 1 25RW 3 5R 23 5RG 1...

Page 201: ...hen throttle switch is in FULL position 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 1 When starter switch is ON and throttle switch is in FULL position measure voltage between throttle relay terminal a inlet wire RW and chassis ground Standa...

Page 202: ...3W BATTERY 1 BATTERY 2 ALTERNATOR 95A PHASE IGNITION INDICATOR BATTERY GROUND 47 SAE J1939 37 SAE J1939 SHIELD 46 SAE J1939 25 DEC CRUISE SET SW 34 SW RETURN 24 INC CRUISE RESUME SW 2 DIAGNOSTIC SW 39 KEY SW SIGNAL ISC2 SW 16 ISC1 SW 4 44 WARNING LAMP 43 STOP LAMP 4 BATTERY 3 BATTERY ENGINE ECM 72 2BrY 72 2BrY 70 8W 70 71 8BW G X AV100 STARTER RELAY 25 1 25BW 12 R 30 1 25RY 20 1 25RW 3 5R 23 5RG 1...

Page 203: ... Check point Check Cause Action 1 F R Lever Switch When starter switch is OFF and F R lever is in forward or reverse position check continuity between F R lever switch terminal COM and terminal NC There is no continuity in normal condition If there is continuity F R lever switch is faulty Replace F R lever switch ...

Page 204: ...C2 P8 C2 P7 C2 P3 C2 P2 C2 P1 C2 P10 C2 P11 C2 P12 A B C POWER PULSE GROUND B SOL PARKING BRAKE SOLENOID 1 4 5 2 4 1 SPEED CHANGE SWITCH REAR MOTOR ROTATION SENSOR FRONT MOTOR ROTATION SENSOR REAR MOTOR PROPORTIONAL SOLENOID SOL 40 1 25G 40 G 36 LgR 38 GR 37 BrW X B X B FRONT MOTOR PROPORTIONAL SOLENOID SOL X B 53 WG 56 GR 60 GB 68 Lg 69 L 57 WL X B X B 40 G 191 Br 192 LR 193 X SHIELD 190 LW 181 L...

Page 205: ...ch 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 or more If above item 1 is OK and item 2 is NG foot brake switch is faulty Replace foot brake switch 3 Parking Brake Switch 1 When star...

Page 206: ...C2 P8 C2 P7 C2 P3 C2 P2 C2 P1 C2 P10 C2 P11 C2 P12 A B C POWER PULSE GROUND B SOL PARKING BRAKE SOLENOID 1 4 5 2 4 1 SPEED CHANGE SWITCH REAR MOTOR ROTATION SENSOR FRONT MOTOR ROTATION SENSOR REAR MOTOR PROPORTIONAL SOLENOID SOL 40 1 25G 40 G 36 LgR 38 GR 37 BrW X B X B FRONT MOTOR PROPORTIONAL SOLENOID SOL X B 53 WG 56 GR 60 GB 68 Lg 69 L 57 WL X B X B 40 G 191 Br 192 LR 193 X SHIELD 190 LW 181 L...

Page 207: ...nal 5 outlet wire LY and chassis ground Standard voltage 12 V or more If above item 1 is OK and 2 or 3 is NG speed change switch is faulty Replace speed change switch 2 Traction Control Box 1 When starter switch is ON measure voltage between traction control box terminal C1 P2 inlet wire G and chassis ground Standard voltage 12 V or more 2 When starter switch is ON and speed change switch is in po...

Page 208: ...C2 P8 C2 P7 C2 P3 C2 P2 C2 P1 C2 P10 C2 P11 C2 P12 A B C POWER PULSE GROUND B SOL PARKING BRAKE SOLENOID 1 4 5 2 4 1 SPEED CHANGE SWITCH REAR MOTOR ROTATION SENSOR FRONT MOTOR ROTATION SENSOR REAR MOTOR PROPORTIONAL SOLENOID SOL 40 1 25G 40 G 36 LgR 38 GR 37 BrW X B X B FRONT MOTOR PROPORTIONAL SOLENOID SOL X B 53 WG 56 GR 60 GB 68 Lg 69 L 57 WL X B X B 40 G 191 Br 192 LR 193 X SHIELD 190 LW 181 L...

Page 209: ...r terminal PULSE outlet wire GR and chassis ground Standard pulse 49 pulses rotation If above items 1 and 2 are OK and item 3 is NG rear motor rotation sensor is faulty Replace rear motor rotation sensor 11 to 19 1 Connector Check front motor rotation sensor connector and traction control box terminal C1 P8 C1 P9 and C2 P2 for corrosion breakage bending and looseness If any abnormality is found co...

Page 210: ...C2 P8 C2 P7 C2 P3 C2 P2 C2 P1 C2 P10 C2 P11 C2 P12 A B C POWER PULSE GROUND B SOL PARKING BRAKE SOLENOID 1 4 5 2 4 1 SPEED CHANGE SWITCH REAR MOTOR ROTATION SENSOR FRONT MOTOR ROTATION SENSOR REAR MOTOR PROPORTIONAL SOLENOID SOL 40 1 25G 40 G 36 LgR 38 GR 37 BrW X B X B FRONT MOTOR PROPORTIONAL SOLENOID SOL X B 53 WG 56 GR 60 GB 68 Lg 69 L 57 WL X B X B 40 G 191 Br 192 LR 193 X SHIELD 190 LW 181 L...

Page 211: ...d resistance 5 7 Ω If resistance is abnormal rear motor proportional solenoid is faulty If resistance is normal traction control box is faulty Replace rear motor proportional solenoid or traction control box 31 to 35 1 Connector Check front motor proportional solenoid connector and traction control box terminal C2 P9 for corrosion breakage bending and looseness If any abnormality is found connecto...

Page 212: ...C2 P8 C2 P7 C2 P3 C2 P2 C2 P1 C2 P10 C2 P11 C2 P12 A B C POWER PULSE GROUND B SOL PARKING BRAKE SOLENOID 1 4 5 2 4 1 SPEED CHANGE SWITCH REAR MOTOR ROTATION SENSOR FRONT MOTOR ROTATION SENSOR REAR MOTOR PROPORTIONAL SOLENOID SOL 40 1 25G 40 G 36 LgR 38 GR 37 BrW X B X B FRONT MOTOR PROPORTIONAL SOLENOID SOL X B 53 WG 56 GR 60 GB 68 Lg 69 L 57 WL X B X B 40 G 191 Br 192 LR 193 X SHIELD 190 LW 181 L...

Page 213: ...starter switch is ON measure voltage between backup buzzer switch terminal COM inlet wire R and chassis ground Standard voltage 12 V or more 2 When starter switch is ON and F R lever is in reverse position measure voltage between backup buzzer switch terminal NO outlet wire LW and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG backup buzzer switch is faulty Rep...

Page 214: ...TCH NO COM 11 12 13 14 1 FUSE BOX 20A 2 3 4 5 6 7 8 9 10 20A 20A 20A 15A 15A 15A 15A 15A 20A COM NO NC B SOL PARKING BRAKE SOLENOID 1 4 36 LgR 38 GR 37 BrW X B 12 R 12 R 13 W 5 3 TO COMBINATION METER TO INTERLOCK RELAY F R LEVER SWITCH REVERSE FORWARD PARKING BRAKE SWITCH ...

Page 215: ... between foot brake switch terminal NO outlet wire LgR and chassis ground There is no electricity in normal condition If electricity flows foot brake switch is faulty Replace foot brake switch 3 Parking Brake Switch When starter switch is ON measure voltage between parking brake switch terminal 3 outlet wire BrW and chassis ground There is no electricity in normal condition If electricity flows pa...

Page 216: ...NIT A B C D E F G A G F E D C B 2 97 RW 97 RW 81 RG 11 Y 9 YR 10 YB 11 Y 30 RY 92 WL 91 LW 120 LB 1 4 THROTTLE SWITCH 3 5 6 30 1 25RY X 1 3 2 VIBRATION MODE CHANGE SWITCH Br G YB 10 YR 9 F R LEVER VIBRATION SWITCH VIBRATION AMPLITUDE SELECTOR SWITCH 1 2 VIBRATOR SOLENOID SOL HIGH LOW X B B 4 1 2 5 b a TO THROTTLE RELAY TO ENGINE ECM ...

Page 217: ...bration amplitude selector switch terminal 5 outlet wire YR and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 or 3 is NG vibration amplitude selector switch is faulty Replace vibration amplitude selector switch 3 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 S...

Page 218: ... E F G A G F E D C B 2 97 RW 97 RW 81 RG 11 Y 9 YR 10 YB 11 Y 30 RY 92 WL 91 LW 120 LB 1 4 THROTTLE SWITCH 3 30 1 25RY X 1 3 2 VIBRATION MODE CHANGE SWITCH Br G YB 10 YR 9 F R LEVER VIBRATION SWITCH VIBRATION AMPLITUDE SELECTOR SWITCH 1 2 VIBRATOR SOLENOID SOL HIGH LOW X B B 4 1 2 5 b a TO THROTTLE RELAY TO ENGINE ECM DIODE UNIT 5 6 ...

Page 219: ...s ground Standard voltage 12 V or more 2 When starter switch is ON and vibration amplitude selector switch is in position measure voltage between vibration amplitude selector switch terminal 2 outlet wire YB and chassis ground Standard voltage 12 V or more 3 When starter switch is ON and vibration amplitude selector switch is in position measure voltage between vibration amplitude selector switch ...

Page 220: ... E F G A G F E D C B 2 97 RW 97 RW 81 RG 11 Y 9 YR 10 YB 11 Y 30 RY 92 WL 91 LW 120 LB 1 4 THROTTLE SWITCH 3 30 1 25RY X 1 3 2 VIBRATION MODE CHANGE SWITCH Br G YB 10 YR 9 F R LEVER VIBRATION SWITCH VIBRATION AMPLITUDE SELECTOR SWITCH 1 2 VIBRATOR SOLENOID SOL HIGH LOW X B B 4 1 2 5 b a TO THROTTLE RELAY TO ENGINE ECM DIODE UNIT 5 6 ...

Page 221: ...above item 1 is OK and item 2 is NG vibration mode change switch is faulty Replace vibration mode change switch 2 F R Lever Vibration Switch 1 When starter switch is ON measure voltage between F R lever vibration switch terminal 1 inlet wire Br and chassis ground Standard voltage 12 V or more 2 When starter switch is ON and F R lever vibration switch is pressed once measure voltage between F R lev...

Page 222: ...OW X B B 4 1 2 5 b a 95E41R N100 95E41R N100 AV60 8WY 4 76 COM NO E X B BATTERY RELAY BATTERY F L 75A 3 8Rx4 BR C B ACC TACHO METER SENSOR CONTROL BOX B B HYDRAULIC FILTER SWITCH 1 HYDRAULIC FILTER SWITCH 2 R B Br LB LR LR LW L GY GR GW G W BrW WR YG YW YR Y COMB METER LAMP GROUND SPRINKLER LIQUID SPRAY TURN SIGNAL L TURN SIGNAL R FLOOD LAMP VIBRATOR GLOW PLUG PARKING BRAKE HYD FILTER WARNING OIL ...

Page 223: ...ause Action 1 Bulbs Check if bulbs have burned out or are poorly contacted Bulbs are faulty or poorly connected Replace bulbs 2 Combination Meter Backlighting When starter switch is ON measure voltage between combination meter backlighting terminal inlet wire No 42 RY and ground terminal wire B Standard voltage 12 V or more If above item is OK and combination meter does not turn on combination met...

Page 224: ...OW X B B 4 1 2 5 b a 95E41R N100 95E41R N100 AV60 8WY 4 76 COM NO E X B BATTERY RELAY BATTERY F L 75A 3 8Rx4 BR C B ACC TACHO METER SENSOR CONTROL BOX B B HYDRAULIC FILTER SWITCH 1 HYDRAULIC FILTER SWITCH 2 R B Br LB LR LR LW L GY GR GW G W BrW WR YG YW YR Y COMB METER LAMP GROUND SPRINKLER LIQUID SPRAY TURN SIGNAL L TURN SIGNAL R FLOOD LAMP VIBRATOR GLOW PLUG PARKING BRAKE HYD FILTER WARNING OIL ...

Page 225: ...minal 1 inlet wire LgB and chassis ground Lamp check relay terminal 5 outlet wire B and chassis ground There is no electricity in normal condition If above item 1 is OK and item 2 is NG lamp check relay is faulty If above items 1 and 2 is OK and item 3 is NG alternator is faulty Repair or replace lamp check relay or alternator 3 Combination Meter Lamp check 1 When starter switch is ON measure volt...

Page 226: ...OW X B B 4 1 2 5 b a 95E41R N100 95E41R N100 AV60 8WY 4 76 COM NO E X B BATTERY RELAY BATTERY F L 75A 3 8Rx4 BR C B ACC TACHO METER SENSOR CONTROL BOX B B HYDRAULIC FILTER SWITCH 1 HYDRAULIC FILTER SWITCH 2 R B Br LB LR LR LW L GY GR GW G W BrW WR YG YW YR Y COMB METER LAMP GROUND SPRINKLER LIQUID SPRAY TURN SIGNAL L TURN SIGNAL R FLOOD LAMP VIBRATOR GLOW PLUG PARKING BRAKE HYD FILTER WARNING OIL ...

Page 227: ...35 YW and ground terminal wire B Standard voltage 12 V or more If above item is OK and no abnormality found in tachometer sensor or control box combination meter is faulty Replace combination meter 4 Harness Connecting Between Terminals Measure resistance of harness connecting between terminals Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 2...

Page 228: ...OW X B B 4 1 2 5 b a 95E41R N100 95E41R N100 AV60 8WY 4 76 COM NO E X B BATTERY RELAY BATTERY F L 75A 3 8Rx4 BR C B ACC TACHO METER SENSOR CONTROL BOX B B HYDRAULIC FILTER SWITCH 1 HYDRAULIC FILTER SWITCH 2 R B Br LB LR LR LW L GY GR GW G W BrW WR YG YW YR Y COMB METER LAMP GROUND SPRINKLER LIQUID SPRAY TURN SIGNAL L TURN SIGNAL R FLOOD LAMP VIBRATOR GLOW PLUG PARKING BRAKE HYD FILTER WARNING OIL ...

Page 229: ... Check Cause Action 1 Fuel Unit Disconnect harness and measure resistance of fuel unit Standard resistance 10 Ω with float in Full position 90 Ω with float in Empty position If resistance is abnormal fuel unit is faulty Replace fuel unit 2 Combination Meter Fuel meter When starter switch is ON measure voltage between combination meter battery terminal inlet wire No 35 YW and ground terminal wire B...

Page 230: ...OW X B B 4 1 2 5 b a 95E41R N100 95E41R N100 AV60 8WY 4 76 COM NO E X B BATTERY RELAY BATTERY F L 75A 3 8Rx4 BR C B ACC TACHO METER SENSOR CONTROL BOX B B HYDRAULIC FILTER SWITCH 1 HYDRAULIC FILTER SWITCH 2 R B Br LB LR LR LW L GY GR GW G W BrW WR YG YW YR Y COMB METER LAMP GROUND SPRINKLER LIQUID SPRAY TURN SIGNAL L TURN SIGNAL R FLOOD LAMP VIBRATOR GLOW PLUG PARKING BRAKE HYD FILTER WARNING OIL ...

Page 231: ...essure relay is faulty Replace oil pressure relay 2 Combination Meter Oil pressure warning lamp 1 When starter switch is ON measure voltage between combination meter battery terminal inlet wire No 35 YW and ground terminal wire B Standard voltage 12 V or more 2 When starter switch is ON measure voltage between combination meter oil pressure terminal outlet wire No 8 YL and chassis ground Standard ...

Page 232: ...OW X B B 4 1 2 5 b a 95E41R N100 95E41R N100 AV60 8WY 4 76 COM NO E X B BATTERY RELAY BATTERY F L 75A 3 8Rx4 BR C B ACC TACHO METER SENSOR CONTROL BOX B B HYDRAULIC FILTER SWITCH 1 HYDRAULIC FILTER SWITCH 2 R B Br LB LR LR LW L GY GR GW G W BrW WR YG YW YR Y COMB METER LAMP GROUND SPRINKLER LIQUID SPRAY TURN SIGNAL L TURN SIGNAL R FLOOD LAMP VIBRATOR GLOW PLUG PARKING BRAKE HYD FILTER WARNING OIL ...

Page 233: ...ge 12 V or more 3 When starter switch is ON measure voltage between diode unit terminal A 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 unit 3 Combination Meter Vibration indicator When starter switch is ON and vibration amplitude selector switch is or position measure voltage between combination meter vibration i...

Page 234: ...OW X B B 4 1 2 5 b a 95E41R N100 95E41R N100 AV60 8WY 4 76 COM NO E X B BATTERY RELAY BATTERY F L 75A 3 8Rx4 BR C B ACC TACHO METER SENSOR CONTROL BOX B B HYDRAULIC FILTER SWITCH 1 HYDRAULIC FILTER SWITCH 2 R B Br LB LR LR LW L GY GR GW G W BrW WR YG YW YR Y COMB METER LAMP GROUND SPRINKLER LIQUID SPRAY TURN SIGNAL L TURN SIGNAL R FLOOD LAMP VIBRATOR GLOW PLUG PARKING BRAKE HYD FILTER WARNING OIL ...

Page 235: ...tion Meter Parking brake indicator 1 When starter switch is ON measure voltage between combination meter battery terminal inlet wire No 35 YW and ground terminal wire B Standard voltage 12 V or more 2 When starter switch is ON and parking brake is applied measure voltage between combination meter parking brake terminal outlet wire No 38 GR and chassis ground Standard voltage 12 V or more If above ...

Page 236: ... 12 13 14 1 FUSE BOX 20A 2 3 4 5 6 7 8 9 10 20A 20A 20A 15A 15A 15A 15A 15A 20A C O M N O N C HORN HORN SWITCH HORN RELAY 5 3 1 2 2 GB 30 RY 30 RY 34 LgW 33 Lg X B X B 12 R 30 1 25RY 12 R BACKUP BUZZER X B 2 GB BACKUP BUZZER SWITCH REVERSE FORWARD ...

Page 237: ...ure resistance of harness connecting between terminals Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 2 7 12 Backup buzzer does not sound Reference Fig 2 7 2 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 bac...

Page 238: ...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 239: ... flows in return circuit to tank If oil is flowing repair solenoid valve or replace it if necessary 5 Suction Filter for Charge Pump Charge pump flow is reduced due to clogged filter Clean suction filter or replace it if necessary 6 Propulsion Circuit Pressure Circuit does not obtain required pressure because setting pressure of high pressure relief is low Measure propulsion circuit pressure If lo...

Page 240: ...Check and adjust F R lever linkage or replace it if necessary 3 Charge Circuit Pressure Stroke of propulsion pump swash plate is small because charge pressure is low decreasing discharge rate of propulsion pump Measure charge pressure If low check and adjust charge relief valve or replace it if necessary Insufficient charge pump discharge Repair charge pump or replace it if necessary Charge pressu...

Page 241: ...ont or Rear Motor Proportional Solenoid Valve Vehicle speed is not switched because front or rear motor proportional solenoid valve spool does not move Repair front or rear motor proportional solenoid valve or replace it if necessary 2 Front or Rear Propulsion Motor Swash Plate Stroke Cylinder Faulty front or rear propulsion motor swash plate stroke cylinder Repair front or rear propulsion motor o...

Page 242: ...lic oil in circuit to rise Measure propulsion circuit pressure If high decrease propulsion load 5 Suction Filter for Charge Pump Load of charge pump increases due to clogged filter causing temperature of hydraulic oil in circuit to rise Clean suction filter or replace it if necessary 6 Hydraulic Oil Filter 1 Charge circuit pressure increases due to clogged filter Clean hydraulic oil filter 1 or re...

Page 243: ... it if necessary 4 Vibrator Circuit Pressure Circuit does not obtain required pressure because setting pressure of high pressure relief is low Measure vibrator circuit pressure If low check and adjust high pressure relief valve or replace them if necessary 5 Vibrator Solenoid Valve Vibrator pump cannot discharge oil because spool of vibrator solenoid valve does not shift Repair vibrator solenoid v...

Page 244: ...ure in vibrator motor case is not within allowable range repair vibrator motor or replace it if necessary Decrease in vibrator motor rpm due to internal leakage in vibrator motor Measure drain quantity from vibrator motor If drain quantity is larger than standard value repair vibrator motor or replace it if necessary 5 Vibrator Pump Insufficient discharge rate from vibrator pump due to reduced eff...

Page 245: ...for Charge Pump Load of charge pump increases due to clogged filter causing temperature of hydraulic oil in circuit to rise Clean suction filter or replace it if necessary 5 Hydraulic Oil Filter 2 Charge circuit pressure increases due to clogged filter Clean hydraulic oil filter 2 or replace it if necessary 3 3 6 Abnormal noise from vibrator system Check point Cause Check Action 1 Vibrator Bearing...

Page 246: ...creases due to internal leakage of steering cylinder Repair steering cylinder or replace it if necessary 5 Suction Filter for Charge Pump Charge pump discharge rate decreases due to clogged filter Clean suction filter or replace it if necessary 6 Charge Pump Discharging pressure is insufficient due to efficiency degradation of charge pump Measure steering circuit pressure If low replace charge pum...

Page 247: ...valve If load is excessively heavy relief valve is open causing temperature of hydraulic oil in circuit to rise Measure steering circuit pressure If high decrease steering load 4 Suction Filter for Charge Pump Load of 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 steeri...

Page 248: ...Printed in Japan 2011 09 50 0 H S 0412 99023 0 30315 D 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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