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Sakai SV540 Series, Shop Manual

Introducing the Sakai SV540 Series - a high-performance machine built for superior results. Ensure the longevity of your investment with our comprehensive Operating & Maintenance Instructions manual available for free download at manualshive.com. Maximize productivity and minimize downtime with this essential guide to keep your equipment running smoothly.

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2. SYSTEM CIRCUIT DIAGRAM

2-1. Electrical Circuit Diagram

0418-99022-0-10926-0

ENGINE ECM (CM2250)

J3(60PIN)

T/

C

 CONTROLLE

R

RL

VIBRATOR PROPORTIONAL

SOLENOID 2

SOL

VIBRATOR PROPORTIONAL

SOLENOID 1

SOL

EC

O

 CONTROLLER

130 15B

130 15B

15WR

90

15WR

90

15L

19

15W

18

49

15

B

49 15B

49 15B

B

121

B

121

B

121

B

121

36 LgR

B

104

LB

120

1.25RG

116

B

104

COM

W

BY

Lg

Y

11

Y

11

Y

11

Y

11

5kΩ

2

1

4

5

1kΩ

1kΩ

FOR VIBRATOR CALCULATION JIG

BR

100

BR

100

32 BY

28 LgW

28 LgW

28 LgW

1.25R

122

24 1.25BR

5 1.25RB

WB

74

GB

63

28

Lg

W

LgW

28

B

104

B

104

B

104

WB

74

120 LB

G

87

1.25RG

116

GB

63

WB

117

1.25RL
73

1.25RL

73

1.25RB

44

BW

94

BW

94

118 WR

GB

63

GB

63

GB

63

GB

63

GB

63

L

86

20

1.25RW

AV30

AV60

AV60

59 8W

B

X

3

4

5

2

1

3

5

2

1

3

5

2

1

1

2

5

4

3

1

2

5

4

3

2

1

3

FUSE

125A

B

B

HEATER

125A

FUSE

66 3B

CYLINDER

BLOCK

B

104

AV30

67 3W

DUAL OUTPUT B(+) 5

INTAKE AIR ) 4

OUTPUT RETURN(-) 13

SWITCH AND TEMPERATURE SENSOR RETURN 19

DIAGNOSTIC 59

STARTER LOCKOUT 15

33 TACHOMETER

BATTERY(-)32

BATTERY(-)31

12(+)BATTERY

11(+)BATTERY

6 WAIT TO STOP LAMP

BATTERY(-)22

BATTERY(-)21

18 CAN A(-)

17 CAN A(+)

52 SENSOR SUPPLY(POWER)

44 COOLANT LEVEL(SIGNAL)

43 OEM SENSOR(SIGNAL RETURN)

3 KEY SWITCH SIGNAL

ISC2 SWITCH(MIDDLE)38

ISC1 SWITCH(FULL)39

16 WARNING LAMP

8 STOP LAMP

2(+)BATTERY

1(+)BATTERY

BY

98

67 W
67 W
67 W
67 W

GY

88

Y

89

L

93

YW

99

FUEL SENSOR

ENGINE
HARNESS

GL

111

BrR

112

RB

64

A

B

C

SENSOR

BR

101

LgR

102

RW

103

G

85

83 L

66 B
66 B
66 B
66 B

91 LW

92 WL

117 WB

L

86

Br

96

BW

94

GB

63

G

87

G

105

RL

73

GW

55

B

X

1.25RG
128

2B

X

X 1.25B

126 1.25WB

126 1.25WB

CIGARETTE

126 1.25WB

1.25W

B

126

1.25RB
127

RL

73

X 1.25B

ACC

CAN -

CAN +

CONTROL P.C.

120Ω

L

113

G

57

120Ω

1

2

5

4

3

GW

80

OPTION

3WR

65

W

119

5R

78

BG

11

4

5RG

23

5R

3

5R

3

BY

4

R

OPTION

R

Y

30

WR

11

8

WR

123

1.25R

122

1.25RB
44

G
40

L

39

YW

35

MOTOR SPEED CHANGE 
SOLENOID (FRONT) 

1.25R

W

20

X B

TACHOMETER SENSOR

B

17

YR

THERMO UNIT

C1-P5

C1-P1

C2-P6

C2-P1

C2-P2

C1-P9

C1-P8

C2-P3

C2-P4

C1-P2

C1-P6

C2-P5

C1-P10

C1-P11

C1-P4

C1-P3

C1-P7

C1-P12

BA

TTE

R

Y

IGNITION

INDCA

TO

R

GROUND

PHASE

ALTERNATOR(70A)

B A

CC

B

R

C

OFF

ON

ST

STARTER SWITCH

STARTER

SWITCH

29 LgB

B

C

BR

1.25Lg
26

24

4 5BY

1.25BR

Lg

B

29

114 BG

36

24

BR

LgR

5BY

20

98 BY

114 BG

4

31 BR

3 8R

1.25RW

23 5RG

3 8R

4 5BY

STARTER MOTOR

BR

1.25B

X

71 8BW

E

X

1.25B

5R

78

AV60

F.L. 65A

F.L. 65A

NO

AV

60

-

+

+

-

AV

30

AV

60

F.L. 75A

75

5G

76

8W

Y

79

5W

L

77

5B

W

F.L. 65A

65

3W

R

5

1.25RB

119 W

8W

59

AV60

G

50

30

GND GND OPEN

REV RATIO SEL.

2

3

4

1

TEMP.CURVE SEL.

2

1

OPEN

OPEN

GND

TEMP. 50-103

SET(NO.0)

(ENGINE:127 PULSE/REV)

127 PULSE/REV SET (NO.7)

COMBINATION METER SET

120Ω

120Ω

WR

J

H

G

F

E

D

C

B

A

118

B

B

B

B

B

B

B

98 BY

OPTION

B

118 WR

120 LB

74 WB

RB

44

1.25RB

44

WR

118

129 R

1.25RL

73

2RG

43

GR

46

GB

45

R

1

R

W

42

RW

97

31 Br

5 1.25RB

24 1.25BR

1.25RL

73

70

35

YW

99

YW

38

GR

Br

31

WR

IOX024-020

 

MCO12-010

L

113

G

57

RW

97

B

X

B

YB

10

YR

9

B

X

B

X

G

105

YB

106

G

105

RY

C1-P5

C1-P7

C1-P6

C1-P8

C1-P4

C1-P3

C1-P2

C1-P1

YR

9

WR

70

G

Br

1

3

2

 2

1

4

5

6

3

2

1

1.25B

R

24

1.25RB

5

1.25RG

41

Y

11

R

W

97

WB

74

1.25R

1

13 W

OPTION

RB

64

B

X

GB

63

YL

8

YB

6

WR

70

YW

35

Y

22

Y

22

BY

32

Br

31

GR

46

GB

45

YL

8

GR

38

B

X

B

X

B

X

B

X

B

X

B

X

113

G

40

YW

99

LgW

62

L

39

LY

51

LW

50

L

G

57

GB

60

L

69

Lg

68

GR

56

W

13

BL

58

BW

54

1.25RG

41

R

129

W

13

B

X

1.25RG

41

1.25RL

73

2RG

43

1.25RG

43

BY

4

1.25G

47

1.25GR

46

1.25GB

45

B

X

LgW

82

BrW

37

LgR

36

GR

38

B

X

B

X

B

X

GB

2

GB

2

LgR

36

R

12

R

12

26

B

X

B

X

B

X

13

5A

12

20A

FUSE BOX 1

11

20A

15

A

15

A

15

A

5A

15

A

15

A

20A

5A

15

A

10

9

8

7

6

5

4

3

2

20A

1

20

5A

14

15

16

17

18

19

30A

10A

20A

15

A

20A

20A

FUSE BOX 2

DIODE UNIT

H

G

F

I
D
C
B
E
A

G

B
A

C

E

F

H

I

D

OPTION

RG

43

RL

48

RL

48

L

39

BY

4

LgW

34

Lg

33

RY

30

RY

30

LgW

82

1.25BW

25

115 1.25BY

B

X

B
X

B

X

B

X

W

13

1.25Lg

4

BY

1.25R

1

1.25R

1

1.25R

1

R

1

RW

42

1.25GB

45

1.25GR

46

R

W

42

1.25RW

42

1.25RW

42

1.25RW

42

LB

120

129

3W

67

LW

124

B

X

1.25YR

125

1.25R

122

WR

123

WR

123

2

1

OPTION

YB

10

Br

31

YB

10

YR

9

Y

11

RG

81

Y

11

1.25RL

73

13 W

R

12

2RG

43

YB

106

R

12

25 1.25BW
70 WR

OPTION

OPTION

CONTROLLER

INDICATOR

PASS COUNTER

W

R

6

R

R

B

W

RADIO

3

4

5

1

2

5

3

4

1

2

3

4

5

2

1

3

4

5

2

1

3

4

5

1

2

1

2

5

4

3

3

4

5

2

1

FORWARD

W

B

R

B

CO

M

NO

NC

COM

NO

NC

REVERSE

REAR LAMP

FRONT LAMP

3

4

5

1

LIGHTING SWITCH

GY

GR

G

FLASHER UNIT

B

L

E

TURN SIGNAL
  SWITCH

FUEL UNIT

11

12

6

1

T.C.LAMP

2

CONNECTION

ENGINE SPEED

1-3,4-5

1-3,4-6

1-2,4-6

FULL

MID

IDLE

THROTTLE SWITCH

CONNECTION

SPEED

1-2,4-5

1-3,4-6

SOL

DIRECTION

PULS

E

POWE

R

GROUND

MOTOR ROTATION 

SENSOR (REAR) 

MOTOR ROTATION 

SENSOR (FRONT) 

5

6

2

3

4

1

SOL

G

B

CL

UNIT

AIR

  

CON

CABIN

G

G

  5

3

4

1

SOL

HORN SWITCH

HORN

HORN RELAY(A-7)

RW

RW

NC NO COM

STOP

X

VIBRATOR

CALCULATION

SWITCH 

C1-P11

(LOW)

C1-P12

 (HI)

C1-P10

(HI)

C1-P9

(LOW)

COMPRESSOR

MAGNET

CLUTCH

CONTROL

PANEL

PRESSURE

SWITCH

THROTTLE

SWITCH

132

133

131

108

109

VIBRATION

SELECT

SWITCH

ROTATORY

LAMP

ROTATORY

LAMP

SWITCH

ECO LAMP

(24V)

MID SPEED CONTROL

RELAY(B-2)

115E41R

(651CCA)

115E41R

(651CCA)

BATTERY

RELAY

BATTERY

STARTER

RELAY

STARTER

LOCKOUT

RELAY(B-6)

MID/FULL

SPEED CONTROL

RELAY(B-3)

DIAGNOSTIC

SWITCH

THROTTLE

RELAY(B-1)

GRID HEATER

RELAY

GRID

HEATER

14 DUAL OUTPUT A(+)

FOR OIL PRESSURE

The wire size is AVS 0.85 unless otherwise specified.

VIBRATION

MODE CHANGE

SWITCH

F-R LEVER

VIBRATION SWITCH

TERMINATING

RESISTOR

ENGINE COOLANT

LEVEL SENSOR

TERMINATING

RESISTOR

ENGINE

DIAGNOSIS

ENGINE OIL PRESSURE

SWITCH RELAY

(B-4)

O

P R

RE

V.

 PULSE INPU

T 

 1

ST

AR

TER SWITCH(ACC)

BA

TTE

R

Y 

24V(+)

GB

OG

LgY

WB

OW

RE

V.

 RA

TIO SEL.2

RE

V.

 RA

TIO SEL.3

RE

V.

 RA

TIO SEL.4

COOLAN

T 

TEMP

. SEL.

1

COOLAN

T 

TEMP

. SEL.

2

COMBINA

TION METER ILLUMINA

TIO

N

WR

TURN SIGNAL(R

)

TURN SIGNAL(L

)

SIDE MARKER LAMP

FLOOD LAMP

W

ATER SPR

AY

LIQUID SPR

AY

VIBR

AT

OR

GROUND

RE

V.

 PULSE INPU

T 

 2

FUEL

 METER

TEMPER

AT

URE METE

R

LAMP

 CHECK

HYDRAULIC OI

L FIL

TER 

WA

RNING

PA

RKING BRAKE

CHARGE 

W

A

RNING

PREHEA

TIN

G

RE

V.

 RA

TIO SEL.1

GL

LR

YL

LW

Br

LB

L

B

Y

YR YW

BrW

GR GW

G

W

GY

RB

ENGINE OI

L PRESSURE 

WA

RNING

B

BrW

YW

G

GW

YR

GR

Y

W

OG

GB

OW

WB

RB

LgY

GY

LW Br LB

L

WR GL

R

LR

P

YL

O

 COMBINATION METER

FLOOD LAMP

(R) (70W)

FLOOD LAMP

(L) (70W)

F-R LEVER

SWITCH

BACKUP

BUZZER

SWITCH

BACKUP

BUZZER

FOOT BRAKE

SWITCH

TERMINATING

RESISTOR

TERMINATING

RESISTOR

SPEED CHANGE SWITCH

SPEED CHANGE

SWITCH

PARKING

BRAKE SOLENOID

PARKING

BRAKE

SWITCH

PARKING INTERLOCK

RELAY(A-2)

INTERLOCK

RELAY(A-1)

BRAKE RELAY

(A-3)

HYDRAURIC OIL 

FILTER SWITCH 1

HYDRAURIC OIL 

FILTER SWITCH 2

HEAD LAMP

(L) (70W)

HEAD LAMP

(R) (70W)

TURN SIGNAL

LAMP(L) (25W)

TURN SIGNAL

LAMP(R) (25W)

LAMP CHECK

RELAY(B-5)

MOTOR PROPORTIONAL

SOLENOID (REAR)

5-003

ELECTRICAL SYSTEM

Summary of Contents for SV540 Series

Page 1: ...SV540 SHOP MANUAL 3498 6418A 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: ...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 SV540D 2 001 1 2 SV540T 2 003 1 3 SV540TF 2 005 1 4 SV540DF 2 007 1 5 SV640D 2 009 1 6 SV640T 2 011 2 TABLE OF STANDARD VALUES 2 1 Engine 2 013 2 2 Propulsion 2 013 2 3 Hydraulic System 2 013 2 4 Steering 2 014 2 5 Brakes 2 014 2 6 Capacities 2 014 3 FUEL AND ...

Page 6: ...2 1 2 Propulsion hydraulic piping front 2 4 005 2 1 3 Propulsion hydraulic piping rear 4 006 2 2 Hydraulic Component Specifications 4 007 2 2 1 Hydraulic pump assembly propulsion vibrator 4 007 2 2 2 Propulsion hydraulic motor front 4 009 2 2 3 Gear box 4 010 2 2 4 Propulsion hydraulic motor rear 4 011 2 2 5 Motor speed change solenoid valve front 4 012 3 VIBRATOR HYDRAULIC SYSTEM 3 1 Vibrator Hyd...

Page 7: ... Harness 2 5 015 4 6 Battery Relay Harness 5 017 4 7 Starter Switch Harness 5 019 4 8 Control Harness 5 020 4 9 Control Switch Harness 5 021 4 10 Motor Rotation Sensor Harness front 5 022 4 11 Fuel Unit Harness 5 023 4 12 Diagnostic Switch Harness 5 024 5 ELECTRICAL COMPONENT SPECIFICATIONS 5 1 Fuse Box 1 5 025 5 2 Fuse Box 2 5 026 5 3 Combination Meter 5 027 6 VIBRATORY DRUM REAR AXLE 1 PRECAUTIO...

Page 8: ... AND ADJUSTMENT 1 INSPECTION AND ADJUSTMENT 1 1 Safety Precautions for Inspection and Adjustment 8 001 1 2 Preparation for Inspection and Adjustment 8 001 1 3 Precautions for Inspection and Adjustment 8 001 1 4 Warm up 8 001 1 5 Inspection and Adjustment of Engine Related Items 8 001 2 MEASUREMENT AND ADJUSTMENT OF PROPULSION CIRCUIT PRESSURE 2 1 Measurement 8 002 2 2 Adjustment 8 003 3 MEASUREMEN...

Page 9: ...EASUREMENT OF PROPULSION MOTOR CASE PRESSURE 11 1 Measurement of Propulsion Motor front 8 020 11 2 Measurement of Propulsion Motor rear 8 021 12 MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE 12 1 Measurement 8 022 13 ADJUSTMENT OF F R LEVER LINKAGE 13 1 Adjustment 8 023 14 BRAKE ADJUSTMENT 14 1 Manually Releasing the Brake 8 024 14 2 Adjustment after Manual Release of Brake 8 025 9 TROUBLESHOOTING 1...

Page 10: ...hed 9 037 2 5 Propulsion 9 039 2 5 1 Machine moves neither forward nor backward 9 039 2 5 2 Machine speed cannot be changed 1 5 9 041 2 5 2 Machine speed cannot be changed 2 5 9 043 2 5 2 Machine speed cannot be changed 3 5 9 045 2 5 2 Machine speed cannot be changed 4 5 9 047 2 5 2 Machine speed cannot be changed 5 5 9 049 2 5 3 Brake cannot be released 9 051 2 5 4 Brake does not work 9 053 2 6 V...

Page 11: ...nor backward 2 2 9 090 3 2 2 Machine moves in one direction only forward or backward 9 090 3 2 3 Slow machine speed or small drive force 1 2 9 090 3 2 3 Slow machine speed or small drive force 2 2 9 091 3 2 4 Machine speed cannot be switched 9 091 3 2 5 Machine does not stop completely with F R lever in N 9 091 3 2 6 Propulsion system is overheating 9 092 3 2 7 Abnormal noise from propulsion syste...

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: ...in ROPS 3 050 mm 120 in Wheelbase 2 970 mm 117 in Compaction width 2 130 mm 84 in Minimum height above ground 405 mm 15 5 in Curb clearance 500 mm 19 5 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 33 3 Hz High amplitude 28 3 Hz Centrifugal force Low amplitude 172 kN 38 665 lbs High amplitude 255 kN 57 325 lbs Amplitude Low amplit...

Page 27: ...fan Inhaling type Electrical system Alternator 24 V 70 A Starter 24 V 4 8 kW Battery 12 V CCA 760 2 pcs 24 V Engine dry weight 390 kg 860 lbs Power line Transmission Type Hydrostatic transmission Speeds 2 speed shifts Reverser Switching the direction of flow delivered from the variable pump Differential Auto lock type Final drive Planetary gear Vibrating system Transmission Hydrostatic transmissio...

Page 28: ...110 mm 122 in Wheelbase 2 970 mm 117 in Compaction width 2 130 mm 84 in Minimum height above ground 450 mm 17 5 in Curb clearance 530 mm 20 5 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 33 3 Hz High amplitude 28 3 Hz Centrifugal force Low amplitude 172 kN 38 665 lbs High amplitude 255 kN 57 325 lbs Amplitude Low amplitude 0 95 m...

Page 29: ...ternator 24 V 70 A Starter 24 V 4 8 kW Battery 12 V CCA 760 2 pcs 24 V Engine dry weight 390 kg 860 lbs Power line Transmission Type Hydrostatic transmission Speeds 2 speed shifts Reverser Switching the direction of flow delivered from the variable pump Differential Auto lock type Final drive Planetary gear Vibrating system Transmission Hydrostatic transmission Vibrator Eccentric shaft type Brakin...

Page 30: ... 115 mm 123 in Wheelbase 2 970 mm 117 in Compaction width 2 130 mm 84 in Minimum height above ground 465 mm 18 0 in Curb clearance 560 mm 22 0 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 33 3 Hz High amplitude 28 3 Hz Centrifugal force Low amplitude 172 kN 38 665 lbs High amplitude 255 kN 57 325 lbs Amplitude Low amplitude 0 62 ...

Page 31: ... 24 V 4 8 kW Battery 12 V CCA 760 2 pcs 24 V Engine dry weight 390 kg 860 lbs Power line Transmission Type Hydrostatic transmission Speeds 2 speed shifts Reverser Switching the direction of flow delivered from the variable pump Differential Auto lock type Final drive Planetary gear Vibrating system Transmission Hydrostatic transmission Vibrator Eccentric shaft type Braking device Service brake Hyd...

Page 32: ... 130 mm 123 in Wheelbase 2 970 mm 117 in Compaction width 2 130 mm 84 in Minimum height above ground 475 mm 18 5 in Curb clearance 580 mm 22 5 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 33 3 Hz High amplitude 28 3 Hz Centrifugal force Low amplitude 172 kN 38 665 lbs High amplitude 255 kN 57 325 lbs Amplitude Low amplitude 0 73 ...

Page 33: ...r 24 V 4 8 kW Battery 12 V CCA 760 2 pcs 24 V Engine dry weight 390 kg 860 lbs Power line Transmission Type Hydrostatic transmission Speeds 2 speed shifts Reverser Switching the direction of flow delivered from the variable pump Differential Auto lock type Final drive Planetary gear Vibrating system Transmission Hydrostatic transmission Vibrator Eccentric shaft type Braking device Service brake Hy...

Page 34: ...050 mm 120 in Wheelbase 2 970 mm 117 in Compaction width 2 130 mm 84 in Minimum height above ground 405 mm 15 5 in Curb clearance 500 mm 19 5 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 33 3 Hz High amplitude 28 3 Hz Centrifugal force Low amplitude 172 kN 38 665 lbs High amplitude 255 kN 57 325 lbs Amplitude Low amplitude 1 02 m...

Page 35: ...fan Inhaling type Electrical system Alternator 24 V 70 A Starter 24 V 4 8 kW Battery 12 V CCA 760 2 pcs 24 V Engine dry weight 390 kg 860 lbs Power line Transmission Type Hydrostatic transmission Speeds 2 speed shifts Reverser Switching the direction of flow delivered from the variable pump Differential Auto lock type Final drive Planetary gear Vibrating system Transmission Hydrostatic transmissio...

Page 36: ...110 mm 122 in Wheelbase 2 970 mm 117 in Compaction width 2 130 mm 84 in Minimum height above ground 450 mm 17 5 in Curb clearance 530 mm 20 5 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 33 3 Hz High amplitude 28 3 Hz Centrifugal force Low amplitude 172 kN 38 665 lbs High amplitude 255 kN 57 325 lbs Amplitude Low amplitude 0 94 m...

Page 37: ...ternator 24 V 70 A Starter 24 V 4 8 kW Battery 12 V CCA 760 2 pcs 24 V Engine dry weight 390 kg 860 lbs Power line Transmission Type Hydrostatic transmission Speeds 2 speed shifts Reverser Switching the direction of flow delivered from the variable pump Differential Auto lock type Final drive Planetary gear Vibrating system Transmission Hydrostatic transmission Vibrator Eccentric shaft type Brakin...

Page 38: ...m 579 lbf ft Tire inflation pressure 137 kPa 20 psi 2 3 Hydraulic System Item Standard value Remarks Propulsion High pressure relief valve setting 42 0 1 0 MPa 6 090 145 psi at 1 800 min 1 Charge relief valve setting 2 4 0 2 MPa 348 29 psi at 40 L min Rear motor flushing valve pressure setting 2 0 MPa 290 psi at 10 L min Case pressure Pump 0 3 MPa 43 5 psi or less Front motor 0 3 MPa 43 5 psi or l...

Page 39: ... 02001 N o t e 1 N o t e 2 Clearance between brake pedal and floorboard when pressed down 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 12 0 L 3 2 gal Fuel tank 265 L 70 gal Coolant 23 4 L 6 2 gal Gear box front motor 4 5 L 1 2 gal Gear box rear axle 2 0 L 0 53 gal Center housing rear axle 11 0 L 2 ...

Page 40: ... VG46 Over 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 CJ4 Gear oil API GL 5 Hydraulic oil ISO VG 46 Grease NLGI 2 CHEVRON DELO 400 LE RPM Universal Gear Lubricants Rando HDZ 46 Multifak EP 2 BP BP Energear HYPO U Bartran HV 46 BP Energrease LS EP 2 CASTROL Tection Extr...

Page 41: ...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 42: ......

Page 43: ...ENGINE AND CONTROLS ...

Page 44: ......

Page 45: ...6 40 3 Bolt M16 40 9 Nut M12 15 Bolt M12 40 4 Bolt M12 30 10 Plate 16 Bolt M16 50 5 Bracket 11 Bolt M 8 20 17 Bolt M12 25 6 Engine 12 Damper 18 Damper N m 3 Bolt M16 40 265 N m 195 lbf ft 14 Bolt M16 40 265 N m 195 lbf ft 4 Bolt M12 30 108 N m 80 lbf ft 15 Bolt M12 40 108 N m 80 lbf ft 9 Nut M12 108 N m 80 lbf ft 16 Bolt M16 50 265 N m 195 lbf ft 11 Bolt M 8 20 31 N m 23 lbf ft 17 Bolt M12 25 108 ...

Page 46: ......

Page 47: ...sure ECM Air intake Water outlet Crankshaft coolant supply Thermo unit Air transfer Oil level gauge Turbocharger Fan drive pulley Water inlet Vibration damper Fuel pump Starter motor Alternator Flywheel Fuel filter The actual equipment may differ from that shown above 1 2 Engine Exterior 3 002 ENGINE AND CONTROLS ...

Page 48: ......

Page 49: ...unit 10 Hose Fuel tank Fuel pre filter 2 Hose Fuel cooler OUT Tank 11 Cap 3 Fuel cooler 12 Breather 4 Hose Fuel gear pump Fuel cooler IN 13 Hose Breather Tank 5 Fuel filter 14 Strainer 6 Hose Fuel gear pump Fuel filter 15 Fuel tank 7 Hose Fuel filter Fuel gear pump 16 Plug 8 Hose Fuel pre filter Fuel gear pump 17 Fuel gear pump 9 Fuel pre filter ...

Page 50: ...W B B F N R 1 2 3 4 5 6 7 8 9 10 11 12 Apply grease 13 A A 1 F R lever switch 6 Nut M12 11 Spring Fill grease 2 Backup buzzer switch 7 Washer Apply grease 12 Steel ball 3 F R lever 8 Rod end Apply grease 13 Rod end Apply grease 4 Control cable 9 Bolt M16 30 5 Bush Apply grease 10 Nut M16 Lithium based grease ...

Page 51: ...SECTION A A 1 2 7 8 9 6 3 4 5 3 M8 1 25 2 M8 1 25 1 Bolt M10 30 6 Housing 2 Bolt 3 8 16UNC 22 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 7 Bolt M14 45 167 N m 123 lbf ft 2 Bolt 3 8 16UNC 22 69 N m 51 lbf ft 9 Bolt M12 35 86 N m 63 lbf ft ...

Page 52: ... engine flywheel with eight bolts 2 N m 2 Bolt 3 8 16UNC 22 69 N m 51 lbf ft Position housing 6 as shown in the figure and secure to engine flywheel housing with twelve bolts 1 and washers N m 1 Bolt M10 30 59 N m 44 lbf ft Engage hub 4 with flange 5 Secure pump 8 to housing 6 with four bolts 7 spring washers and washers N m 7 Bolt M14 45 167 N m 123 lbf ft NOTICE Bolt 2 is treated with thread loc...

Page 53: ...HYDRAULIC SYSTEMS ...

Page 54: ......

Page 55: ......

Page 56: ...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 57: ...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 58: ......

Page 59: ...1 4 1 4 1 1 4 1 4 1 4 1 4 1 4 1 4 172KN 2000vpm 17 5 ton 255KN 1700vpm 26 0 ton 2 0 MPa at 10 L min 44 5 cc rev FVA FVD FVB AD4 AD3 VPA VPB VD1 VD2 PD1 PPB PD2 PDV LOB VPC PCF PPC PPA AD5 Vibrator motor 60 0 30 0 cc rev 80 0 28 0 cc rev Vibrator pump SOL 2 28 MPa 28 MPa 42 0 MPa 42 0 MPa SOL 1 2 4 Mpa at 18 9 L min 2 4 Mpa at 40 L min SERVO SERVO SERVO SERVO 51 0 cc rev 75 0 cc rev SCP SCT SCA Byp...

Page 60: ......

Page 61: ...ow each port and the arrow symbols show the hose connection and the direction of the flow of the oil Hose AD1 FMC Hose AD1 FMC AD2 Hose AD1 FMC Hose RMB FMB Hose RMB FMB Hose RMA FMA Hose RMA FMA Hose FMD T4 Hose FMD T4 SECTION A A Hose AD1 FMC Hose RMB FMB Hose RMA FMA Hose FMD T4 Hose AD2 FGB Hose AD2 FGB Hose AD2 FGB Hose AD2 FGB D D 2 PROPULSION HYDRAULIC SYSTEM 2 1 Propulsion Hydraulic Piping...

Page 62: ......

Page 63: ...ch port and the arrow symbols show the hose connection and the direction of the flow of the oil Hose Hose SCT BTS SCA AD1 SECTION A A SECTION B B Hose BPS SCP Hose SCT BTS Hose SCA AD1 SCP SCA SCP A A B B E E F F Motor speed change solenoid valve front BPS SCA AD1 SCA AD1 C C 2 1 2 Propulsion hydraulic piping front 2 4 005 HYDRAULIC SYSTEMS ...

Page 64: ......

Page 65: ...l cooler Propulsion motor Rear T6 Hose AD6 T6 RBP Hose CO AD6 CO Bypass valve BV1 BV2 Hose RAB BV2 RAP RMD RAB AD5 CS AD6 PPB PD1 RBB SECTION A A SECTION B B VIEW C VIEW E A A B B C D E Hose Hose RMD PD1 Hose PPA RAP PPB RBP Hose Hose PDC AD5 PPA RAP Hose PDC AD5 Hose Hose Hose PPB RBP Hose RMD PD1 Coupling High pressure gauge port Coupling High pressure gauge port VIEW D PD2 PDC PPA RAP PDC AD5 2...

Page 66: ......

Page 67: ......

Page 68: ...ly propulsion vibrator SV520 04001 1 5 A VIEW A 2 8 2 7 2 6 2 2 2 5 1 4 1 3 1 7 1 10 1 9 2 12 2 13 2 15 2 14 2 16 2 17 1 11 2 9 2 11 2 10 1 8 1 12 1 6 1 2 1 1 1 2 4 2 3 2 1 2 Pump circuit diagram 1 2 1 9 1 4 1 5 2 11 2 5 2 2 2 1 2 10 2 13 2 7 2 6 2 14 2 4 2 3 2 12 1 7 1 8 1 12 1 3 1 1 B N A ...

Page 69: ...9 16 18UNF 2 3 Control pressure gauge port 9 16 18UNF 2 4 Servo pressure gauge port 9 16 18UNF 2 5 Drain port VD1 1 5 16 12UN 2 6 High pressure gauge port For Port A2 9 16 18UNF 2 7 Port A2 Low amplitude VPA 1 1 16 12UN 2 8 Charge relief valve 2 9 High pressure check relief valve port For Port A2 2 10 Charge supply port VPC 3 4 16UNF 2 11 Drain port VD2 1 5 16 12UN 2 12 Servo pressure gauge port 9...

Page 70: ...pressure gauge port min 9 16 18UNF 7 Port B Reverse FMB 3 4 DN19 3 Control pressure port FMC 9 16 18UNF 8 Speed sensor 4 Drain port 7 8 14UNF 9 Gauge port For Port A 7 8 12 5 Servo pressure gauge port max 9 16 18UNF 10 Gauge port For Port B 7 8 12 Motor specifications Displacement max 60 0 cm3 rev 3 66 cu in rev min 30 0 cm3 rev 1 83 cu in rev Allowable motor case pressure 0 3 MPa 43 5 psi or less...

Page 71: ...n port M16 P 1 5 2 Oil filler port Oil level check port M16 P 1 5 5 Brake port FGB M16 P 1 5 3 Oil filler port Oil level check port M16 P 1 5 Specifications Reduction ratio 1 85 33 Brake release pressure 1 8 MPa 261 psi or more Oil capacity 4 5 L 1 19 gal Weight 121 1 kg 267 lbs ...

Page 72: ... max 9 16 18UNF 3 Port A Forward RPA 1 DN25 9 Speed sensor 4 Drain port RMD 7 8 14UNF 10 Gauge port For Port B RMB 1 1 16 12UN 5 Port B Reverse RPB 1 DN25 11 Gauge port For Port A RMA 1 1 16 12UN 6 Solenoid valve speed change 12 Charge pressure relief valve Motor specifications Displacement max 80 0 cm3 rev 4 88 cu in rev min 28 0 cm3 rev 1 71 cu in rev Charge relief valve pressure setting 2 0 MPa...

Page 73: ... 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 SCP 9 16 18UNF 2B 7 Port A SCA 9 16 18UNF 2B 8 Port T SCT 9 16 18UNF 2B Specifications Rated pressure 4 9 MPa 710 psi 6 7 0 5 MPa 72 5 psi 8 Rated flow 30 L min 7 9 gal min Weight 1 5 kg 3 3 lbs ...

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Page 75: ... B VIEW E VIEW F Hose FVD T1 C C D D F B B A A E FVA FVB AD4 AD3 PD2 FVD PDV VD2 Hose AD4 FVB VD1 Coupling High pressure gauge port VPB VPA Hose VPB AD4 Hose VPA AD3 Coupling High pressure gauge port Hose LO2 T2 Hose VD2 LS2 Hose VPB AD4 Hose VPA AD3 Hose VD1 PDV Hose LO2 T2 Hose Hose VPB AD4 Hose VPA AD3 Hose AD3 FVA Hose AD4 FVB Hose AD3 FVA Hydraulic oil tank T1 T2 FVD T1 Hose VPB AD4 Hose VPA ...

Page 76: ......

Page 77: ... 3 4 Flow of oil 1 2 Clockwise rotation 2 1 Counterclockwise rotation SV510 04008 1 Port A FVA SAE 3 4 2 Port B FVB SAE 3 4 3 Drain port L FVD 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 2 MPa 29 psi Weight 17 kg 37 lbs ...

Page 78: ......

Page 79: ...ON C C SECTION A A VIEW D VIEW F SECTION B B LO1 Hydraulic oil filter 1 LS1 SCS Hose T3 SCS T3 SCS T3 SCD Steering cylinder L Hose T LS1 The letters and figures such as T and LS1 show each port and the arrow symbols show the hose connection and the direction of the flow of the oil R SRR Hose R SRR Hose L SLL D F C C E E B B A A Orbitrol P R T L Coupling Charge pressure gauge port Suction filter 4 ...

Page 80: ......

Page 81: ...YDRAULIC SYSTEMS 4 2 Steering Wheel 0418 62801 0 10174 C 2 1 3 4 5 1 Steering wheel 4 Nut M12 P 1 25 2 Bolt M10 30 5 Orbitrol 3 Column shaft N m 2 Bolt M10 30 49 N m 36 lbf ft 4 Nut M12 P 1 25 35 N m 26 lbf ft ...

Page 82: ... SV510 04010 1 2 4 4 5 3 3 1 2 Hydraulic circuit diagram 1 Port L L 3 4 16UNF 4 Port T T 3 4 16UNF 2 Port R R 3 4 16UNF 5 Relief valve 3 Port P P 3 4 16UNF Specifications Displacement 400 cm3 rev 24 4 cu in rev Relief valve pressure setting 15 0 MPa 2 175 psi Weight 7 kg 15 lbs ...

Page 83: ...harge pump SV540 04004 2 3 Hydraulic circuit diagram A VIEW A 3 1 2 1 Pump 2 Outlet port SCD 7 8 14UNF 3 Inlet port SCS 1 5 16 12UN Specifications Displacement 24 9 cm3 rev 1 5 cu in rev Rated pressure 20 6 MPa 2 987 psi Weight 3 8 kg 8 4 lbs ...

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Page 85: ...ELECTRICAL SYSTEM ...

Page 86: ......

Page 87: ...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 88: ...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 89: ...40 YW 99 LgW 62 L 39 LY 51 LW 50 L G 57 GB 60 L 69 Lg 68 GR 56 W 13 BL 58 BW 54 1 25RG 41 R 129 W 13 B X 1 25RG 41 1 25RL 73 2RG 43 1 25RG 43 BY 4 1 25G 47 1 25GR 46 1 25GB 45 B X LgW 82 BrW 37 LgR 36 GR 38 B X B X B X GB 2 GB 2 LgR 36 R 12 R 12 26 B X B X B X 13 5A 12 20A FUSE BOX 1 11 20A 15A 15A 15A 5A 15A 15A 20A 5A 15A 10 9 8 7 6 5 4 3 2 20A 1 20 5A 14 15 16 17 18 19 30A 10A 20A 15A 20A 20A F...

Page 90: ......

Page 91: ...1 9 7 6 10 A A B B C SECTION A A SECTION B B 1 Cord Fuse Alternator 7 Cord Battery Ground 2 Alternator 8 Cord Battery Battery 3 Starter motor 9 Cord Battery Battery relay COM 4 Cord Starter motor terminal G Battery 10 Cord Battery relay COM Fuse 5 Cord Battery Starter motor terminal 30 11 Battery relay 6 Battery 12 Fuse 125A ...

Page 92: ......

Page 93: ...Grid heater relay GB G WR L Fuse 125A W L Motor proportional solenoid rear BW Ground B Tachometer sensor GW B DETAIL G Ground NEG Backup buzzer HI GB Backup buzzer B Parking brake solenoid P BrW B G L p 5 006 A B K S N J BL B Fuel unit YB B Terminating resistor L G p 5 007 MAF connector Mark R not in use BrB B Not in use R INC DEC switch not in use L BW G Motor rotation sensor harness front P 5 02...

Page 94: ......

Page 95: ...ne harness Terminating resistor Terminating resistor For vibrator calculation jig For P C ECO controller Datalink interface connector engine ECM F R lever vibration switch Engine harness DETAIL N W Br G RG Y Cylinder block M P B 5 W P 5 007 BW YR P 5 007 P 5 007 Fuse relay harness 1 P 5 013 P 5 015 P 5 013 Engine harness P 5 007 P 5 015 P 5 007 P 5 009 P 5 013 P 5 015 P 5 013 P 5 007 P 5 013 P 5 0...

Page 96: ... L 89 Y 88 GY 80 GW 94 X 96 Br B BW 6T3 7T2 4T6 20 1 25RW 104 B X 3B 78 5R 67 3W 65 3WR 50 50 50 3 0 0 T a p e 100 Tape 50 Ta pe Marking tape Marking tape color green color gray Marking tape color blue 100 150 Tape 90 50 Fuse relay harness 2 P 5 015 040DL 20PF Motor speed change solenoid front SWP 2PF not in use DT06 2S DTM06 6S DT06 2S DT06 2S Motor proportional solenoid rear Motor rotation senso...

Page 97: ... motor 30 5R 2 5 7T2 GW 2 7A3 Tachometer sensor NO SIZE COLOR CONTACT POINTS CONNECTION L 4 Datalink interface connector D Engine ECM 18 Terminating resistor 120Ω B 2 X 2 Terminating resistor 120Ω C 2 G 4 Datalink interface connector C Engine ECM 17 Terminating resistor 120Ω A 2 L 2 10T1 Engine ECM 15 G 2 1 Engine ECM 4 GY 2 7A3 Engine ECM 8 Y 2 7A3 Engine ECM 16 8WR 15WR 2 3 2 Grid heater LW 2 10...

Page 98: ... RB RW 1 25RW 1 25RG 1 25R SWP 16PM SWP 12PF Combination meter 1 25Lg 1 25BR 28 LgW 26 24 4 5BY 7 5G SWP 3PM 58Y 2PF 42 42 94 BW 96 Br 93 L 95 G 39 L YR 9 BrW 37 RG 43 42 RG 81 LgR 36 LgW 82 1 25RL 73 41 RY 30 Y 11 B X 48 RL 38 GR 10 YB 52 BrB 1 LB 120 97 WB 74 44 39 L 50 LW 51 LY 94 BW 100 BR 100 BR X B 27 Y 8 YL 22 Y 38 GR 32 BY B X YG 21 YB 6 YR 17 31 Br 1 R 46 GR 45 GB 42 RW WR 70 YW 35 GW 80 ...

Page 99: ...ion meter 16PF Lg 2 5F4 Horn switch LgW 2 5F4 Horn YW 4 5F4 Combination meter 12PF ENGINE STOP lamp not in use WARNING lamp not in use LgR 3 5F4 B1 Foot brake switch BrW 2 9A1 B1 GR 2 B1 Combination meter 16PF L 4 4T4 5F4 B1 B2 NO SIZE COLOR CONTACT POINTS CONNECTION 1 25RG 2 5F4 B1 RW 1 25RW 6 B1 Combination meter 12PF 5D 2 option Head lamp option 2 RG 2RG 3 9A1 B1 5D option RB 1 25RB 2 4T4 B2 GB...

Page 100: ... in use Not in use 060 1PFS Vibration mode change switch Vibration select switch 060 1PFS 060 1PFS Lighting switch option Tape 50 Tape 50 Tape 50 150 150 150 150 150 150 150 150 150 150 150 150 150 Rotatory lamp swtich option 060 1PFS Speed change switch not in use Panel harness 1 P 5 009 060 1PFS Tape 50 Tape 50 Tape 50 100 Tape 200 Tape 250 Tape 50 50 50 150 150 Parking brake switch 060 1PFS 150...

Page 101: ... Parking brake switch 3 GR 2 B1 Parking brake switch 4 NO SIZE COLOR CONTACT POINTS CONNECTION L 2 B1 Speed change switch 1 not in use 1 25RG 3 B1 Lighting switch 1 option Lighting switch 4 not in use 1 25RW 2 B1 Lighting switch 3 option RG 2 B1 Rotatory lamp switch 1 option RL 2 B1 Rotatory lamp switch 2 option BrB 2 B1 Speed change switch 2 not in use RL 1 25RL 3 B1 Vibration mode change switch ...

Page 102: ... SWP 6PM with cap SWP 6PF 133 BY 131 Lg 10 YB 132 W 9 YR Y 11 Vibrator calculation jig 12 11 10 9 7 8 1 2 3 4 6 5 1 25B X L B E 150 Tape 50 Tape 50 1 25WB 126 1 25R 122 YW 35 1 25RB 127 400 Tape B 104 5R 3 41 BY WR 70 4 20 25 R 12 5R 3 RY 30 WR 123 L 39 YB 106 5RG 23 2RG 43 1 25RW 1 25BW 1 25RG LY 16 1 25RB 1 25BY BG 114 1 25BW 1 25BY 1 25BY 1 25Lg 30 RY LgW 34 30 Lg 33 RY X B BY 32 28 LgB 29 LgW ...

Page 103: ...3 12F1 Relay box A 5 6 RY 4 5F4 Fuse box 1 10 Relay box A 7 2 Br 2 5F4 Diode unit BY 2 5F4 Relay box A 6 Lg 2 5F4 Relay box A 7 LgW 2 5F4 Relay box A 7 NO SIZE COLOR CONTACT POINTS CONNECTION YW 2 5F4 Fuse box 1 8 LgR 2 5F4 Relay box A 3 L 2 5F4 Fuse box 1 6 1 25RG 2 5F4 Fuse box 1 4 1 25RG 2RG 3 12F1 Fuse box 1 1 Flasher unit option 1 25G 2 5F4 Flasher unit option G 3 11T7 ECO controller 3 For P ...

Page 104: ...2 WB 117 Pass counter option SWP 3PF 129 13 B X 58Y 2PF black SWP 16PF 040DL 20PM 50 113 L 57 G SWP 2PM 50 58X 2PF 3W 67 3WR 65 50 6T3 GB L LgB WR 116 1 25RB R W 68 Lg 69 L 60 GB 1 0 0 T a p e 5 0 T a p e 50 Tape 1 0 0 T a p e 150 Tape 1 5 0 T a p e GW 55 Twist pair cable AVSSCS 0 75f 2 8_18 SWP 2PF Spare power source 1 25RG 128 40 Tape 100 Tape 1 4 0 T a p e 7T2 3B X 5R 78 11T7 128 1 25RG 9P 150 ...

Page 105: ...gW 2 4T4 T C controller C2 5 GB 4 10T1 Relay box B 3 4 6 RB 2 10T1 Relay box B 4 3WR 2 6T3 Fuse box 2 14 3W 2 6T3 Fuse box 2 14 NO SIZE COLOR CONTACT POINTS CONNECTION Lg 3 4T4 10T1 T C controller C1 8 L 3 4T4 10T1 T C controller C1 9 RL 1 25RL 3 4T4 Relay box B 2 3 WB 2 4T4 Relay box B 1 5R 2 7T2 Fuse box 2 17 L 2 10T1 Relay box B 6 LW 2 10T1 Relay box B 1 WL 2 10T1 Relay box B 1 RW 2 4T4 Relay b...

Page 106: ...G 50 116 LA105 Engine harness P 5 007 50 6 71 8BW 8W 59 50 5 8R 3 78 5R 50 4 4 5BY 5RG 23 50 3 90 90 8WR 8WR 58X 2PM 2 50 3B 3WR X 65 SWP 6PM 1 5 1 25RG W 63 GB 116 1 25B X 119 G 87 1 25RB Marking tape color white 1 1 25B 50 X 8WR 1 Connection status 15WR 90 90 90 8WR 50 Tape 130 Tape 100 130 Tape 1 5 0 T a p e 19 15L 50 LA408 90 15WR 50 LA408 GB 60 87 G 60 63 Grid heater relay LA105 LA105 LA408 1...

Page 107: ...5RG 2 4 F L 65A 8W 2 6 Starter relay GB 2 1 Grid heater relay 3WR 2 2 Battery relay COM NO SIZE COLOR CONTACT POINTS CONNECTION 8BW 2 6 Starter relay 5G 2 Battery relay NO F L 65A 8WY 2 Battery relay NO F L 75A 5BW 2 Battery relay COM F L 65A 5R 2 5 F L 65A 5WL 2 Battery relay NO F L 65A G 2 1 Grid heater relay 8WR 15WR 3 3 2 Grid heater relay 1 25RG 2 1 Starter relay W 2 1 Battery relay COM 5 018...

Page 108: ......

Page 109: ...5 B LA305 R2 not in use LA105 BR LA105 C 5BY 70 1 25BR 70 5G 70 1 25Lg 70 Panel harness 1 P 5 009 Starter Switch Tape NO SIZE COLOR CONTACT POINTS CONNECTION 5BY 2 Panel harness 1 Starter switch B 5G 2 Panel harness 1 Starter switch R2 1 25BR 2 Panel harness 1 Starter switch BR 1 25Lg 2 Panel harness 1 Starter switch C LgW 2 Panel harness 1 Starter switch ACC ...

Page 110: ...er switch 50 Tape CA104 NC CB104 COM ECO lamp switch not in use R 50 G 50 50 50 CB104 COM CA104 NO Backup buzzer switch GB 50 R 50 100 1000 450 Tape 150 SWP 6PM 2C 50 Tape 100 Fuse relay harness 1 P 5 013 NO SIZE COLOR CONTACT POINTS CONNECTION GB 2 2C Backup buzzer switch NO Y 2 2C F R lever vibration switch 2 R 4 2C Backup buzzer switch COM F R lever switch COM ECO lamp switch COM not in use W 2...

Page 111: ...94 LB 120 RW 97 LY 51 LW 50 WB 74 RB 44 L 39 150 150 150 150 B2 50 300 Tape Tape 50 Tape 50 2 LgW 82 Wire color Wire number 060 1PES Switch terminal number NO SIZE COLOR CONTACT POINTS CONNECTION L 3 B2 Speed change switch 1 Speed change switch 4 RB 2 B2 Throttle switch 4 LW 2 B2 Speed change switch 5 LY 2 B2 Speed change switch 2 WB 2 B2 Throttle switch 3 BW 2 B2 Throttle switch 1 RW 2 B2 Throttl...

Page 112: ...arness 1 P 5 009 20 L 69 GB 60 3 4 1 2 5 6 Lg 68 Woven braid color black GB 60 Lg 68 SWP 4PＭ L 69 TC Motor rotation sensor front DTM 06 6S NO SIZE COLOR CONTACT POINTS CONNECTION GB 2 TC Motor rotation sensor front Lg 2 TC Motor rotation sensor front L 2 TC Motor rotation sensor front ...

Page 113: ...uel Unit Harness SV540 05011 Engine harness P 5 007 Fuel unit CA104 CB104 CB104 CA104 B 50 YB 50 B 50 YB 50 150 6 X X 6 Corrugate䇭 7 NO SIZE COLOR CONTACT POINTS CONNECTION B 2 Engine harness Fuel unit YB 2 Engine harness Fuel unit ...

Page 114: ... P 5 009 LA104 1 93 L 100 Diagnostic switch LA104 2 LA104 3 96 94 Br 100 BW 100 INC DEC switch not in use BW L G 95 93 94 96 Br Tape 100 NO SIZE COLOR CONTACT POINTS CONNECTION L 2 J INC DEC switch 1 not in use BW 3 J Diagnostic switch 2 INC DEC switch 2 not in use G 2 J INC DEC switch 3 not in use Br 2 J Diagnostic switch 3 ...

Page 115: ...ion R F R lever switch Backup buzzer switch Foot brake switch 13 5A 12 20A 11 20A 15A 15A 15A 5A 15A 15A 20A 5A 15A 10 9 8 7 6 5 4 3 2 20A 1 T C controller R RG Lighting switch option WB Cigarette option RW Stater lockout relay YB ECO controller RG Rotatory lamp switch option Flasher unit option Cabin option Harness color codes R Red RW Red White stripe L Blue RY Red Yellow stripe BW Black White s...

Page 116: ...ler BY Engine ECM Engine ECM R Pass counter option G BG Brake relay RB Throttle switch MID FULL speed control relay WR Engine diagnosis W 20 5A 14 15 16 17 18 19 30A 10A 20A 15A 20A 20A Harness color codes W White BG Black Green stripe R Red WR White Red stripe G Green RB Red Black stripe BY Black Yellow stripe ...

Page 117: ...EL 2 REV ratio SEL 3 REV ratio SEL 4 Side marker lamp Combination meter ilumination Turn signal right Turn signal left Vibration Liquid spray Water spray Flood lamp Preheating Parking brake Charge warning Engine oil pressure warning Lamp check Coolant temp SEL 1 Coolant temp SEL 2 System configuration diagram Harness side Harness side SWP 16F SWP 16F SWP 16PM SWP 12M SWP 12M SWP 12PF X B YL 8 22 Y...

Page 118: ......

Page 119: ...VIBRATORY DRUM REAR AXLE ...

Page 120: ......

Page 121: ...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 122: ...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 123: ...res must support the machine s body weight too Rear axle weight SV540D 5 240 kg 11 550 lbs SV540T 5 235 kg 11 540 lbs SV540TF 5 230 kg 11 530 lbs SV540DF 5 170 kg 11 400 lbs SV640D 6 000 kg 13 230 lbs SV640T 6 040 kg 13 320 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 se...

Page 124: ... 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 8 and 9 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 10 11 and 12 connecting to vibrator motor ...

Page 125: ...9 833 lbs SV540T 4 785 kg 10 549 lbs SV540TF 7 190 kg 15 851 lbs SV540DF 6 145 kg 13 547 lbs SV640D 4 505 kg 9 932 lbs SV640T 4 835 kg 10 659 lbs 7 Put chocks or the like under removed drum 13 to prevent it from moving SV540 06106 Support stand Lift with crane 2 13 SV540 06106 Support stand Lift with crane 2 13 SV540 06107 Chock 13 SV540 06107 Chock 13 ...

Page 126: ...ross member 3 Bolts M20 100 539 N m 398 lbf ft 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 s...

Page 127: ...haft 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 45 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 M12 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 38 B...

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Page 129: ...oden 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 SV540D 4 425 kg 9 755 lbs SV540T 4 750 kg 10 472 lbs SV540TF 7 155 kg 15 774 lbs SV540DF 6 110 kg 13 470 lbs SV640D 4 475 kg ...

Page 130: ...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 SV540D T TF DF 155 kg 342 lbs SV640D T 205 kg 452 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 131: ...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 132: ... 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 133: ...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 49 side facing up Total weight of parts to be lifted SV540D 3 720 kg 8 201 lbs SV540T 4 045 kg 8 918 lbs SV540TF 6 450 kg 14 220 lbs SV540DF 5 400 kg 11 905 lbs SV640D 3 720 kg 8 201 lbs SV640T 4 045 kg 8 918 lbs 15 Remove two bol...

Page 134: ...LE 16 Remove propulsion motor 49 17 Install lifting bolts M20 to holders 46 and 54 18 Remove twenty bolts 48 SV540 06019 49 SV540 06019 49 SV540 06501 46 54 Lifting bolt SV540 06501 46 54 Lifting bolt SV540 06502 48 SV540 06502 48 ...

Page 135: ...rts to be lifted 220 kg 485 lbs 20 Install lifting bolts M20 to gear box 42 Remove nineteen bolts 3 21 Lift gear box subassembly 42 with a crane and remove it 42 Gear box subassembly 190 kg 419 lbs SV540 06016 45 46 54 2 SV540 06016 45 46 54 2 SV540 06503 Lifting bolt 42 3 SV540 06503 Lifting bolt 42 3 SV540 06012 42 SV540 06012 42 ...

Page 136: ...t 41 Remove sixteen bolts 39 23 Lift axle shaft 41 with a crane and remove it 41 Axle shaft 230 kg 507 lbs 24 Put removed axle shaft 41 on wooden blocks SV540 06504 39 Lifting bolt 41 SV540 06504 39 Lifting bolt 41 SV540 06006 41 SV540 06006 41 SV540 06505 41 SV540 06505 41 ...

Page 137: ...aft subassembly 35 removed from vibratory drum 26 Remove six bolts 32 Remove cover 24 24 Cover 10 kg 22 lbs 27 Remove eight bolts 25 Remove cover 29 Remove shim 33 SV510 06032 35 SV510 06032 35 SV510 06033 32 24 SV510 06033 32 24 SV510 06034 25 29 33 SV510 06034 25 29 33 ...

Page 138: ...oller bearing from axle shaft 35 29 Install lifting bolts M12 to housing 12 30 Lift housing subassembly 12 with a crane and separate it from axle shaft 35 12 Housing subassembly 45 kg 99 lbs SV510 06035 Puller 35 12 Wooden board SV510 06035 Puller 35 12 Wooden board SV510 06036 Lifting bolt 12 SV510 06036 Lifting bolt 12 SV510 06037 12 35 SV510 06037 12 35 ...

Page 139: ...tion shown axle shaft 41 removed from vibratory drum 32 Remove bolt 38 33 Remove vibrator bearing 4 from axle shaft 41 using long bolts M10 SV540 06509 41 SV540 06509 41 SV540 06506 38 SV540 06506 38 SV540 06507 41 Long bolt 4 SV540 06507 41 Long bolt 4 ...

Page 140: ...tion 1 Vibratory drum SV540D 3 060 kg 6 746 lbs SV540T 3 385 kg 7 463 lbs SV540TF 5 790 kg 12 765 lbs SV540DF 4 740 kg 10 450 lbs SV640D 3 060 kg 6 746 lbs SV640T 3 385 kg 7 463 lbs 2 Apply a thin coat of gear oil to axle shaft 41 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 ...

Page 141: ...Axle shaft 230 kg 507 lbs Install lifting bolts M20 to axle shaft 41 6 Lift axle shaft 41 with a crane and lower it on mounting surface of vibratory drum 1 41 Axle shaft 230 kg 507 lbs NOTICE When installing axle shaft take care not to allow the O ring to protrude from the fitting groove SV540 06003 38 41 SV540 06003 38 41 SV540 06004 41 Lifting bolt SV540 06004 41 Lifting bolt SV540 06005 41 1 SV...

Page 142: ... gear box 42 NOTICE Align Φ8 to 10 holes with oil check port as shown 9 Secure ring 44 to gear box 42 with twenty bolts 43 and washers N m 43 Bolt M16 70 P 1 5 284 N m 209 lbf ft SV540 06007 41 1 39 SV540 06007 41 1 39 SV540 06008 Brake port 8 to 10 holes Oil check port Align 42 44 SV540 06008 Brake port 8 to 10 holes Oil check port Align 42 44 SV540 06009 43 42 44 SV540 06009 43 42 44 ...

Page 143: ...rane and lower it on the mounting surface of axle shaft 41 42 Gear box subassembly 155 kg 342 lbs 12 Secure gear box subassembly 42 with nineteen bolts 3 and washers N m 3 Bolts M20 70 539 N m 398 lbf ft SV540 06010 42 Lifting bolt SV540 06010 42 Lifting bolt SV540 06011 42 41 SV540 06011 42 41 SV540 06013 3 42 SV540 06013 3 42 ...

Page 144: ...ght 14 Lift disc subassembly 2 with a crane and lower it on mounting surface of gear box 42 2 Disc subassembly 220 kg 485 lbs 15 Position disc subassembly 2 as shown right SV540 06014 54 2 45 Lifting bolt 46 SV540 06014 54 2 45 Lifting bolt 46 SV540 06015 2 42 SV540 06015 2 42 SV540 06017 Holes 2 8 to 10 holes SV540 06017 Holes 2 8 to 10 holes ...

Page 145: ...N m 44 Bolts M20 50 P 1 5 588 N m 434 lbf ft 17 Install propulsion motor 49 to gear box 42 18 Secure propulsion motor 49 with two bolts 50 and washers N m 50 Bolts M16 40 265 N m 195 lbf ft SV540 06018 48 2 SV540 06018 48 2 SV540 06021 49 42 SV540 06021 49 42 SV540 06022 50 49 SV540 06022 50 49 ...

Page 146: ...n 1 Vibratory drum SV540D 3 720 kg 8 201 lbs SV540T 4 045 kg 8 918 lbs SV540TF 6 450 kg 14 220 lbs SV540DF 5 400 kg 11 905 lbs SV640D 3 720 kg 8 201 lbs SV640T 4 045 kg 8 918 lbs 20 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 21 Install a lifting bolt M10 to the end of eccentric shaft subassembly 5 SV510 06056 1 Wooden block SV510 06...

Page 147: ...g the eccentric shaft put the movable weights at their outmost position 23 Insert eccentric shaft subassembly 5 into vibrator bearing 4 while taking care not to tilt vibrator bearing inner race installed on axle shaft 41 24 Reassembly of axle shaft subassembly 35 24 1 Fix axle shaft 35 with wooden blocks SV505 06034 5 Movable weight SV505 06034 5 Movable weight SV505 06035 5 4 41 Inner race SV505 ...

Page 148: ...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 24 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 149: ...stall oil seal 13 Apply a thin coat of grease to lip of oil seal 13 24 6 Install lifting bolts M12 to housing subassembly 12 24 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 150: ...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 151: ...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 152: ...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 SV520 06001 12 24 Hole 4 Hole 3 Hole 2 Hole 1 Breather mounting hole Vibrator motor mounting bolt hole SV520 06001 12 24 Hole 4 Hole 3 Hole 2 Hole 1 Brea...

Page 153: ...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 154: ... M20 60 539 N m 398 lbf ft 29 Install a lifting bolt M8 on shaft end of eccentric shaft 5 30 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 155: ...g 342 lbs SV640D T 205 kg 452 lbs 33 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 060...

Page 156: ...Apply molybdenum based grease to splined portion of sleeve 8 Fit sleeve 8 to splined shaft on eccentric shaft end 36 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 157: ... as shown on the right Hold with chocks Vibratory drum assembly SV540D 4 425 kg 9 755 lbs SV540T 4 750 kg 10 472 lbs SV540TF 7 155 kg 15 774 lbs SV540DF 6 110 kg 13 470 lbs SV640D 4 475 kg 9 866 lbs SV640T 4 805 kg 10 593 lbs NOTICE Make sure that the drum is placed on level ground 39 Remove plugs 11 1 and 11 3 Supply gear oil from oil supply port Check that oil drips from gauge port Quantity of g...

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Page 159: ...0 Differential 11 Gear box 12 Valve 13 Plug hub reduction gear filler level gauge and drain 14 Parking brake release port RBR G1 4 15 Parking brake release port RBL 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 13...

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Page 161: ...ifferential 11 Gear box 12 Valve 13 Plug hub reduction gear filler level gauge and drain 14 Parking brake release port RBR G1 4 15 Parking brake release port RBL 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 137 5...

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Page 163: ...e Gear box Hub 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 GL5 SAE90 See recommended lubrication Change oil quantity Gear box 2 0 L 0 53 gal Center housing 11 0 L 2 90 gal Hub reduction gear 1 75 L 2 0 46 gal 2 ...

Page 164: ...IBRATORY DRUM REAR AXLE 3 4 Rear Axle Structure 3 4 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 165: ...2 3 3 6 12 7 10 11 12 13 14 15 8 4 7 5 9 1 1 SV510 ޓ 06101 1 Bolt 6 Bevel gear set 11 Taper roller bearing 2 Ring nut 7 Nospin differential 12 Shim 3 Taper roller bearing 8 Spacer 13 Seal 4 Bolt 9 Bolt 14 Spacer 5 Differential carrier 10 Ring nut 15 Shim ...

Page 166: ...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 167: ...6 043 VIBRATORY DRUM REAR AXLE 3 4 4 Brake 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 168: ...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 169: ...BRAKE ...

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Page 171: ...7 001 BRAKE 1 BRAKE PEDAL 0418 62801 0 10174 C 1 2 3 4 5 A DETAIL A 1 Brake pedal 4 Stopper bolt M10 50 2 Return spring 5 Foot brake switch 3 Nut M10 ...

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Page 173: ...he flow of the oil SECTION B B SECTION A A VIEW D VIEW C D E C TVB TBL VBT TBR RBR RBL VBB VBA VB1 VBP LOB BTV VB2 Valve block BSA AD2 Hose BTV VBB Hose VB1 TVB Hose VB2 AD2 Hose VB2 AD2 Hose VBT T5 Hose VB1 TVB Hose VBT T5 Hose VBT T5 Axle ASSY Hydraulic oil tank T5 Hose LOB BPF Hose TBL RBL Hose TBR RBR Hose VB1 TVB Hose VB2 AD2 Hose BSA VBA Parking brake solenoid valve A A B B DETAIL E BPF BSP ...

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Page 175: ...ing brake switch Brake OFF condition Steering charge pump Hand pump Rotary valve Parking brake solenoid valve when brake is ON without solenoid excited Brake Brake ON condition Brake Brake ON condition Parking brake solenoid valve when brake is OFF with solenoid excited The arrow symbol shows the direction of the hydraulic oil flow 1 4 3 2 5 ...

Page 176: ... 8 1 3 4 5 6 Hydraulic circuit diagram 7 8 6 2 1 Solenoid 2 O ring 1B P14 3 Spool J 4 Body 5 Spring 6 Port P BSP 9 16 18UNF 2B 7 Port A BSA 9 16 18UNF 2B 8 Port T BST 9 16 18UNF 2B Specifications Rated pressure 4 9 MPa 710 psi 6 7 0 5 MPa 72 5 psi 8 Rated flow 30 L min 7 9 gal min Weight 1 5 kg 3 3 lbs ...

Page 177: ...rt B2 VB2 9 16 18UNF 3 Port B1 VB1 9 16 18UNF 6 Rotary valve 70 N m 51 6 lbf ft 4 Port A VBA 9 16 18UNF 7 Hand pump 70 N m 51 6 lbf ft 5 Port P VBP 9 16 18UNF Specifications Maximum working pressure 1 8 MPa 261 psi Maximum flow 5 L min 1 3 gal min Hand pump displacement 5 7 mL stroke 0 0015 gal stroke N m N m ...

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Page 179: ...INSPECTION AND ADJUSTMENT ...

Page 180: ......

Page 181: ...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 182: ...e gauge port Forward 2 High pressure gauge port Reverse 1 Pressure gauge 0 to 50 MPa 0 to 7 250 psi Set propulsion speed change 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 ...

Page 183: ...5 psi turn If there is no evidence of nut having loosened remove multifunction valve Check removed multifunction valve for trapped dirt and scratches on its seat If trapped dirt is present disassemble and clean multifunction valve If a scratch is found on seat replace multifunction valve After adjustment measure pressure again and check that pressure reaches maximum circuit pressure range N m 1 Nu...

Page 184: ...llowing 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 8 on vibrator pump side Tighten adjustment screw 2 by two complete turns Adjustment screw turned clockwise Pressure rise Adjustment screw turned counterclockwise Pressure drop Pressure change rate 0 56 MPa turn 81 2 psi turn The number 2 8 appearing in above...

Page 185: ...Coupling 9 16 18UNF M16 Adapter for hose ⓢ M16 P 2 0 Pressure gauge connector ⓤ M16 G3 8 Pressure gauge 0 to 5 MPa 0 to 725 psi Apply parking brake by pressing parking brake switch button Start the engine and set throttle switch to Full Then read pressure indicated by pressure gauge Standard charge relief valve setting 2 4 0 2 MPa 348 29 psi SV540 08001 1 SV540 08001 1 PG003163 s u PG003163 s u ...

Page 186: ...nge rate 0 39 MPa turn 57 psi turn If there is no evidence of nut having loosened remove charge relief valve Check removed charge relief valve for trapped dirt and scratches on its seat If trapped dirt is present disassemble and clean charge relief valve If a scratch is found on seat replace charge relief valve After adjustment measure pressure again and check that pressure reaches standard charge...

Page 187: ...ith the adapter ⓗ Adapter ⓗ 9 16 18UNF Servo pressure gauge port Low 1 Servo pressure gauge port High 2 Pressure gauge 0 to 5 MPa 0 to 725 psi Apply parking brake by pressing parking brake switch button Set propulsion speed change switch to or Start the engine and set throttle switch to Full Then read pressure indicated by pressure gauge Standard charge relief valve setting 2 4 0 2 MPa 348 29 psi ...

Page 188: ... 9 16 18UNF Servo pressure gauge port Low 1 Servo pressure gauge port High 2 Pressure gauge 0 to 5 MPa 0 to 725 psi Apply parking brake by pressing parking brake switch button Set propulsion speed change switch to or Start the engine and set throttle switch to Full Then read pressure indicated by pressure gauge Standard charge relief valve setting 2 0 0 2 MPa 290 29 psi SV540 08004 1 SV540 08004 1...

Page 189: ...adapter ⓦ Hose 1 Gear box Hose 2 Rear axle Adapter ⓦ 4 4LOHL6G5TP Parker part number Pressure gauge 0 to 5 MPa 0 to 725 psi Confirm that F R lever is N properly Apply parking brake by pressing parking brake switch button Start the engine and set throttle switch to Full Release parking brake by pressing parking brake switch button Then read brake release pressure indicated by pressure gauge Brake r...

Page 190: ...apter for hose ⓢ M16 P 2 0 Pressure gauge connector ⓤ M16 G3 8 High pressure gauge port 2 Low amplitude High pressure gauge port 1 High amplitude Pressure gauge 0 to 50 MPa 0 to 7 250 psi Apply parking brake by pressing parking brake switch button Set vibration mode change switch to Start the engine and set throttle switch to Full Press F R lever vibration switch ON Then read pressure gauge for ma...

Page 191: ...ure check relief valve If pressure still deviates from maximum circuit pressure range after valve is disassembled and cleaned replace high pressure check relief valve After inspection measure pressure again and check that pressure reaches maximum circuit pressure range N m Plug 70 N m 52 lbf ft NOTICE Carefully disassemble and reassemble after taking steps to prevent foreign material from getting ...

Page 192: ...ure that oil does not escape to the charge relief valve on propulsion pump side Loosen nut 2 from charge relief valve 1 6 on propulsion pump side Tighten adjustment screw 3 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 6 appearing in above illustrations is cons...

Page 193: ...Coupling 9 16 18UNF M16 Adapter for hose ⓢ M16 P 2 0 Pressure gauge connector ⓤ M16 G3 8 Pressure gauge 0 to 5 MPa 0 to 725 psi Apply parking brake by pressing parking brake switch button Start the engine and set throttle switch to Full Then read pressure indicated by pressure gauge Standard charge relief valve setting 2 4 0 2 MPa 348 29 psi SV540 08001 1 SV540 08001 1 PG003163 s u PG003163 s u ...

Page 194: ...ure drop Pressure change rate 0 56 MPa turn 81 2 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 ...

Page 195: ... 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 in measured pressures of 2 4 and 2 12 are same With vibration select switch is in or measured pressures of 2 4 and 2 12 are different Standard charge relief valve setting 2 4 0 2 MPa 348 29 psi The number 2 4 and 2 12 a...

Page 196: ...ose L or R from steering cylinder Attach pressure gauge through adapter ⓧ Adapter ⓧ 6 4LOHL6G5TP Parker part number Pressure gauge 0 to 25 MPa 0 to 3 625 psi Confirm that F R lever is N properly Start the engine and set throttle switch to Full Turn steering wheel to operate relief valve Then read pressure indicated by pressure gauge Standard maximum circuit pressure orbitroll relief pressure charg...

Page 197: ... 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 198: ...number Pressure gauge 0 to 5 MPa 0 to 725 psi Set propulsion speed change 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 measure pressure when speed change switch is in and and F R lever is in N F and R respectively Allowabl...

Page 199: ...ch pressure gauge through adapter ⓚ Adapter ⓚ 12 4LOHL6G5TF Parker part number 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 in and respectively Press F R lever vibration switch...

Page 200: ... 0 to 5 MPa 0 to 725 psi Set propulsion speed change 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 measure pressure when speed change switch is in and and F R lever is in N F and R respectively Allowable motor case pressure...

Page 201: ...Set propulsion speed change 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 measure pressure when speed change switch is in and and F R lever is in N F and R respectively Allowable motor case pressure 0 3 MPa 43 5 psi or less...

Page 202: ...rain 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 in and respectively Press F R lever vibration switch OFF as so...

Page 203: ...ordance 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 Specified dimension b 205 mm 8 07 in Confirm the strokes of propulsion pump control lever 3 Specified dimension c 25 mm 1 0 in SV520 08020 1 F N R 2 a SV520 08020 1 F N R 2 a SV520 08021 2 3 b...

Page 204: ...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 205: ... 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 207: ...TROUBLESHOOTING ...

Page 208: ......

Page 209: ...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 210: ...rating it Check the problem yourself 4 Identify the problem with either a mechanical hydraulic or electrical system source 5 Isolate the problem to a particular component or circuit 6 Eliminate the simplest or easiest to check possibilities first to prevent unnecessary disassembly of components 7 Following repair or replacement of any parts perform operational tests to verify that the problem has ...

Page 211: ...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 212: ...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 213: ...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 214: ...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 215: ... 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 216: ...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 217: ...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 218: ...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 219: ... go off one at a time at an interval of approximately 0 5 seconds each ENGINE STOP Lamp The ENGINE STOP lamp provides critical operator messages These messages require immediate and decisive operator response The ENGINE STOP lamp is also used to flash out diagnostic fault codes WARNING Lamp The WARNING lamp provides important operator messages These messages require timely operator attention The W...

Page 220: ...he first fault code after the switch is turned on Each active fault shall flash out twice wrapping around to the first fault code at the end Flashing of fault codes The diagram below depicts the pattern of the fault code flash out scheme as indicated by the ENGINE STOP lamp A blink is equivalent to the ENGINE STOP lamp being on for 0 5 seconds and off for 0 5 seconds A pause between fault code dig...

Page 221: ...or pedal or lever position sensor circuit Voltage below normal or shorted to low source Remote accelerator will not operate Remote accelerator position will be set to zero percent 135 Orange Engine oil rifle pressure 1 sensor circuit Voltage above normal or shorted to high source None on performance No engine protection for oil pressure 141 Orange Engine oil rifle pressure 1 sensor circuit Voltage...

Page 222: ...r supply 2 circuit Voltage below normal or shorted to low source Engine power derate 195 Orange Coolant level sensor 1 circuit Voltage above normal or shorted to high source None on performance 196 Orange Coolant level sensor 1 circuit Voltage below normal or shorted to low source None on performance 197 Orange Coolant level Data valid but below normal operation range Moderately severe level None ...

Page 223: ...sor circuit Received network data in error The engine will not respond to the remote throttle Engine may only idle The primary or cab accelerator may be able to be used 292 Red Auxiliary temperature sensor input 1 Special instructions Possible engine derate 293 Orange Auxiliary temperature sensor input 1 circuit Voltage above normal or shorted to high source None on performance 294 Orange Auxiliar...

Page 224: ...8 Orange Water in fuel indicator sensor circuit Voltage above normal or shorted to high source None on performance No water in fuel warning available 429 Orange Water in fuel indicator sensor circuit Voltage below normal or shorted to low source None on performance No water in fuel warning available 431 Orange Accelerator pedal or lever idle validation switch Data erratic intermittent or incorrect...

Page 225: ...iliary input output 3 circuit Voltage above normal or shorted to high source None on performance 553 Orange Injector metering rail 1 pressure Data valid but above normal operation range Moderately severe level None or possible engine noise associated with higher injection pressures especially at idle or light load Engine power is reduced 555 Orange Crankcase pressure Data valid but above normal op...

Page 226: ...nformation trip information and maintenance monitor data can be inaccurate 1239 Orange Accelerator pedal or lever position sensor 2 circuit Voltage above normal or shorted to high source Severe derate in power output of the engine Limp home power only 1241 Orange Accelerator pedal or lever position sensor 2 circuit Voltage below normal or shorted to low source Severe derate in power output of the ...

Page 227: ... performance 2182 Orange Engine brake actuator driver 1 circuit Voltage above normal or shorted to high source Engine brake on cylinders 1 2 and 3 can not be activated 2183 Orange Engine brake actuator driver 1 circuit Voltage below normal or shorted to low source Engine brake on cylinders 1 2 and 3 can not be activated 2185 Orange Sensor supply 4 circuit Voltage above normal or shorted to high so...

Page 228: ...Voltage below normal or shorted to low source None on performance 2375 Orange Exhaust gas recirculation temperature sensor circuit Voltage above normal or shorted to high source EGR valve actuation will be disabled 2376 Orange Exhaust gas recirculation temperature sensor circuit Voltage below normal or shorted to low source EGR valve actuation will be disabled 2377 Orange Fan control circuit Volta...

Page 229: ...icle speed Abnormal update rate None on performance 3527 Red Accelerator pedal or lever idle validation switch Received network data in error Engine will only idle 3528 Red Accelerator pedal or lever idle validation switch Abnormal update rate Engine will only idle 3616 None Engine VGT nozzle position Mechanical system not responding or out of adjustment Engine power may be derated 3697 Red Engine...

Page 230: ...d to the T C controller via CAN in order to control the torque in accordance with the road surface condition Anti spin control The ECO controller has safeguard features error detection error display and error bypass action and displays each status with LED indicators Normal Red LED OFF green LED ON Abnormal An error code depending on the error type is indicated by a combination of long and short r...

Page 231: ... of signal voltage 32 Signal wire open circuit 64 Ground wire open circuit 128 Power supply voltage wire open circuit 256 1 long 6 short Motor rotation sensor front Shortage of power supply voltage 1 Over voltage of power supply voltage 2 Signal frequency is below threshold limit values for measurement 4 Signal frequency is over threshold 8 Shortage of signal voltage not in use 16 Over voltage of ...

Page 232: ...TARTER SWITCH B C BR 1 25Lg 26 24 4 5BY 1 25BR 114 BG 36 24 BR LgR 98 BY 98 BY STARTER MOTOR BR 1 25B X 71 8BW E X 1 25B 4 5BY F L 65A NO AV60 AV30 AV60 AV60 F L 75A 75 76 8WY 79 5WL F L 65A 77 5BW 65 3WR 5 1 25RB AV60 G 50 30 120Ω 120Ω WR J H G F E D C B A 118 98 BY 120 LB 74 WB RB 44 WR 118 1 25BR 24 1 25RB 5 RW 97 WB 74 13 W RB 64 B X GB 63 YL 8 LgW 82 BrW 37 LgR 36 GR 38 B X B X LgR 36 R 12 26...

Page 233: ...ween starter motor terminal 30 and chassis ground Standard voltage 24 V or more 2 When starter switch is START measure voltage between starter motor terminal 50 and chassis ground Standard voltage 24 V or more If starter motor does not run even though above items 1 and 2 are OK starter motor is faulty Replace starter motor 4 Diode Unit 1 When starter switch is ON measure voltage between diode unit...

Page 234: ...TARTER SWITCH B C BR 1 25Lg 26 24 4 5BY 1 25BR 114 BG 36 24 BR LgR 98 BY 98 BY STARTER MOTOR BR 1 25B X 71 8BW E X 1 25B 4 5BY F L 65A NO AV60 AV30 AV60 AV60 F L 75A 75 76 8WY 79 5WL F L 65A 77 5BW 65 3WR 5 1 25RB AV60 G 50 30 120Ω 120Ω WR J H G F E D C B A 118 98 BY 120 LB 74 WB RB 44 WR 118 1 25BR 24 1 25RB 5 RW 97 WB 74 13 W RB 64 B X GB 63 YL 8 LgW 82 BrW 37 LgR 36 GR 38 B X B X LgR 36 R 12 26...

Page 235: ...oltage 24 V or more 2 When starter switch is ON measure voltage between starter relay terminal 3 inlet wire BW and chassis ground Standard voltage 24 V or more 3 When starter switch is START measure voltage between starter relay terminal 5 outlet wire W and chassis ground Standard voltage 24 V or more If above items 1 and 2 are OK and item 3 is NG starter relay is faulty Replace starter relay 8 F ...

Page 236: ...TARTER SWITCH B C BR 1 25Lg 26 24 4 5BY 1 25BR 114 BG 36 24 BR LgR 98 BY 98 BY STARTER MOTOR BR 1 25B X 71 8BW E X 1 25B 4 5BY F L 65A NO AV60 AV30 AV60 AV60 F L 75A 75 76 8WY 79 5WL F L 65A 77 5BW 65 3WR 5 1 25RB AV60 G 50 30 120Ω 120Ω WR J H G F E D C B A 118 98 BY 120 LB 74 WB RB 44 WR 118 1 25BR 24 1 25RB 5 RW 97 WB 74 13 W RB 64 B X GB 63 YL 8 LgW 82 BrW 37 LgR 36 GR 38 B X B X LgR 36 R 12 26...

Page 237: ...r more 2 When starter switch is START measure voltage between interlock relay A 1 terminal 3 inlet wire Lg and chassis ground Standard voltage 24 V or more 3 When starter switch is START measure voltage between interlock relay A 1 terminal 5 outlet wire BY and chassis ground Standard voltage 24 V or more If above items 1 and 2 are OK and item 3 is NG interlock relay A 1 is faulty Replace interlock...

Page 238: ...TARTER SWITCH B C BR 1 25Lg 26 24 4 5BY 1 25BR 114 BG 36 24 BR LgR 98 BY 98 BY STARTER MOTOR BR 1 25B X 71 8BW E X 1 25B 4 5BY F L 65A NO AV60 AV30 AV60 AV60 F L 75A 75 76 8WY 79 5WL F L 65A 77 5BW 65 3WR 5 1 25RB AV60 G 50 30 120Ω 120Ω WR J H G F E D C B A 118 98 BY 120 LB 74 WB RB 44 WR 118 1 25BR 24 1 25RB 5 RW 97 WB 74 13 W RB 64 B X GB 63 YL 8 LgW 82 BrW 37 LgR 36 GR 38 B X B X LgR 36 R 12 26...

Page 239: ...e 24 V or more 2 When starter switch is ON measure voltage between brake relay A 3 terminal 3 inlet wire BR and chassis ground Standard voltage 24 V or more 3 When starter switch is ON measure voltage between brake relay A 3 terminal 5 outlet wire BG and chassis ground Standard voltage 24 V or more If above items 1 and 2 are OK and item 3 is NG brake relay A 3 is faulty Replace brake relay A 3 14 ...

Page 240: ...OUBLESHOOTING Fig 2 4 2 SV540 09010 7 6 1 2 3 5 4 VIEW A VIEW B DETAIL C A C B 1 Fuel from supply tank 5 Fuel filter 2 Priming pump 6 Fuel gear pump 3 Fuel to fuel filter 7 Fuel supply to pump 4 Fuel pre filter ...

Page 241: ...ine may fail Replace fuel in tank with an appropriate one 2 Water Fuel Pre Filter Fuel Filter Pressure Side Check that water does not cover water in fuel WIF sensor in contaminant collection bowl If water covers the sensor engine may not start Drain water Check filter for clogging Insufficient supply of proper fuel due to clogging of filter NOTICE Air bleeding should be performed whenever filter i...

Page 242: ...TARTER SWITCH B C BR 1 25Lg 26 24 4 5BY 1 25BR 114 BG 36 24 BR LgR 98 BY 98 BY STARTER MOTOR BR 1 25B X 71 8BW E X 1 25B 4 5BY F L 65A NO AV60 AV30 AV60 AV60 F L 75A 75 76 8WY 79 5WL F L 65A 77 5BW 65 3WR 5 1 25RB AV60 G 50 30 120Ω 120Ω WR J H G F E D C B A 118 98 BY 120 LB 74 WB RB 44 WR 118 1 25BR 24 1 25RB 5 RW 97 WB 74 13 W RB 64 B X GB 63 YL 8 LgW 82 BrW 37 LgR 36 GR 38 B X B X LgR 36 R 12 26...

Page 243: ... normal grid heater is faulty Replace grid heater 2 Grid Heater Relay 1 When starter switch is ON measure voltage between grid heater relay terminal 2 inlet wire GB and chassis ground Standard voltage 24 V or more 2 When starter switch is ON measure voltage between grid heater relay terminal 3 inlet wire L and chassis ground Standard voltage 24 V or more 3 When starter switch is ON measure voltage...

Page 244: ...TARTER SWITCH B C BR 1 25Lg 26 24 4 5BY 1 25BR 114 BG 36 24 BR LgR 98 BY 98 BY STARTER MOTOR BR 1 25B X 71 8BW E X 1 25B 4 5BY F L 65A NO AV60 AV30 AV60 AV60 F L 75A 75 76 8WY 79 5WL F L 65A 77 5BW 65 3WR 5 1 25RB AV60 G 50 30 120Ω 120Ω WR J H G F E D C B A 118 98 BY 120 LB 74 WB RB 44 WR 118 1 25BR 24 1 25RB 5 RW 97 WB 74 13 W RB 64 B X GB 63 YL 8 LgW 82 BrW 37 LgR 36 GR 38 B X B X LgR 36 R 12 26...

Page 245: ...eck continuity between throttle switch terminals 1 and 3 4 and 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 B 1 1 When starter switch is ON and throttle switch is FULL m...

Page 246: ...BATTERY 31 12 BATTERY 11 BATTERY 6 WAIT TO STOP LAMP BATTERY 22 BATTERY 21 18 CAN A 17 CAN A 52 SENSOR SUPPLY POWER 44 COOLANT LEVEL SIGNAL 43 OEM SENSOR SIGNAL RETURN 3 KEY SWITCH SIGNAL ISC2 SWITCH MIDDLE 38 ISC1 SWITCH FULL 39 16 WARNING LAMP 8 STOP LAMP 2 BATTERY 1 BATTERY BY 98 67 W 67 W 67 W 67 W GY 88 Y 89 L 93 66 B 66 B 66 B 66 B ACC W 119 5R 78 5R 78 5RG 23 5RG 23 5R 3 5R 3 5R 3 BY 4 BY 4...

Page 247: ...h is ON measure voltage between foot brake switch terminal COM inlet wire R and chassis ground Standard voltage 24 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 24 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 start...

Page 248: ...BATTERY 31 12 BATTERY 11 BATTERY 6 WAIT TO STOP LAMP BATTERY 22 BATTERY 21 18 CAN A 17 CAN A 52 SENSOR SUPPLY POWER 44 COOLANT LEVEL SIGNAL 43 OEM SENSOR SIGNAL RETURN 3 KEY SWITCH SIGNAL ISC2 SWITCH MIDDLE 38 ISC1 SWITCH FULL 39 16 WARNING LAMP 8 STOP LAMP 2 BATTERY 1 BATTERY BY 98 67 W 67 W 67 W 67 W GY 88 Y 89 L 93 66 B 66 B 66 B 66 B ACC W 119 5R 78 5R 78 5RG 23 5RG 23 5R 3 5R 3 5R 3 BY 4 BY 4...

Page 249: ...oid Rear Disconnect harness and measure resistances of coil Standard resistance 14 2 Ω If resistance is abnormal motor proportional solenoid rear is faulty Replace motor proportional solenoid rear 3 Speed Change Switch 1 When starter switch is ON measure voltage between speed change switch terminal 1 inlet wire L terminal 4 inlet wire L and chassis ground Standard voltage 24 V or more 2 When start...

Page 250: ...BATTERY 31 12 BATTERY 11 BATTERY 6 WAIT TO STOP LAMP BATTERY 22 BATTERY 21 18 CAN A 17 CAN A 52 SENSOR SUPPLY POWER 44 COOLANT LEVEL SIGNAL 43 OEM SENSOR SIGNAL RETURN 3 KEY SWITCH SIGNAL ISC2 SWITCH MIDDLE 38 ISC1 SWITCH FULL 39 16 WARNING LAMP 8 STOP LAMP 2 BATTERY 1 BATTERY BY 98 67 W 67 W 67 W 67 W GY 88 Y 89 L 93 66 B 66 B 66 B 66 B ACC W 119 5R 78 5R 78 5RG 23 5RG 23 5R 3 5R 3 5R 3 BY 4 BY 4...

Page 251: ...C1 P7 inlet wire W and chassis ground There is no electricity in normal condition 5 Check that T C controller terminal C1 P1 wire B is grounded 6 When starter switch is ON measure current between T C controller and chassis ground Front motor side T C controller terminal C2 P3 outlet wire BL and chassis ground Standard current 0 mA When speed change switch is and F R lever is R 600 mA Except when s...

Page 252: ...BATTERY 31 12 BATTERY 11 BATTERY 6 WAIT TO STOP LAMP BATTERY 22 BATTERY 21 18 CAN A 17 CAN A 52 SENSOR SUPPLY POWER 44 COOLANT LEVEL SIGNAL 43 OEM SENSOR SIGNAL RETURN 3 KEY SWITCH SIGNAL ISC2 SWITCH MIDDLE 38 ISC1 SWITCH FULL 39 16 WARNING LAMP 8 STOP LAMP 2 BATTERY 1 BATTERY BY 98 67 W 67 W 67 W 67 W GY 88 Y 89 L 93 66 B 66 B 66 B 66 B ACC W 119 5R 78 5R 78 5RG 23 5RG 23 5R 3 5R 3 5R 3 BY 4 BY 4...

Page 253: ...s faulty Replace connector or terminal 2 Harness Measure resistances between motor proportional solenoid rear terminal wire BW and T C controller terminal C2 P4 wire BW Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 1 long 3 short or 1 long 4 short 1 Connector Check motor speed change solenoid front connector and T C controller terminal C2 P3...

Page 254: ...BATTERY 31 12 BATTERY 11 BATTERY 6 WAIT TO STOP LAMP BATTERY 22 BATTERY 21 18 CAN A 17 CAN A 52 SENSOR SUPPLY POWER 44 COOLANT LEVEL SIGNAL 43 OEM SENSOR SIGNAL RETURN 3 KEY SWITCH SIGNAL ISC2 SWITCH MIDDLE 38 ISC1 SWITCH FULL 39 16 WARNING LAMP 8 STOP LAMP 2 BATTERY 1 BATTERY BY 98 67 W 67 W 67 W 67 W GY 88 Y 89 L 93 66 B 66 B 66 B 66 B ACC W 119 5R 78 5R 78 5RG 23 5RG 23 5R 3 5R 3 5R 3 BY 4 BY 4...

Page 255: ...terminal C1 P8 wire Lg Motor rotation sensor rear terminal PULSE wire GR and T C controller terminal C2 P2 wire GR Motor rotation sensor rear terminal GROUND wire L and T C controller terminal C1 P9 wire L Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 3 Motor Rotation Sensor Rear 1 When starter switch is ON measure voltage between motor rota...

Page 256: ...BATTERY 31 12 BATTERY 11 BATTERY 6 WAIT TO STOP LAMP BATTERY 22 BATTERY 21 18 CAN A 17 CAN A 52 SENSOR SUPPLY POWER 44 COOLANT LEVEL SIGNAL 43 OEM SENSOR SIGNAL RETURN 3 KEY SWITCH SIGNAL ISC2 SWITCH MIDDLE 38 ISC1 SWITCH FULL 39 16 WARNING LAMP 8 STOP LAMP 2 BATTERY 1 BATTERY BY 98 67 W 67 W 67 W 67 W GY 88 Y 89 L 93 66 B 66 B 66 B 66 B ACC W 119 5R 78 5R 78 5RG 23 5RG 23 5R 3 5R 3 5R 3 BY 4 BY 4...

Page 257: ...ation Sensor Front 1 When starter switch is ON measure voltage between motor rotation sensor front terminal POWER inlet wire Lg and chassis ground Standard voltage 5 0 0 25 V 2 Check that motor rotation sensor front terminal GROUND wire L is grounded 3 Start engine and rotate drum Measure pulse between motor rotation sensor front terminal PULSE outlet wire GB and chassis ground Standard pulse 71 p...

Page 258: ...BATTERY 31 12 BATTERY 11 BATTERY 6 WAIT TO STOP LAMP BATTERY 22 BATTERY 21 18 CAN A 17 CAN A 52 SENSOR SUPPLY POWER 44 COOLANT LEVEL SIGNAL 43 OEM SENSOR SIGNAL RETURN 3 KEY SWITCH SIGNAL ISC2 SWITCH MIDDLE 38 ISC1 SWITCH FULL 39 16 WARNING LAMP 8 STOP LAMP 2 BATTERY 1 BATTERY BY 98 67 W 67 W 67 W 67 W GY 88 Y 89 L 93 66 B 66 B 66 B 66 B ACC W 119 5R 78 5R 78 5RG 23 5RG 23 5R 3 5R 3 5R 3 BY 4 BY 4...

Page 259: ...tween foot brake switch terminal NO outlet wire LgR and chassis ground Standard voltage 24 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 starter switch is ON measure voltage between parking brake switch terminal 1 inlet wire LgR and chassis ground Standard voltage 24 V or more 2 When starter switch is ON measure...

Page 260: ...BATTERY 31 12 BATTERY 11 BATTERY 6 WAIT TO STOP LAMP BATTERY 22 BATTERY 21 18 CAN A 17 CAN A 52 SENSOR SUPPLY POWER 44 COOLANT LEVEL SIGNAL 43 OEM SENSOR SIGNAL RETURN 3 KEY SWITCH SIGNAL ISC2 SWITCH MIDDLE 38 ISC1 SWITCH FULL 39 16 WARNING LAMP 8 STOP LAMP 2 BATTERY 1 BATTERY BY 98 67 W 67 W 67 W 67 W GY 88 Y 89 L 93 66 B 66 B 66 B 66 B ACC W 119 5R 78 5R 78 5RG 23 5RG 23 5R 3 5R 3 5R 3 BY 4 BY 4...

Page 261: ...ge between parking brake switch terminal 3 outlet wire BrW and chassis ground There is no electricity in normal condition If electricity flows parking brake switch is faulty Replace parking brake switch 3 Foot Brake Switch When starter switch is ON measure voltage between foot brake switch terminal NO outlet wire LgR and chassis ground There is no electricity in normal condition If electricity flo...

Page 262: ... P2 C1 P6 C2 P5 C1 P10 C1 P11 C1 P4 C1 P3 C1 P7 C1 P12 B X B X G 40 YW 99 LgW 62 L 39 LY 51 LW 50 GB 60 L 69 Lg 68 GR 56 BL 58 BW 54 L 39 REAR LAMP FRONT LAMP T C LAMP SOL DIRECTION PULSE POWER GROUND MOTOR ROTATION SENSOR REAR MOTOR ROTATION SENSOR FRONT 5 6 2 3 4 1 SOL SPEED CHANGE SWITCH MOTOR PROPORTIONAL SOLENOID REAR CONNECTION SPEED 1 2 4 5 1 3 4 6 SPEED CHANGE SWITCH T C CONTROLLER IOX024 ...

Page 263: ...ndard resistance 36 Ω If resistance is abnormal vibrator proportional solenoid 2 is faulty Replace vibrator proportional solenoid 2 3 Vibration Select Switch 1 When starter switch is ON measure voltage between vibration select switch terminal 1 inlet wire Y terminal 4 inlet wire Y and chassis ground Standard voltage 24 V or more 2 When starter switch is ON and vibration select switch is measure vo...

Page 264: ... P2 C1 P6 C2 P5 C1 P10 C1 P11 C1 P4 C1 P3 C1 P7 C1 P12 B X B X G 40 YW 99 LgW 62 L 39 LY 51 LW 50 GB 60 L 69 Lg 68 GR 56 BL 58 BW 54 L 39 REAR LAMP FRONT LAMP T C LAMP SOL DIRECTION PULSE POWER GROUND MOTOR ROTATION SENSOR REAR MOTOR ROTATION SENSOR FRONT 5 6 2 3 4 1 SOL SPEED CHANGE SWITCH MOTOR PROPORTIONAL SOLENOID REAR CONNECTION SPEED 1 2 4 5 1 3 4 6 SPEED CHANGE SWITCH T C CONTROLLER IOX024 ...

Page 265: ...l relay B 3 6 ECO controller 1 When starter switch is ON measure voltage between ECO controller terminal C1 P2 inlet wire YB and chassis ground Standard voltage 24 V 2 When starter switch is ON and vibration select switch is or measure voltage between ECO controller terminal wires and chassis ground ECO controller terminal C1 P9 inlet wire YR and chassis ground ECO controller terminal C1 P10 inlet...

Page 266: ... P2 C1 P6 C2 P5 C1 P10 C1 P11 C1 P4 C1 P3 C1 P7 C1 P12 B X B X G 40 YW 99 LgW 62 L 39 LY 51 LW 50 GB 60 L 69 Lg 68 GR 56 BL 58 BW 54 L 39 REAR LAMP FRONT LAMP T C LAMP SOL DIRECTION PULSE POWER GROUND MOTOR ROTATION SENSOR REAR MOTOR ROTATION SENSOR FRONT 5 6 2 3 4 1 SOL SPEED CHANGE SWITCH MOTOR PROPORTIONAL SOLENOID REAR CONNECTION SPEED 1 2 4 5 1 3 4 6 SPEED CHANGE SWITCH T C CONTROLLER IOX024 ...

Page 267: ...or and ECO controller terminal C1 P11 for corrosion breakage bending and looseness If any abnormality is found connector is faulty Replace connector or terminal 2 Harness Measure resistances between vibrator proportional solenoid 1 terminal wire RL and ECO controller terminal C1 P11 wire RL Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 2 lon...

Page 268: ... P2 C1 P6 C2 P5 C1 P10 C1 P11 C1 P4 C1 P3 C1 P7 C1 P12 B X B X G 40 YW 99 LgW 62 L 39 LY 51 LW 50 GB 60 L 69 Lg 68 GR 56 BL 58 BW 54 L 39 REAR LAMP FRONT LAMP T C LAMP SOL DIRECTION PULSE POWER GROUND MOTOR ROTATION SENSOR REAR MOTOR ROTATION SENSOR FRONT 5 6 2 3 4 1 SOL SPEED CHANGE SWITCH MOTOR PROPORTIONAL SOLENOID REAR CONNECTION SPEED 1 2 4 5 1 3 4 6 SPEED CHANGE SWITCH T C CONTROLLER IOX024 ...

Page 269: ...en vibration select switch terminal 1 inlet wire Y terminal 4 inlet wire Y and chassis ground Standard voltage 24 V or more 2 When starter switch is ON and vibration select switch is measure voltage vibration select switch terminal wires and chassis ground Vibration select switch terminal 2 outlet wire YR and chassis ground Vibration select switch terminal 5 outlet wire YB and chassis ground There...

Page 270: ... P2 C1 P6 C2 P5 C1 P10 C1 P11 C1 P4 C1 P3 C1 P7 C1 P12 B X B X G 40 YW 99 LgW 62 L 39 LY 51 LW 50 GB 60 L 69 Lg 68 GR 56 BL 58 BW 54 L 39 REAR LAMP FRONT LAMP T C LAMP SOL DIRECTION PULSE POWER GROUND MOTOR ROTATION SENSOR REAR MOTOR ROTATION SENSOR FRONT 5 6 2 3 4 1 SOL SPEED CHANGE SWITCH MOTOR PROPORTIONAL SOLENOID REAR CONNECTION SPEED 1 2 4 5 1 3 4 6 SPEED CHANGE SWITCH T C CONTROLLER IOX024 ...

Page 271: ...e switch terminal 3 outlet wire WB terminal 5 outlet wire LB and chassis ground Standard voltage 24 V or more If above items 1 and 2 are OK and item 3 is NG throttle switch is faulty Replace throttle switch 5 MID speed control relay B 2 1 When starter switch is ON and throttle switch is MID measure voltage between MID speed control relay B 2 terminal 1 inlet wire RW and chassis ground Standard vol...

Page 272: ... P2 C1 P6 C2 P5 C1 P10 C1 P11 C1 P4 C1 P3 C1 P7 C1 P12 B X B X G 40 YW 99 LgW 62 L 39 LY 51 LW 50 GB 60 L 69 Lg 68 GR 56 BL 58 BW 54 L 39 REAR LAMP FRONT LAMP T C LAMP SOL DIRECTION PULSE POWER GROUND MOTOR ROTATION SENSOR REAR MOTOR ROTATION SENSOR FRONT 5 6 2 3 4 1 SOL SPEED CHANGE SWITCH MOTOR PROPORTIONAL SOLENOID REAR CONNECTION SPEED 1 2 4 5 1 3 4 6 SPEED CHANGE SWITCH T C CONTROLLER IOX024 ...

Page 273: ...throttle switch is MID voltage between ECO controller terminal C1 P8 inlet wire G and chassis ground Standard voltage 24 V 5 After starting engine and vibration select switch is or measure current between ECO controller terminal wires and chassis ground ECO controller terminal C1 P11 outlet wire RL and chassis ground Standard current 450 mA at throttle switch is MID 340 mA at throttle switch is FU...

Page 274: ... P2 C1 P6 C2 P5 C1 P10 C1 P11 C1 P4 C1 P3 C1 P7 C1 P12 B X B X G 40 YW 99 LgW 62 L 39 LY 51 LW 50 GB 60 L 69 Lg 68 GR 56 BL 58 BW 54 L 39 REAR LAMP FRONT LAMP T C LAMP SOL DIRECTION PULSE POWER GROUND MOTOR ROTATION SENSOR REAR MOTOR ROTATION SENSOR FRONT 5 6 2 3 4 1 SOL SPEED CHANGE SWITCH MOTOR PROPORTIONAL SOLENOID REAR CONNECTION SPEED 1 2 4 5 1 3 4 6 SPEED CHANGE SWITCH T C CONTROLLER IOX024 ...

Page 275: ...ange Switch 1 When starter switch is ON measure voltage between vibration mode change switch terminal 1 inlet wire RL and chassis ground Standard voltage 24 V or more 2 When starter switch is ON measure voltage between vibration mode change switch terminal 3 outlet wire RG and chassis ground Standard voltage 24 V or more If above item 1 is OK and item 2 is NG vibration mode change switch is faulty...

Page 276: ... P2 C1 P6 C2 P5 C1 P10 C1 P11 C1 P4 C1 P3 C1 P7 C1 P12 B X B X G 40 YW 99 LgW 62 L 39 LY 51 LW 50 GB 60 L 69 Lg 68 GR 56 BL 58 BW 54 L 39 REAR LAMP FRONT LAMP T C LAMP SOL DIRECTION PULSE POWER GROUND MOTOR ROTATION SENSOR REAR MOTOR ROTATION SENSOR FRONT 5 6 2 3 4 1 SOL SPEED CHANGE SWITCH MOTOR PROPORTIONAL SOLENOID REAR CONNECTION SPEED 1 2 4 5 1 3 4 6 SPEED CHANGE SWITCH T C CONTROLLER IOX024 ...

Page 277: ...ation select switch is or measure voltage between ECO controller terminal wires and chassis ground ECO controller terminal C1 P9 inlet wire YR and chassis ground ECO controller terminal C1 P10 inlet wire YB and chassis ground Standard voltage 24 V 3 Check ECO controller terminal C1 P1 wire B is grounded 4 When starter switch is ON and throttle switch is MID voltage between ECO controller terminal ...

Page 278: ... PRESSURE WARNING B BrW YW G GW YR GR Y W OG GB OW WB RB LgY GY LW Br LB L WR GL R LR P YL O COMBINATION METER HYDRAURIC OIL FILTER SWITCH 1 HYDRAURIC OIL FILTER SWITCH 2 LAMP CHECK RELAY B 5 TO GRID HEATER RELAY COM AV60 AV60 B 66 3B CYLINDER BLOCK DUAL OUTPUT B 5 INTAKE AIR HEATER 4 OUTPUT RETURN 13 SWITCH AND TEMPERATURE SENSOR RETURN 19 DIAGNOSTIC 59 STARTER LOCKOUT 15 33 TACHOMETER BATTERY 32...

Page 279: ...ge between lamp check relay B 5 terminal 3 outlet wire B and chassis ground There is no electricity in normal condition 3 When starter switch is ON measure voltage between lamp check relay B 5 terminal 3 outlet wire B and chassis ground Standard voltage 24 V or more If above item 1 is OK and item 2 is NG lamp check relay B 5 is faulty If above item 3 is OK and item 1 is NG alternator is faulty Rep...

Page 280: ... PRESSURE WARNING B BrW YW G GW YR GR Y W OG GB OW WB RB LgY GY LW Br LB L WR GL R LR P YL O COMBINATION METER HYDRAURIC OIL FILTER SWITCH 1 HYDRAURIC OIL FILTER SWITCH 2 LAMP CHECK RELAY B 5 TO GRID HEATER RELAY COM AV60 AV60 B 66 3B CYLINDER BLOCK DUAL OUTPUT B 5 INTAKE AIR HEATER 4 OUTPUT RETURN 13 SWITCH AND TEMPERATURE SENSOR RETURN 19 DIAGNOSTIC 59 STARTER LOCKOUT 15 33 TACHOMETER BATTERY 32...

Page 281: ...above items 1 and 2 are OK and pulse is NG in item 3 tachometer sensor is faulty If above items 1 and 2 are OK and tachometer reading is NG in item 3 combination meter is faulty Replace tachometer sensor or combination meter 2 Harness Connecting Between Terminals Measure resistance of harness connecting between terminals Standard resistance 10 Ω or less If resistance is abnormal harness is faulty ...

Page 282: ... PRESSURE WARNING B BrW YW G GW YR GR Y W OG GB OW WB RB LgY GY LW Br LB L WR GL R LR P YL O COMBINATION METER HYDRAURIC OIL FILTER SWITCH 1 HYDRAURIC OIL FILTER SWITCH 2 LAMP CHECK RELAY B 5 TO GRID HEATER RELAY COM AV60 AV60 B 66 3B CYLINDER BLOCK DUAL OUTPUT B 5 INTAKE AIR HEATER 4 OUTPUT RETURN 13 SWITCH AND TEMPERATURE SENSOR RETURN 19 DIAGNOSTIC 59 STARTER LOCKOUT 15 33 TACHOMETER BATTERY 32...

Page 283: ...of harness connecting between terminals Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 2 7 5 Fuel meter is abnormal Reference Fig 2 7 1 Check point Check Cause Action 1 Fuel Unit Disconnect harness and measure resistance of fuel unit Standard resistance 13 5 Ω with float in F 80 0 Ω with float in E If resistance is abnormal fuel unit is fault...

Page 284: ... PRESSURE WARNING B BrW YW G GW YR GR Y W OG GB OW WB RB LgY GY LW Br LB L WR GL R LR P YL O COMBINATION METER HYDRAURIC OIL FILTER SWITCH 1 HYDRAURIC OIL FILTER SWITCH 2 LAMP CHECK RELAY B 5 TO GRID HEATER RELAY COM AV60 AV60 B 66 3B CYLINDER BLOCK DUAL OUTPUT B 5 INTAKE AIR HEATER 4 OUTPUT RETURN 13 SWITCH AND TEMPERATURE SENSOR RETURN 19 DIAGNOSTIC 59 STARTER LOCKOUT 15 33 TACHOMETER BATTERY 32...

Page 285: ...ity 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 indicator lamp 1 When starter switch is ON measure voltage between combination meter terminal wires and ground terminal wire Battery terminal inlet wire No 70 inlet wire WR and ground terminal wire B Starter switch t...

Page 286: ... PRESSURE WARNING B BrW YW G GW YR GR Y W OG GB OW WB RB LgY GY LW Br LB L WR GL R LR P YL O COMBINATION METER HYDRAURIC OIL FILTER SWITCH 1 HYDRAURIC OIL FILTER SWITCH 2 LAMP CHECK RELAY B 5 TO GRID HEATER RELAY COM AV60 AV60 B 66 3B CYLINDER BLOCK DUAL OUTPUT B 5 INTAKE AIR HEATER 4 OUTPUT RETURN 13 SWITCH AND TEMPERATURE SENSOR RETURN 19 DIAGNOSTIC 59 STARTER LOCKOUT 15 33 TACHOMETER BATTERY 32...

Page 287: ...elay B 4 1 When starter switch is ON measure voltage between engine oil pressure switch relay B 4 terminal 1 inlet wire RB and chassis ground There is no electricity in normal condition 2 When starter switch is ON measure voltage between engine oil pressure switch relay B 4 terminal 3 outlet wire B and chassis ground There is no electricity in normal condition If above item 1 is OK and item 2 is N...

Page 288: ...1 25RB 44 RB 44 1 25RB 44 RW 97 RW 97 B X B YB 10 YR 9 B X B X G 105 YB 106 YB 106 G 105 RY C1 P5 C1 P7 C1 P6 C1 P8 C1 P4 C1 P3 C1 P2 C1 P1 YR 9 G Br 1 3 2 2 1 4 5 6 3 2 1 Y 11 RW 97 YB 10 Br 31 Br 31 YB 10 YR 9 Y 11 RG 81 Y 11 1 25RL 73 YB 106 6 5 3 4 1 2 CONNECTION ENGINE SPEED 1 3 4 5 1 3 4 6 1 2 4 6 FULL MID IDLE THROTTLE SWITCH X VIBRATOR CALCULATION SWITCH C1 P11 LOW C1 P12 HI C1 P10 HI C1 P...

Page 289: ...itch is ON and vibration select switch is measure voltage between diode unit terminal E inlet wire YB and chassis ground Standard voltage 24 V or more 3 When starter switch is ON measure voltage between diode unit terminal F outlet wire Br and chassis ground Standard voltage 24 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 Vibr...

Page 290: ...1 25RB 44 RB 44 1 25RB 44 RW 97 RW 97 B X B YB 10 YR 9 B X B X G 105 YB 106 YB 106 G 105 RY C1 P5 C1 P7 C1 P6 C1 P8 C1 P4 C1 P3 C1 P2 C1 P1 YR 9 G Br 1 3 2 2 1 4 5 6 3 2 1 Y 11 RW 97 YB 10 Br 31 Br 31 YB 10 YR 9 Y 11 RG 81 Y 11 1 25RL 73 YB 106 6 5 3 4 1 2 CONNECTION ENGINE SPEED 1 3 4 5 1 3 4 6 1 2 4 6 FULL MID IDLE THROTTLE SWITCH X VIBRATOR CALCULATION SWITCH C1 P11 LOW C1 P12 HI C1 P10 HI C1 P...

Page 291: ... continuity parking 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 Battery terminal wire No 70 inlet wire WR and ground terminal wire B Starter switch terminal wire No 35 inlet wire YW and ground terminal wire B Standard voltage 24 V or...

Page 292: ...1 25RB 44 RB 44 1 25RB 44 RW 97 RW 97 B X B YB 10 YR 9 B X B X G 105 YB 106 YB 106 G 105 RY C1 P5 C1 P7 C1 P6 C1 P8 C1 P4 C1 P3 C1 P2 C1 P1 YR 9 G Br 1 3 2 2 1 4 5 6 3 2 1 Y 11 RW 97 YB 10 Br 31 Br 31 YB 10 YR 9 Y 11 RG 81 Y 11 1 25RL 73 YB 106 6 5 3 4 1 2 CONNECTION ENGINE SPEED 1 3 4 5 1 3 4 6 1 2 4 6 FULL MID IDLE THROTTLE SWITCH X VIBRATOR CALCULATION SWITCH C1 P11 LOW C1 P12 HI C1 P10 HI C1 P...

Page 293: ...d Standard voltage 24 V or more 2 When starter switch is ON measure voltage between throttle switch terminal 6 outlet wire RW and chassis ground Standard voltage 24 V or more If above items 1 is OK and item 2 is NG throttle switch is faulty Replace throttle switch 3 MID Speed Control Relay B 2 1 When starter switch is ON measure voltage between MID speed control relay B 2 terminal 1 inlet wire RW ...

Page 294: ...TERNATOR B ACC BR C OFF ON ST STARTER SWITCH STARTER SWITCH B C BR 24 4 5BY 1 25BR TO STARTER MOTOR BR 1 25B X E NO AV60 AV30 AV60 AV60 F L 75A 75 76 8WY 79 5WL F L 65A 4 5BY F L 65A 77 5BW 65 5 1 25RB AV60 1 25BR 24 1 25RB 5 13 5A 12 20A FUSE BOX 1 11 20A 15A 15A 15A 5A 15A 15A 20A 5A 15A 10 9 8 7 6 5 4 3 2 20A 1 TO FUSE BOX 2 DIODE UNIT H G F I D C B E A G B A C E F H I D 115E41R 651CCA 115E41R ...

Page 295: ...n 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 7 12 Backup buzzer does not sound Reference Fig 2 7 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...

Page 296: ...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 297: ... pump or replace it if necessary Charge pressure decreases due to internal leakage of solenoid valve connecting oil supply 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 Suction Filter for Steering Charge Pump Steering ch...

Page 298: ...int Cause Check Action 1 F R Lever Linkage 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 ...

Page 299: ... if necessary Discharge flow rate is insufficient due to wear of propulsion pump drive shaft splines Replace propulsion pump Propulsion circuit pressure is not held in propulsion pump case If pressure in propulsion pump case is not within allowable range repair propulsion pump or replace it if necessary 3 2 4 Machine speed cannot be switched Check point Cause Check Action 1 Speed Change Solenoid V...

Page 300: ... oil in circuit to 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...

Page 301: ...hift Repair vibrator proportional 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 ...

Page 302: ...alve or replace it if necessary Vibrator circuit pressure is not held in vibrator motor case If pressure in vibrator motor case is not within allowable range repair vibrator motor or replace it if necessary Decrease in vibrator motor rpm due to internal leakage in vibrator motor Measure drain quantity from vibrator motor If drain quantity is larger than standard value repair vibrator motor or repl...

Page 303: ... If load is excessively heavy 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...

Page 304: ...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 305: ... is excessively heavy relief valve is open causing temperature of hydraulic oil in circuit to rise Measure steering circuit pressure If high decrease steering load 4 Suction Filter for Steering Charge Pump Load of steering charge pump increases due to clogged filter causing temperature of hydraulic oil in circuit to rise Clean suction filter or replace it if necessary 3 4 5 Abnormal noise from ste...

Page 306: ...Printed in Japan 2013 11 50 0 H S 0418 99045 0 31159 0 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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