Sakai SW300-1 Shop Manual Download Page 2

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00̲Hyo1̲Intro̲Contents.indd 002

2012/11/20 8:11:18

Summary of Contents for SW300-1

Page 1: ...SW300 1 SW TW320 1 TW TW330 1 SHOP MANUAL 3498 64454 0 00 Hyo1 Intro Contents indd 001 00 Hyo1 Intro Contents indd 001 2012 11 20 8 11 17 2012 11 20 8 11 17...

Page 2: ...00 Hyo1 Intro Contents indd 002 00 Hyo1 Intro Contents indd 002 2012 11 20 8 11 18 2012 11 20 8 11 18...

Page 3: ...esult 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 poten...

Page 4: ...00 Hyo1 Intro Contents indd 004 00 Hyo1 Intro Contents indd 004 2012 11 20 8 11 18 2012 11 20 8 11 18...

Page 5: ...ntenance 1 005 1 11 Transporting the Machine 1 007 2 SPECIFICATIONS 1 SPECIFICATION DATA 1 1 SW300 1 2 001 1 2 SW320 1 2 003 1 3 SW330 1 2 005 1 4 TW320 1 2 007 1 5 TW330 1 2 009 2 TABLE OF STANDARD V...

Page 6: ...007 2 1 4 Propulsion hydraulic piping 3 SW types rear 4 008 2 1 5 Propulsion hydraulic piping 3 TW types rear 4 009 2 2 Hydraulic Component Specifications 4 010 2 2 1 Propulsion pump 4 010 2 2 2 Propu...

Page 7: ...IONS FOR DISASSEMBLY AND REASSEMBLY 6 001 2 VIBRATORY DRUM 2 1 Removal and Installation of Vibratory Drum 6 003 2 1 1 Removal of front vibratory drum 6 004 2 1 2 Removal of rear vibratory drum 6 006 2...

Page 8: ...MENT AND INSPECTION OF PROPULSION CIRCUIT PRESSURE 2 1 Measurement 9 002 2 2 Inspection 9 003 3 MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT PRESSURE 3 1 Measurement 9 004 3 2 Adjustment 9...

Page 9: ...g a tester 10 004 2 1 3 Inspection of electrical system 10 009 2 2 Engine 10 012 2 2 1 Engine will not start Starter motor does not run 1 2 10 012 2 2 1 Engine will not start Starter motor does not ru...

Page 10: ...light 10 050 2 6 15 Horn does not sound 10 052 2 6 16 Backup buzzer does not sound 10 052 3 HYDRAULIC SYSTEM TROUBLESHOOTING 3 1 When Performing Hydraulic System Troubleshooting 10 053 3 2 Propulsion...

Page 11: ...2 Steering response is slow 10 061 3 4 3 Steering wheel backlash or play is large 10 062 3 4 4 Steering system is overheating 10 062 3 4 5 Abnormal noise from steering system 10 062 00 Hyo1 Intro Con...

Page 12: ...00 Hyo1 Intro Contents indd 012 00 Hyo1 Intro Contents indd 012 2012 11 20 8 11 18 2012 11 20 8 11 18...

Page 13: ...SAFETY 01 SAFETY P001 010 indd 1 01 SAFETY P001 010 indd 1 2012 11 20 8 18 16 2012 11 20 8 18 16...

Page 14: ...01 SAFETY P001 010 indd 2 01 SAFETY P001 010 indd 2 2012 11 20 8 18 16 2012 11 20 8 18 16...

Page 15: ...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...

Page 16: ...o 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 Safe...

Page 17: ...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 w...

Page 18: ...pactor 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...

Page 19: ...attaching and securing lifting tackle to individual parts and large assemblies being removed or repositioned for repair purposes to avoid the risk of accident Use lifting devices that are in perfect...

Page 20: ...sly authorized as there may be a risk of fire or explosion Disconnect the battery when welding on the machine Clean the machine and its surrounding from dust or other flammable substances and make sur...

Page 21: ...e hauling vehicle when loading and unloading the compactor Ensure that the haul vehicle is on level ground and approach the loading ramps squarely to make sure that the compactor does not slide off th...

Page 22: ...01 SAFETY P001 010 indd 10 01 SAFETY P001 010 indd 10 2012 11 20 8 18 17 2012 11 20 8 18 17...

Page 23: ...SPECIFICATIONS 02 SPECIFICATIONS P001 018 indd 1 02 SPECIFICATIONS P001 018 indd 1 2012 11 05 13 56 37 2012 11 05 13 56 37...

Page 24: ...02 SPECIFICATIONS P001 018 indd 2 02 SPECIFICATIONS P001 018 indd 2 2012 11 05 13 56 37 2012 11 05 13 56 37...

Page 25: ...02 SPECIFICATIONS P001 018 indd 3 02 SPECIFICATIONS P001 018 indd 3 2012 11 05 13 56 37 2012 11 05 13 56 37...

Page 26: ...0 mm 69 in Wheelbase 1 950 mm 77 in Compaction width 1 000 mm 39 in Minimum height above ground 250 mm 10 in Curb clearance 550 mm 21 5 in Speed Forward Reverse 0 to 12 km h 0 to 7 5 mile h Vibration...

Page 27: ...80 Ah 1 pcs 12 V Engine dry weight 159 kg 351 lbs Power line Transmission Type Hydrostatic transmission Speeds Single speed shift Reverser Switching the direction of flow delivered from the variable p...

Page 28: ...Wheelbase 1 950 mm 77 in Compaction width 1 200 mm 47 in Minimum height above ground 250 mm 10 in Curb clearance 550 mm 21 5 in Speed Forward Reverse 0 to 12 km h 0 to 7 5 mile h Vibration performanc...

Page 29: ...1 pcs 12 V Engine dry weight 159 kg 351 lbs Power line Transmission Type Hydrostatic transmission Speeds Single speed shift Reverser Switching the direction of flow delivered from the variable pump Fi...

Page 30: ...Wheelbase 1 950 mm 77 in Compaction width 1 300 mm 51 in Minimum height above ground 250 mm 10 in Curb clearance 550 mm 21 5 in Speed Forward Reverse 0 to 12 km h 0 to 7 5 mile h Vibration performanc...

Page 31: ...x 1 pcs 12 V Engine dry weight 159 kg 351 lbs Power line Transmission Type Hydrostatic transmission Speeds Single speed shift Reverser Switching the direction of flow delivered from the variable pump...

Page 32: ...Wheelbase 1 950 mm 77 in Compaction width 1 200 mm 47 in Minimum height above ground 250 mm 10 in Curb clearance 550 mm 21 5 in Speed Forward Reverse 0 to 11 7 km h 0 to 7 3 mile h Vibration performan...

Page 33: ...ine dry weight 159 kg 351 lbs Power line Transmission Type Hydrostatic transmission Speeds Single speed shift Reverser Switching the direction of flow delivered from the variable pump Final drive Fron...

Page 34: ...Wheelbase 1 950 mm 77 in Compaction width 1 300 mm 51 in Minimum height above ground 250 mm 10 in Curb clearance 550 mm 21 5 in Speed Forward Reverse 0 to 11 7 km h 0 to 7 3 mile h Vibration performan...

Page 35: ...ine dry weight 159 kg 351 lbs Power line Transmission Type Hydrostatic transmission Speeds Single speed shift Reverser Switching the direction of flow delivered from the variable pump Final drive Fron...

Page 36: ...f belt pressed at 98 N 22 lbf Valve clearance intake 0 18 to 0 22 mm 0 0071 to 0 0086 in Valve clearance exhaust 0 18 to 0 22 mm 0 0071 to 0 0086 in Compression pressure Standard value 3 24 to 3 72 MP...

Page 37: ...Difference pressure with case internal pressure Motor drainage SW types Front 3 8 L min 1 0 gal min Rear TW types Front Rear 2 1 L min 0 6 gal min Vibration High pressure relief valve setting 12 7 0 5...

Page 38: ...2 6 Capacities Item Standard value Remarks Engine oil pan 7 0 L 1 8 gal Fuel tank SW types 50 L 13 2 gal TW types 43 L 11 3 gal Coolant 7 0 L 1 8 gal Hydraulic oil tank 42 L 11 1 gal Vibrator case SW3...

Page 39: ...el Diesel oil ASTM D975 2D 3 2 Recommended Lubricants Lubricant Oil company Engine oil API CC Gear oil API GL 4 Hydraulic oil VG 46 Grease NLGI II CALTEX RPM DELO 300 oil Universal Thuban 90 Rando Oil...

Page 40: ...5 539 398 686 506 686 506 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...

Page 41: ...ENGINE AND CONTROLS 03 ENGINE AND CONTROLS indb 1 03 ENGINE AND CONTROLS indb 1 2012 11 14 17 13 35 2012 11 14 17 13 35...

Page 42: ...03 ENGINE AND CONTROLS indb 2 03 ENGINE AND CONTROLS indb 2 2012 11 14 17 13 35 2012 11 14 17 13 35...

Page 43: ...5 Bracket 11 Bracket 17 Bolt M12 30 P 1 25 6 Bolt M12 30 P 1 25 12 Rubber isolator N m 1 Nut M12 P 1 25 88 N m 65 lbf ft 10 Nut M12 P 1 25 88 N m 65 lbf ft 3 Bolt M12 30 78 N m 58 lbf ft 13 Bolt M10...

Page 44: ...03 ENGINE AND CONTROLS indb 4 03 ENGINE AND CONTROLS indb 4 2012 11 14 17 13 35 2012 11 14 17 13 35...

Page 45: ...eel housing Crank pulley Flywheel Engine stop solenoid Oil pressure switch Starter motor Thermostat Intake manifold Fan pulley SW300 1 03002 Tachometer sensor Speed control lever Glow plug 1 2 Engine...

Page 46: ...03 ENGINE AND CONTROLS indb 6 03 ENGINE AND CONTROLS indb 6 2012 11 14 17 13 36 2012 11 14 17 13 36...

Page 47: ...15 14 13 12 11 9 17 1 Control cable 10 Bolt M 6 30 2 Throttle lever 11 Disc spring 3 Lock nut M 8 12 Plug 4 Stopper bolt IDLE M 8 35 13 Nut M14 5 Lock nut M 8 14 Washer 6 Stopper bolt FULL M 8 35 15...

Page 48: ...d M 8 25 18 Spring Fill grease 3 F R lever 11 Friction plate 19 Steel ball 4 Control cable 12 Bolt M 8 45 20 Bolt M 8 25 5 Backup buzzer switch 13 Disc spring Apply grease 21 Bush 6 F R lever switch 1...

Page 49: ...W A A 1 Cover 4 Coupling 2 Bolt M10 40 P 1 25 5 Pump 3 Bolt M 8 20 6 Bolt M14 40 N m 2 Bolt M10 40 P 1 25 49 N m 36 lbf ft 3 Bolt M 8 20 17 N m 13 lbf ft 6 Bolt M14 40 167 N m 123 lbf ft 03 ENGINE AND...

Page 50: ...ashers NOTICE When secure housing 1 it is cautious of attachment position N m 6 Bolt M14 40 167 N m 123 lbf ft Spline of pump subassembly is united with spline of coupling and then secure pump subasse...

Page 51: ...HYDRAULIC SYSTEMS 04 HYDRAULIC SYSTEMS indb 1 04 HYDRAULIC SYSTEMS indb 1 2012 11 15 16 46 00 2012 11 15 16 46 00...

Page 52: ...04 HYDRAULIC SYSTEMS indb 2 04 HYDRAULIC SYSTEMS indb 2 2012 11 15 16 46 00 2012 11 15 16 46 00...

Page 53: ...04 HYDRAULIC SYSTEMS indb 3 04 HYDRAULIC SYSTEMS indb 3 2012 11 15 16 46 00 2012 11 15 16 46 00...

Page 54: ...nes 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 Mo...

Page 55: ...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 line...

Page 56: ...04 HYDRAULIC SYSTEMS indb 6 04 HYDRAULIC SYSTEMS indb 6 2012 11 15 16 46 01 2012 11 15 16 46 01...

Page 57: ...12 7MPa SW300 1 1000 SW320 1 1200 SW330 1 1300 700 700 Drum Front Drum Rear SW300 1 1000 SW320 1 1200 SW330 1 1300 1 4 8 14 cc rev 1 2 FMA FMB Brake release bolt M10X25 Brake release bolt M10X25 FMP F...

Page 58: ...04 HYDRAULIC SYSTEMS indb 8 04 HYDRAULIC SYSTEMS indb 8 2012 11 15 16 46 01 2012 11 15 16 46 01...

Page 59: ...rev 34 5MPa 34 5MPa 1 9MPa 1 1 4 Vibrator pump 3 8 0 4MPa 12 7MPa 1 2 1 2 1 2 1 2 8 4 cc rev Vibrator motor Front Suction filter FVD FVB FVA VTF VPF VBF 3 8 TW320 1 1200 TW330 1 1300 700 Drum Front 1...

Page 60: ...04 HYDRAULIC SYSTEMS indb 10 04 HYDRAULIC SYSTEMS indb 10 2012 11 15 16 46 01 2012 11 15 16 46 01...

Page 61: ...Hose PBR RB Hose RPR RP Hose PAR RA Hose PBR RB Hose PAR RA SECTION D D SECTION G G SECTION F F Hose RPR RP Hose Hose PAR RA Hose PBR RB RD1 T6 Hose RD1 T6 CO RD1 CS RPR PPR RD2 FB FD FA FP CS CO Hose...

Page 62: ...04 HYDRAULIC SYSTEMS indb 12 04 HYDRAULIC SYSTEMS indb 12 2012 11 15 16 46 01 2012 11 15 16 46 01...

Page 63: ...A Hose PBF FB Hose PBR FPB Hose PAR DA Hose RPR PR Hose PBR FPB Hose PAR DA Hose PC2 DC CO CS DC FPB OTK FB FD FA FP CS CO Differential lock valve Hose PAR DA PD2 T11 PD1 PD Hose FD T7 Hose PBF FB Hos...

Page 64: ...04 HYDRAULIC SYSTEMS indb 14 04 HYDRAULIC SYSTEMS indb 14 2012 11 15 16 46 01 2012 11 15 16 46 01...

Page 65: ...FP FMP Hose FA FMA Hose FMD FD Hose FB FMB FD FB FA FP FMB FMD FMP FMA Propulsion motor The letters and figures such as FP and FMP show each port and the arrow symbols show the hose connection and the...

Page 66: ...MA Hose RP RPR Hose RMD RD Hose RB RMB RD RB RA RP RMB RMD RPR RMA Propulsion motor The letters and figures such as RMD and RD show each port and the arrow symbols show the hose connection and the dir...

Page 67: ...he hose connection and the direction of the flow of the oil To propulsion hydraulic piping 1 TW types main RRP RRA RRD RRB RLA RLD RLB RLP Hose LM3 RLP Hose B2 RLB Hose RLD LDR Hose TLA RLA Hose RM3 R...

Page 68: ...04 HYDRAULIC SYSTEMS indb 20 04 HYDRAULIC SYSTEMS indb 20 2012 11 15 16 46 01 2012 11 15 16 46 01...

Page 69: ...04 HYDRAULIC SYSTEMS indb 21 04 HYDRAULIC SYSTEMS indb 21 2012 11 15 16 46 01 2012 11 15 16 46 01...

Page 70: ...Propulsion pump SW300 1 04005 VIEW A A 1 9 1 10 1 11 1 1 8 1 7 1 4 1 1 1 2 1 3 1 5 1 6 1 14 1 13 1 12 1 3 1 8 1 7 1 2 1 14 1 4 1 9 1 5 1 6 1 1 Pump circuit diagram 04 HYDRAULIC SYSTEMS indb 4 010 04...

Page 71: ...ure relief and bypass valves 1 12 High pressure relief and bypass valves 1 13 Charge relief valve 1 14 Drain port 1 1 16 12UN Specifications Displacement 28 cm3 rev 1 7 cu in rev High pressure relief...

Page 72: ...ual brake release port 4 Drain port FMD RMD G3 8 Motor specifications Displacement 417 cm3 rev 25 cu in rev Maximum working pressure 34 3 MPa 4 974 psi Allowable motor case pressure 0 3 MPa 43 5 psi B...

Page 73: ...ease port 4 Drain port RLD RRD G3 8 Motor specifications Displacement 224 cm3 rev 14 cu in rev Maximum working pressure 41 2 MPa 5 974 psi Allowable motor case pressure 0 3 MPa 43 5 psi Brake release...

Page 74: ...8 Flow control valve A Specifications Maximum control flow interflow 45 L min 12 gal min Rated pressure 20 6 MPa 2 987 psi Check valve cracking pressure 0 034 MPa 5 psi Flow division ratio B1 B2 1 1...

Page 75: ...BF VRD VTR VPF VAR VRA VFD VFB VS T5 T9 T4 T2 T3 VIN VFA C C B B D D E A Vibrator pump Hose in front VO2 Hose in back VO1 Hose VRA T5 Hose VFA T4 Hose VFD T9 Hose VTF T3 Hose VTR T2 Hose VPF VFB Hydra...

Page 76: ...04 HYDRAULIC SYSTEMS indb 28 04 HYDRAULIC SYSTEMS indb 28 2012 11 15 16 46 02 2012 11 15 16 46 02...

Page 77: ...oil tank Hose VO2 VBR Hose VO1 VBF The letters and figures such as VBR and VPF show each port and the arrow symbols show the hose connection and the direction of the flow of the oil Vibrator solenoid...

Page 78: ...04 HYDRAULIC SYSTEMS indb 30 04 HYDRAULIC SYSTEMS indb 30 2012 11 15 16 46 02 2012 11 15 16 46 02...

Page 79: ...B VFA VFD FVD FVB FVA The letters and figures such as FVA and FVB show each port and the arrow symbols show the hose connection and the direction of the flow of the oil Vibrator motor Front To vibrato...

Page 80: ...VRA VRD Vibrator motor Rear RVD RVB RVA The letters and figures such as RVA and RVB show each port and the arrow symbols show the hose connection and the direction of the flow of the oil To vibrator...

Page 81: ...rev No 2 pump 12 5 cm3 rev 0 76 cu in rev Rated pressure No 1 pump 17 2 MPa 2 494 psi No 2 pump 17 2 MPa 2 494 psi Weight 7 0 kg 15 4 lbs 3 2 Hydraulic Component Specifications 3 2 1 Vibrator pump SW3...

Page 82: ...fications Displacement 8 4 cm3 rev 0 51 cu in rev Rated pressure 25 2 MPa 3 654 psi Allowable motor case pressure 0 7 MPa 101 5 psi or less Weight 2 7 kg 5 9 lbs SW300 1 04002 Hydraulic circuit diagra...

Page 83: ...olenoid valve 3 Body 4 Port A VAR G3 4 5 Port T VTF VTR G3 4 6 Port P VPF G3 4 Specifications Maximum flow 70 L min 18 5 gal min Maximum pressure 20 6 MPa 2 987 psi Relief valve pressure setting 12 7...

Page 84: ...04 HYDRAULIC SYSTEMS indb 36 04 HYDRAULIC SYSTEMS indb 36 2012 11 15 16 46 03 2012 11 15 16 46 03...

Page 85: ...e connection and the direction of the flow of the oil DETAIL A SECTION B B A Hose Hose B B Hose SPO SP Hose SP P LS Hose TL LS SPO SS CR CL TL SP Orbitrol Hose T TL Hose R CL Steering cylinder Suction...

Page 86: ...04 HYDRAULIC SYSTEMS indb 38 04 HYDRAULIC SYSTEMS indb 38 2012 11 15 16 46 03 2012 11 15 16 46 03...

Page 87: ...2 P 1 25 4 Bolt M10 35 2 Steering wheel 5 Orbitrol 3 Column shaft N m 1 Nut M12 P 1 25 64 N m 47 lbf ft 4 Bolt M10 35 39 N m 29 lbf ft Steering wheel assembly weight 11 kg 24 lbs 04 HYDRAULIC SYSTEMS...

Page 88: ...SPS 28 pipe 2 Outlet port SPO 15 hole Specifications Theoretical discharge 8 14 cm3 rev 0 5 cu in rev Maximum pressure 14 7 MPa 2 132 psi Rotational speed at hydraulic pump rpm 950 to 2 800 rpm Weigh...

Page 89: ...16UNF 2 Port R R 3 4 16UNF 3 Port P P 3 4 16UNF 4 Port T T 3 4 16UNF 5 Relief valve Specifications Displacement 96 cm3 rev 5 9 cu in rev Relief valve pressure setting 13 2 MPa 1 914 psi Weight 6 0 kg...

Page 90: ...ll bearing 8 Bracket lower 3 Bolt M16 50 6 Bracket upper N m 1 Bolt M16 60 265 N m 195 lbf ft 2 Bolt M16 60 265 N m 195 lbf ft 3 Bolt M16 50 265 N m 195 lbf ft 0445 61801 0 10043 B 1 2 3 8 4 5 6 7 04...

Page 91: ...ELECTRICAL SYSTEM 05 ELECTRICAL SYSTEM indb 1 05 ELECTRICAL SYSTEM indb 1 2012 11 14 17 58 11 2012 11 14 17 58 11...

Page 92: ...05 ELECTRICAL SYSTEM indb 2 05 ELECTRICAL SYSTEM indb 2 2012 11 14 17 58 11 2012 11 14 17 58 11...

Page 93: ...AMP L 55W 2GB 2GB 3 B B 23 23 R R G 72 GR R L G GR GY GY 71 73 Br B YW YL WR B LW GR G GB Y BrB GB 24 31 81 33 22 32 21 29 73 72 23 15 14 23 GY GW B 71 70 YG L LR LR L B B YG Y Sb B 1 3 2 RB 24 81 31...

Page 94: ...05 ELECTRICAL SYSTEM indb 4 05 ELECTRICAL SYSTEM indb 4 2012 11 14 17 58 12 2012 11 14 17 58 12...

Page 95: ...34 PULSE REV SET NO 3 TEMP CURVE SEL 2 1 OPEN OPEN GND TEMP 50 103 SET NO 0 COMBI METER SET FUEL UNIT THERMO UNIT OIL PRESSURE SWITCH TACHOMETER SENSOR YB 25 3LB 3LY B LW GY BrR BrY RW G BrR Br 28 29...

Page 96: ...05 ELECTRICAL SYSTEM indb 6 05 ELECTRICAL SYSTEM indb 6 2012 11 14 17 58 12 2012 11 14 17 58 12...

Page 97: ...bination meter Liquid spray switch TW types only Liquid spray pump TW types only Liquid spray pump Fuel pump TW types only Lighting switch Horn switch Vibration indicator lamp relay Interlock relay Vi...

Page 98: ...05 ELECTRICAL SYSTEM indb 8 05 ELECTRICAL SYSTEM indb 8 2012 11 14 17 58 12 2012 11 14 17 58 12...

Page 99: ...witch Foot brake switch Flasher unit option Lighting switch W R G RG GW R Liquid spray switch TW types only Br Water spray switch Water spray relay Water spray mode select switch option LY Backup buzz...

Page 100: ...rake Charge warning Engine oil pressure warning Lamp check Coolant temp SEL 1 Coolant temp SEL 2 System configuration diagram Harness side Wire color and number Refer to 1 4 Wire Color Code and Number...

Page 101: ...VIBRATORY DRUM REAR WHEEL 06 VIBRATORY DRUM indb 1 06 VIBRATORY DRUM indb 1 2012 11 20 8 26 03 2012 11 20 8 26 03...

Page 102: ...06 VIBRATORY DRUM indb 2 06 VIBRATORY DRUM indb 2 2012 11 20 8 26 03 2012 11 20 8 26 03...

Page 103: ...iping 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 scr...

Page 104: ...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 specif...

Page 105: ...emoval and Installation of Vibratory Drum Hold vibratory drum with chocks Lock front and rear frames with lock pin 1 SW300 1 06001 Chock Chock SW300 1 06002 1 06 VIBRATORY DRUM indb 6 003 06 VIBRATORY...

Page 106: ...g piping 1 1 Propulsion motor piping Remove bolts 3 Remove clamp 2 Disconnect hydraulic hoses 4 5 6 and 7 connecting to propulsion motor NOTICE Plug both ends of the disconnected hoses or implement ot...

Page 107: ...1 1 315 kg 2 900 lbs SW320 1 1 400 kg 3 085 lbs SW330 1 1 440 kg 3 175 lbs TW320 1 1 410 kg 3 110 lbs TW330 1 1 450 kg 3 195 lbs Flip up scraper blades 13 and 15 Remove bolts 14 left and right sides...

Page 108: ...1 1 Propulsion motor piping Remove bolts 21 Remove clamp 20 Disconnect hydraulic hoses 22 23 24 and 25 connecting to propulsion motor NOTICE Plug both ends of the disconnected hoses or implement othe...

Page 109: ...e body Rear axle weight SW300 1 1 410 kg 3 110 lbs SW320 1 1 490 kg 3 285 lbs SW330 1 1 530 kg 3 375 lbs Flip up scraper blades 31 and 33 Remove bolts 32 left and right sides 3 Removal of vibratory dr...

Page 110: ...ve nuts 38 Remove plate 19 35 37 Plate 45 kg 99 lbs 2 Removal of vibrator motor side plate Remove nuts 41 Remove plate 18 36 40 Plate 45 kg 99 lbs SW300 1 06007 Chock 19 35 38 39 Lift with crane SW300...

Page 111: ...6 x 160 265 N m 195 lbf ft SW TW320 1 Bolt M16 x 210 265 N m 195 lbf ft SW TW330 1 38 Nut M16 196 N m 145 lbf ft 41 Nut M16 196 N m 145 lbf ft 2 Upon installing vibratory drum pay particular attention...

Page 112: ...06 VIBRATORY DRUM indb 12 06 VIBRATORY DRUM indb 12 2012 11 20 8 26 04 2012 11 20 8 26 04...

Page 113: ...0 Oil seal 31 Bolt M12x20 32 Bolt M16x40 33 Bolt M16x40 34 Disc 35 Bolt M16x40 36 Nut M16 37 Damper 38 Bolt M10x25 39 Bolt M16x40 40 Plate 41 Bolt M16x60 SW300 1 M16x160 SW TW320 1 M16x210 SW TW330 1...

Page 114: ...06 VIBRATORY DRUM indb 14 06 VIBRATORY DRUM indb 14 2012 11 20 8 26 04 2012 11 20 8 26 04...

Page 115: ...s 11 1 and 11 3 Drain gear oil Quantity of gear oil SW300 1 2 5 L 0 7 gal SW TW320 1 4 0 L 1 1 gal SW TW330 1 4 8 L 1 3 gal WARNING When standing the drum use wooden blocks of sufficient strength to s...

Page 116: ...bolts 43 Remove vibrator motor 45 Remove breather 16 45 Vibrator motor 3 kg 7 lbs 6 Remove sleeve 21 SW300 1 06016 Adapter SW300 1 06017 16 45 43 SW300 1 06018 21 06 VIBRATORY DRUM indb 6 012 06 VIBRA...

Page 117: ...cover 26 using two pulling bolts M10 40 Remove cover 26 9 Remove bolts 17 Remove dampers 19 SW300 1 06019 25 SW300 1 06020 Pulling bolt 26 SW300 1 06021 17 19 06 VIBRATORY DRUM indb 6 013 06 VIBRATOR...

Page 118: ...disc SUBASSY with roller bearing from boss SUBASSY WARNING When installing lifting bolts screw in the threads fully before using 12 Install lifting bolts M16 to disc SUBASSY SW300 1 06022 23 24 28 SW...

Page 119: ...UBASSY Disc SUBASSY 25 kg 55 lbs 14 Remove bolts 10 15 Lift boss SUBASSY using two pulling bolts M16 40 SW300 1 06025 Boss SUBASSY Disc SUBASSY SW300 1 06026 10 SW300 1 06027 Pulling bolt 06 VIBRATORY...

Page 120: ...ith boss SUBASSY tap on the shaft end with a wooden hammer via a wooden bar during lifting Boss SUBASSY 25 kg 55 lbs 18 Install a lifting bolt M5 to end of shaft 5 SW300 1 06028 Lifting bolt SW300 1 0...

Page 121: ...es risk Confirm that the surrounding area is safe and work in a natural unstrained posture 20 Reverse drum SUBASSY Drum SUBASSY SW300 1 440 kg 970 lbs SW TW320 1 500 kg 1 102 lbs SW TW330 1 525 kg 1 1...

Page 122: ...BASSY Disc SUBASSY 20 kg 44 lbs 24 Install lifting bolts M16 to propulsion motor 44 Remove bolts 33 SW300 1 06034 39 Disc SUBASSY SW300 1 06035 Disc SUBASSY SW300 1 06036 44 33 Lifting bolt 06 VIBRATO...

Page 123: ...45 kg 99 lbs 26 Remove bolts 32 27 Lift holder SUBASSY using two pulling bolts M16 40 Remove holder SUBASSY SW300 1 06037 44 SW300 1 06038 32 SW300 1 06039 Pulling bolt Holder SUBASSY 06 VIBRATORY DR...

Page 124: ...er SUBASSY 29 Remove holder SUBASSY from drum Remove vibrator bearing 4 Holder SUBASSY 20 kg 44 lbs SW300 1 06040 Lifting bolt Holder SUBASSY SW300 1 06041 4 Holder SUBASSY 06 VIBRATORY DRUM indb 6 02...

Page 125: ...drum 6 with its propulsion motor side facing up 6 Drum SW300 1 350 kg 772 lbs SW TW320 1 410 kg 904 lbs SW TW330 1 435 kg 959 lbs NOTICE Direction with tapping hole M12 is propulsion motor side 2 Reas...

Page 126: ...SY 20 kg 44 lbs WARNING When installing lifting bolts screw in the threads fully before using Install lifting bolts M16 to holder SUBASSY SW300 1 06094 SW300 1 06044 3 Holder SUBASSY SW300 1 06045 Lif...

Page 127: ...rude from its groove 5 Secure holder SUBASSY with eight bolts 32 and washers N m 32 Bolts M16 40 265 N m 195 lbf ft 6 Install lifting bolts M16 to propulsion motor 44 SW300 1 06046 6 Holder SUBASSY SW...

Page 128: ...44 on mounting surface of holder SUBASSY 44 Propulsion motor 45 kg 99 lbs 9 Secure propulsion motor 44 with six bolts 33 and washers N m 33 Bolts M16 40 265 N m 195 lbf ft SW300 1 06049 44 1 SW300 1 0...

Page 129: ...Y 20 kg 44 lbs NOTICE The longer direction of the disc must be parallel with the side of the propulsion motor port A SW300 1 06051 Disc SUBASSY SW300 1 06095 Disc SUBASSY SW300 1 06052 Propulsion moto...

Page 130: ...reversing the drum involves risk Confirm that the surrounding area is safe and work in a natural unstrained posture 14 Reverse drum SUBASSY Drum SUBASSY SW300 1 440 kg 970 lbs SW TW320 1 500 kg 1 102...

Page 131: ...entric shaft 5 5 Eccentric shaft SW300 1 15 kg 33 lbs SW TW320 1 20 kg 44 lbs SW TW330 1 20 kg 44 lbs 17 Insert eccentric shaft 5 into vibrator bearing 4 while taking care not to tilt vibrator bearing...

Page 132: ...ant gloves when handling heated parts to avoid burns 18 3 Heat up roller bearing 15 inner race by using a ring heater or the like Apply a coat of gear oil to boss SUBASSY at where bearing inner will b...

Page 133: ...gs 11 19 Install lifting bolts M16 to boss SUBASSY 20 Lift boss SUBASSY Apply grease to O ring 9 Install O ring 9 to boss SUBASSY SW300 1 06060 11 SW300 1 06061 Lifting bolt SW300 1 06062 9 06 VIBRATO...

Page 134: ...nt tilting of vibrator bearing inner race during installation 22 Secure boss SUBASSY with eight bolts 10 and washers N m 10 Bolts M16 40 265 N m 195 lbf ft 23 Install a lifting bolt M5 to end of shaft...

Page 135: ...es will be press fitted Drive roller bearings 15 outer races into disc 29 Apply liquid packing to periphery of oil seal 30 Drive in oil seal 30 Apply grease to lip of oil seal 30 26 Install lifting bo...

Page 136: ...s of roller bearing 15 inner race Drive in roller bearing 15 inner race until rollers come in contact with outer race 29 Preload adjustment of roller bearing Install a shim of about 1 mm 0 04 in and s...

Page 137: ...ICE It is necessary to rotate the bearing to lift the rollers while pressing in the inner race Otherwise the bearing will not seat no matter how forcibly the inner race is pressed Remove bolts 23 Remo...

Page 138: ...nd washers Using a thickness gauge measure clearance A Preload adjusting shim thickness A 0 1 mm 0 04 in Remove bolts 23 Remove cover 24 SW300 1 06074 23 24 Boss SUBASSY SW300 1 06075 A No gap SW300 1...

Page 139: ...Bolts M8 25 31 N m 23 lbf ft 30 Apply grease to O ring 18 Install O ring 18 to cover 26 31 Secure cover 26 to disc SUBASSY with six bolts 25 and spring washers N m 25 Bolts M10 25 49 N m 36 lbf ft SW...

Page 140: ...65 N m 195 lbf ft 33 Drive two spring pins 22 into sleeve 21 34 Apply molybdenum based grease to splined portion of sleeve 21 Fit sleeve 21 to splined portion on shaft end SW300 1 06079 17 19 SW300 1...

Page 141: ...r 16 to cover 26 Secure vibrator motor 45 to cover 26 with two bolts 43 and washers 45 Vibrator motor 3 kg 7 lbs N m 43 Bolts M10 35 49 N m 36 lbf ft 37 Apply grease to O ring for adapters Install ada...

Page 142: ...lbs 39 Remove plugs 11 1 and 11 2 Supply gear oil from oil supply port Check that oil drips from gauge port Quantity of gear oil SW300 1 2 5 L 0 7 gal SW TW320 1 4 0 L 1 1 gal SW TW330 1 4 8 L 1 3 gal...

Page 143: ...Propulsion motor right 28 Adapter 9 Tire 19 Bolt M16 40 29 Hose 10 Disc wheel 20 Adapter 30 Adapter N m 8 Nut M14 P1 5 186 N m 137 lbf ft 19 Bolt M16 40 265 N m 195 lbf ft 12 Bolt M14 50 167 N m 123...

Page 144: ...nd Installation of Rear Axle TW Types Hold vibratory drum with chocks Lock front and rear frames with lock pin 1 SW300 1 06087 Chock SW300 1 06002 1 06 VIBRATORY DRUM indb 6 040 06 VIBRATORY DRUM indb...

Page 145: ...area is safe and work in a natural unstrained posture Also to firmly secure the machine body use a support stand of sufficient strength 1 Supporting rear frame Lift frame with a crane Place support s...

Page 146: ...lic hoses in this condition can cause burns Wait for the hydraulic oil to cool down before starting the work 4 Disconnecting piping Disconnect hydraulic hoses 13 21 23 and 29 connecting to rear propul...

Page 147: ...otor 5 Hold up propulsion motor SUBASSY with forklift Remove bolts 22 Remove propulsion motor SUBASSY Propulsion motor SUBASSY 125 kg 276 lbs SW300 1 06093 22 Propulsion motor SUBASSY SW300 1 06100 2...

Page 148: ...entioned 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 oil is at specified leve...

Page 149: ...BRAKE 07 BRAKE P000 002 indd 7 07 BRAKE P000 002 indd 7 2012 10 05 9 39 43 2012 10 05 9 39 43...

Page 150: ...07 BRAKE P000 002 indd 7 008 07 BRAKE P000 002 indd 7 008 2012 10 05 9 39 44 2012 10 05 9 39 44...

Page 151: ...2 Nut M10 9 F R lever 3 Rod end 10 Shaft 4 Brake pedal 11 Return spring 5 Nut M10 P 1 25 12 Ball Apply lithium based grease 6 Bolt with rubber M10 25 P 1 25 13 Foot brake switch 7 Bolt with rubber M1...

Page 152: ...l pressed Propulsion motor F Propulsion motor R Brake Brake ON condition Brake Brake ON condition The arrow symbol shows the direction of the hydraulic oil flow To combination meter Steering charge pu...

Page 153: ...e pedal pressed Propulsion motor F Propulsion motor R R Propulsion motor R L Brake Brake ON condition Brake Brake ON condition Brake Brake ON condition The arrow symbol shows the direction of the hydr...

Page 154: ...07 BRAKE P000 002 indd 7 004 07 BRAKE P000 002 indd 7 004 2012 10 05 9 39 44 2012 10 05 9 39 44...

Page 155: ...SPRAY SYSTEMS 08 SPRAY SYSTEMS indb 1 08 SPRAY SYSTEMS indb 1 2012 10 17 10 41 15 2012 10 17 10 41 15...

Page 156: ...08 SPRAY SYSTEMS indb 2 08 SPRAY SYSTEMS indb 2 2012 10 17 10 41 15 2012 10 17 10 41 15...

Page 157: ...spray pump OUT Check valve Filter Water spray pump Drain valve Drain valve Check valve Hose Water spray tank 3 Way valve Filter IN Hose Tee 1 Water spray pipe R Water spray tank Drain valve Nozzle Wat...

Page 158: ...08 SPRAY SYSTEMS indb 4 08 SPRAY SYSTEMS indb 4 2012 10 17 10 41 16 2012 10 17 10 41 16...

Page 159: ...alve A A The letters and figures such as Filter OUT and Water spray pump IN show each port and the arrow symbols show the hose connection and the direction of the flow of the water Water spray tank Dr...

Page 160: ...08 SPRAY SYSTEMS indb 6 08 SPRAY SYSTEMS indb 6 2012 10 17 10 41 16 2012 10 17 10 41 16...

Page 161: ...e Liquid spray tank Filter IN Hose Liquid spray pipe Liquid spray tank Hose Filter OUT Liquid spray pump IN Hose Drain valve To outside Hose Hose Filter OUT Liquid spray pump IN Filter OUT Pump IN Hos...

Page 162: ...08 SPRAY SYSTEMS indb 8 08 SPRAY SYSTEMS indb 8 2012 10 17 10 41 16 2012 10 17 10 41 16...

Page 163: ...INSPECTION AND ADJUSTMENT 09 INSPECTION AND ADJUSTMENT indd 1 09 INSPECTION AND ADJUSTMENT indd 1 2012 11 14 20 03 04 2012 11 14 20 03 04...

Page 164: ...09 INSPECTION AND ADJUSTMENT indd 2 09 INSPECTION AND ADJUSTMENT indd 2 2012 11 14 20 03 04 2012 11 14 20 03 04...

Page 165: ...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 app...

Page 166: ...ish 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 me...

Page 167: ...after valve is disassembled and cleaned replace high pressure relief and bypass valves After inspection measure pressure again and check that pressure reaches maximum circuit pressure range N m Bypass...

Page 168: ...apter Adapter 9 16 18UNF Pressure gauge 0 to 5 MPa 0 to 725 psi Apply parking brake by pressing parking brake switch button Start the engine and set throttle lever to Full Check that F R lever is in N...

Page 169: ...6 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...

Page 170: ...n motor Attach pressure gauge through adapter Adapter G1 4 Pressure gauge 0 to 5 MPa 0 to 725 psi Confirm that F R lever is in N Apply parking brake by pressing parking brake switch button Start the e...

Page 171: ...N Apply parking brake by pressing parking brake switch button Start the engine and set throttle lever to Full Release parking brake by pressing parking brake switch button Then read brake release pre...

Page 172: ...hrough adapter Adapter G1 2 Pressure gauge 0 to 24 5 MPa 0 to 3 552 5 psi Apply parking brake by pressing parking brake switch button Start the engine and set throttle lever to Full Set vibration mode...

Page 173: ...tach pressure gauge through adapter Adapter G3 8 Pressure gauge 0 to 25 MPa 0 to 3 625 psi Confirm that F R lever is in N properly Start the engine and set throttle lever to Full Turn steering wheel t...

Page 174: ...d 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...

Page 175: ...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 F R lever is in N F and R respectiv...

Page 176: ...auge 0 to 5 MPa 0 to 725 psi Start the engine and set throttle lever to Full Establish a condition in which machine propulsion load becomes maximum Pressure does not build up unless propulsion load is...

Page 177: ...le lever to Full Establish a condition in which machine propulsion load becomes maximum Pressure does not build up unless propulsion load is applied With propulsion load at maximum measure pressure wh...

Page 178: ...ttach control cable 2 to fuel injection pump s control lever Start the engine Loosen lock nut 4 Using stopper bolt 3 adjust so that standard minimum no load rotational speed is achieved Standard minim...

Page 179: ...R lever 1 are positioned by notches Set F R lever in N Attach control cable 2 to F R lever 1 Specified dimension a 235 5 mm 9 27 in Attach control cable 2 to propulsion hydraulic pump control lever 3...

Page 180: ...4 to F R lever Tighten lock nut 5 Set F R lever in R Loosen lock nut 6 Touch stopper bolt 7 to F R lever Tighten lock nut 6 SW300 1 09030 5 4 F N SW300 1 09031 6 7 R N 09 INSPECTION AND ADJUSTMENT ind...

Page 181: ...TROUBLESHOOTING 10 TROUBLESHOOTING oku indd 1 10 TROUBLESHOOTING oku indd 1 2012 11 14 20 25 55 2012 11 14 20 25 55...

Page 182: ...10 TROUBLESHOOTING oku indd 2 10 TROUBLESHOOTING oku indd 2 2012 11 14 20 25 55 2012 11 14 20 25 55...

Page 183: ...ake 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 engi...

Page 184: ...ize and wire color are shown as above in electrical circuit diagrams 100 3 BW Wire color AVS wire size Wire number SW880 11020 B Black BW Black White stripe BY Black Yellow stripe BR Black Red stripe...

Page 185: ...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 relate...

Page 186: ...d 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...

Page 187: ...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 equipmen...

Page 188: ...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...

Page 189: ...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 connec...

Page 190: ...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 No...

Page 191: ...s 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...

Page 192: ...es 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 opera...

Page 193: ...10 TROUBLESHOOTING oku indd 13 10 TROUBLESHOOTING oku indd 13 2012 11 14 20 25 56 2012 11 14 20 25 56...

Page 194: ...RY FUEL PUMP FUSE BOX B R RB 3G 5R 5BR 8WY WR 3GW 5RW 2Y AV60 12V 80AH 95D31R 5WG GLOW PLUGS ALTERNATOR STARTER SWITCH FUSE LgR LgW 6 8 10 11 17 20 21 5 7 18 9 F L 48 R1 BrB 5 W G LgR 3W 5WR 2Y 3W 5BR...

Page 195: ...ndard voltage 12 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 Battery Relay 1 When starter switch is OFF measure volta...

Page 196: ...RY FUEL PUMP FUSE BOX B R RB 3G 5R 5BR 8WY WR 3GW 5RW 2Y AV60 12V 80AH 95D31R 5WG GLOW PLUGS ALTERNATOR STARTER SWITCH FUSE LgR LgW 6 8 10 11 17 20 21 5 7 18 9 F L 48 R1 BrB 5 W G LgR 3W 5WR 2Y 3W 5BR...

Page 197: ...nlet wire W and chassis ground Standard voltage 12 V or more 3 When starter switch is START measure voltage between interlock relay terminal f outlet wire BR and chassis ground Standard voltage 12 V o...

Page 198: ...RY FUEL PUMP FUSE BOX B R RB 3G 5R 5BR 8WY WR 3GW 5RW 2Y AV60 12V 80AH 95D31R 5WG GLOW PLUGS ALTERNATOR STARTER SWITCH FUSE LgR LgW 6 8 10 11 17 20 21 5 7 18 9 F L 48 R1 BrB 5 W G LgR 3W 5WR 2Y 3W 5BR...

Page 199: ...OK and engine does not start engine stop solenoid is faulty Replace engine stop solenoid 3 Harness Connecting Between Terminals Measure resistance of harness connecting between terminals Standard resi...

Page 200: ...RY FUEL PUMP FUSE BOX B R RB 3G 5R 5BR 8WY WR 3GW 5RW 2Y AV60 12V 80AH 95D31R 5WG GLOW PLUGS ALTERNATOR STARTER SWITCH FUSE LgR LgW 6 8 10 11 17 20 21 5 7 18 9 F L 48 R1 BrB 5 W G LgR 3W 5WR 2Y 3W 5BR...

Page 201: ...starter switch is faulty Replace starter switch 2 Glow Plug When starter switch is HEAT measure voltage between glow plug inlet wire WG and chassis ground Standard voltage 12 V or more If voltage is...

Page 202: ...6 5 FUSE BOX TO COMBINATION METER 1 3 4 6 7 8 2 5 11 14 13 10 9 3G 6 5R 8 5W 5W 5WR LgW 65A F L 1 2 1 BATTERY RELAY F L COM BR BATTERY 3G 5R 3GW 5RW AV60 12V 80AH 95D31R STARTER SWITCH FUSE LgR LgW 6...

Page 203: ...When starter switch is ON measure voltage between foot brake switch terminal NO outlet wire RW and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG foot brake switc...

Page 204: ...6 5 FUSE BOX TO COMBINATION METER 1 3 4 6 7 8 2 5 11 14 13 10 9 3G 6 5R 8 5W 5W 5WR LgW 65A F L 1 2 1 BATTERY RELAY F L COM BR BATTERY 3G 5R 3GW 5RW AV60 12V 80AH 95D31R STARTER SWITCH FUSE LgR LgW 6...

Page 205: ...d chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG foot brake switch is faulty Replace foot brake switch 3 Parking Brake Switch 1 When starter switch is ON measure v...

Page 206: ...6 5 FUSE BOX TO COMBINATION METER 1 3 4 6 7 8 2 5 11 14 13 10 9 3G 6 5R 8 5W 5W 5WR LgW 65A F L 1 2 1 BATTERY RELAY F L COM BR BATTERY 3G 5R 3GW 5RW AV60 12V 80AH 95D31R STARTER SWITCH FUSE LgR LgW 6...

Page 207: ...WB 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 measur...

Page 208: ...IBRATOR RELAY VIBRATION INDICATOR LAMP RELAY RL RL 44 33 43 43 B D F H E G B B BrR BrB BrB 44 75 75 1 3 2 5 FUSE BOX TO COMBINATION METER 1 3 4 6 7 8 2 5 11 12 14 13 10 9 RY 39 RY F R LEVER SWITCH GY...

Page 209: ...is ON measure voltage between vibrator relay terminal E inlet wire GY and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between vibrator relay terminal G inl...

Page 210: ...LAY VIBRATION INDICATOR LAMP RELAY RL RL 44 33 43 43 B D F H E G B B BrR BrB BrB 44 75 75 1 3 2 5 FUSE BOX TO COMBINATION METER 1 3 4 6 7 8 2 5 11 12 14 13 10 9 RY 39 RY F R LEVER SWITCH GY FORWARD RE...

Page 211: ...al F inlet wire RW and chassis ground Standard voltage 12 V or more 2 When starter switch is ON and one of F R lever vibration switches keep pressing measure voltage between vibrator relay terminal H...

Page 212: ...SPRAY RELAY FUSE BOX 1 3 2 5 27 1 25Br 3LY 87 TO COMBINATION METER TO COMBINATION METER 3 4 6 7 8 2 5 11 12 14 13 10 9 3G 6 5W 5W 5WR LgW 65A F L 1 2 1 BATTERY RELAY COM BR BATTERY 3G 3GW AV60 12V 80A...

Page 213: ...oltage between water spray relay terminal 3 inlet wire LY and chassis ground Standard voltage 12 V or more 3 When starter switch is ON measure voltage between water spray relay terminal 5 outlet wire...

Page 214: ...SPRAY RELAY FUSE BOX 1 3 2 5 27 1 25Br 3LY 87 TO COMBINATION METER TO COMBINATION METER 3 4 6 7 8 2 5 11 12 14 13 10 9 3G 6 5W 5W 5WR LgW 65A F L 1 2 1 BATTERY RELAY COM BR BATTERY 3G 3GW AV60 12V 80A...

Page 215: ...uid Spray Switch 1 When starter switch is ON measure voltage between liquid spray switch terminal 1 inlet wire Br and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure v...

Page 216: ...uid spray indicator Side marker lamp indicator Flood lamp indicator Vibration indicator Turn signal indicator left Turn signal indicator right Parking brake indicator Engine oil pressure warning indic...

Page 217: ...ighting switch terminal 1 inlet wire R terminal 4 inlet wire R and chassis ground Standard voltage 12 V or more 2 When starter switch is ON and lighting switch is ON measure voltage between lighting s...

Page 218: ...uid spray indicator Side marker lamp indicator Flood lamp indicator Vibration indicator Turn signal indicator left Turn signal indicator right Parking brake indicator Engine oil pressure warning indic...

Page 219: ...does not turn on combination meter is faulty Replace combination meter 2 6 3 Combination meter warning lamp or indicator lamp is abnormal Reference Fig 2 6 1 Check point Check Cause Action 1 Harness M...

Page 220: ...uid spray indicator Side marker lamp indicator Flood lamp indicator Vibration indicator Turn signal indicator left Turn signal indicator right Parking brake indicator Engine oil pressure warning indic...

Page 221: ...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...

Page 222: ...uid spray indicator Side marker lamp indicator Flood lamp indicator Vibration indicator Turn signal indicator left Turn signal indicator right Parking brake indicator Engine oil pressure warning indic...

Page 223: ...tance 10 or less If resistance is abnormal harness is faulty Repair or replace harness 2 6 7 Fuel meter is abnormal Reference Fig 2 6 1 Check point Check Cause Action 1 Fuel Unit Disconnect harness an...

Page 224: ...uid spray indicator Side marker lamp indicator Flood lamp indicator Vibration indicator Turn signal indicator left Turn signal indicator right Parking brake indicator Engine oil pressure warning indic...

Page 225: ...ine Oil Pressure Switch Disconnect engine oil pressure switch and check continuity between its terminals There is continuity in normal condition If there is continuity engine oil pressure switch is fa...

Page 226: ...EV pulse input 2 square wave Fuel sensor Coolant temp sensor REV ratio SEL 1 REV ratio SEL 2 REV ratio SEL 3 REV ratio SEL 4 Side marker lamp Combination meter ilumination Turn signal right Turn signa...

Page 227: ...chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG vibration indicator lamp relay is faulty Replace vibration indicator lamp relay 3 Combination Meter Vibration indica...

Page 228: ...oil pressure warning Lamp check Coolant temp SEL 1 Coolant temp SEL 2 System configuration diagram Hydraulic oil filter warning R WB B B SOL 42 PARKING BRAKE SOLENOID RY 1 3 4 6 7 8 9 10 2 5 20A 20A...

Page 229: ...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 15...

Page 230: ...er spray indicator Liquid spray indicator Side marker lamp indicator Flood lamp indicator Vibration indicator Turn signal indicator left Turn signal indicator right Parking brake indicator Engine oil...

Page 231: ...tion meter is faulty Replace combination meter 2 6 13 Liquid spray indicator lamp does not light TW types Check that liquid spray pump can be activated Reference Fig 2 6 4 Check point Check Cause Acti...

Page 232: ...rter switch ACC Input interface TA input interface Frequency divider selector AD input interface Input interface Input interface REV pulse input 1 pickup REV pulse input 2 square wave Fuel sensor Cool...

Page 233: ...ground Terminal 5 inlet wire WL and chassis ground Standard voltage 12 V or more 3 When starter switch is HEAT measure voltage between glow lamp timer terminal 6 inlet wire YW and chassis ground Stand...

Page 234: ...rter switch ACC Input interface TA input interface Frequency divider selector AD input interface Input interface Input interface REV pulse input 1 pickup REV pulse input 2 square wave Fuel sensor Cool...

Page 235: ...erminals Standard resistance 10 or less If resistance is abnormal harness is faulty Repair or replace harness 2 6 16 Backup buzzer does not sound Reference Fig 2 6 5 Check point Check Cause Action 1 B...

Page 236: ...es 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...

Page 237: ...mp 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 When solenoid is energi...

Page 238: ...igh Pressure Relief Valve Low circuit pressure due to incorrect high pressure relief setting or internal leakage of high pressure relief valve Interchange two high pressure relief valves If faulty con...

Page 239: ...lace it 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 p...

Page 240: ...replace it if necessary 5 Hydraulic Oil Filter Charge circuit pressure increases due to clogged filter Clean hydraulic oil filter or replace it if necessary 3 2 7 Abnormal noise from propulsion syste...

Page 241: ...Repair vibrator solenoid valve or replace it if necessary 4 Vibrator Motor Internal leakage of vibrator motor Measure drain quantity from vibrator motor If drain quantity is larger than standard value...

Page 242: ...rate of vibrator pump with flow meter If discharge flow rate is not within specified range repair vibrator pump or replace it if necessary Insufficient pump discharge due to wear of vibrator pump dri...

Page 243: ...se clamp securing hydraulic hose is loose Tighten bolts of loose hydraulic hose clamp to specified torque 3 Suction Filter for Vibrator Pump Cavitation is occurring in vibrator pump due to clogged fil...

Page 244: ...ering cylinder or replace it if necessary 5 Suction Filter for Steering Pump Steering pump discharge rate decreases due to clogged filter Clean suction filter or replace it if necessary 6 Steering Pum...

Page 245: ...causing temperature of hydraulic oil in circuit to rise Measure steering circuit pressure If high decrease steering load 4 Suction Filter for Steering Pump Load of steering pump increases due to clog...

Page 246: ...006 0 30073 C 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 Te...

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