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4-003

How to Make a Fault Diagnosis

2. How to Make a Fault Diagnosis

Procedure 1. Confirmation of trouble
1) Make inquiries about the following items

upon request of repair from customer.

• Customer’s name
• Model and serial number of machine in question
• Work site and working condition etc.
2) Seize outline of trouble by questioning.
• Details of trouble
• Details of work when trouble has occured
• Details of working environment
• Information on services conducted in the

past

Procedure 2. Estimation of source of trouble
1) Determine source of trouble by referring

to “FAULT DIAGNOSIS” in this manual.

Procedure 3. Preparation of necessary tools
for diagnosis
1) Prepare tools recommended in this manual.
• Tester and extension cable etc.
• Pressure gauge etc.
2) Prepare spare parts referring to the parts

catalogue.

Procedure 4. Going to site where the faulty
machine stays idle.

Procedure 7.
• Fault diagnosis
• Determination of remedy
1) Before diagnosis, find out and correct simple

failures. Do the following:

• Daily inspections
• Other inspections required
2) With reference to “FAULT DIAGNOSIS” in this manual,

make a diagnosis by following proper diagnosis flow
chart best applicable to correct the trouble.

Procedure 5. Getting detailed information from operator
concerning the trouble
• Had there been any unusual signs before the trouble

has occured?

• Had the trouble occured all of a sudden without any

unusual signs in advance?

• Had the machine been repaired before the trouble

has occured?

Office and repair shop (Maker’s side)

Procedure 6. Making the machine recur the trouble

• By letting the machine travel or perform the work,

check to see if the trouble is attributable to a serious
cause like the defective component parts or if the
trouble has been caused by improper handling.

Site (Customer’s side)

Customer

Work site

Work shop

Field repair

Shop repair

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Summary of Contents for SW352

Page 1: ...liable maintenance techniques for machines in question Included in this literature are descriptions of SPECIFICATIONS STRUCTURE OPERATION INSPECTION ADJUSTEMNT FAULT DIAGNOSIS and DISASSEMBLY ASSEMBLY Systematic explanations are being given to each of these five cathegories in this sequence Rollers principally concern qualitative factors as represented by compaction density to say nothing of quant...

Page 2: ...nosis modes For effective fault finding this chapter employs block type flow charts easy to handle Electric wiring diagrams used herein identify wires by means of color coding and identification numbers Standard values or fault finding conditions are noted where necessary In the final section DISASSEMBLY ASSEMBLY descriptions are being given of removal reinstallation disassembly and reassembly pro...

Page 3: ...CONTENTS SPECIFICATIONS 1 001 STRUCTURE AND OPERATION 2 001 INSPECTION AND ADJUSTMENT 3 001 FAULT DIAGNOSIS 4 001 DISASSEMBLY AND ASSEMBLY 5 001 ...

Page 4: ......

Page 5: ...SPECIFICATIONS ...

Page 6: ......

Page 7: ...1 001 SPECIFICATIONS 1 External Views and Specification Data 1 1 SW352 1 002 1 2 TW352 1 003 1 3 SW502 1 004 1 4 TW502 1 005 ...

Page 8: ... mm 79 Roll dia x width 675 x 1 200 mm 27 x 47 Roll dia x width 675 x 1 200 mm 27 x 47 Performance Travel speed forward reverse Low High 0 9 km h 0 5 6 mile h 0 12 km h 0 7 5 mile h Vibrating power Frequency Centrifugal force Gradability Rolling width Minimum turning radius 55 Hz 20 6 kN 4 630 lbs 21 degrees 1 200 mm 47 3 8 m 150 Engine Model Total displacement Rated output Max torque KUBOTA D1503...

Page 9: ...x width 675 x 1 200 mm 27 x 47 Tire 9 5 65 15 6PR Performance Travel speed forward reverse Low High 0 9 km h 0 5 6 mile h 0 12 km h 0 7 5 mile h Vibrating power Frequency Centrifugal force Gradability Rolling width Minimum turning radius 55 Hz 20 6 kN 4 630 lbs 21 degrees 1 200 mm 47 3 8 m 150 Engine Model Total displacement Rated output Max torque KUBOTA D1503 KA Diesel Engine 1 499 liters 91 cu ...

Page 10: ... 300 mm 31 x 51 Roll dia x width 800 x 1 300 mm 31 x 51 Performance Travel speed forward reverse Low High 0 7 5 km h 0 4 7 mile h 0 10 0 km h 0 6 2 mile h Vibrating power Frequency Centrifugal force Gradability Rolling width Minimum turning radius 21 degrees 1 300 mm 51 4 3 m 169 Low 55 Hz 26 5 kN 5 955 lbs High 55 Hz 34 3 kN 7 710 lbs Engine Model Total displacement Rated output Max torque KUBOTA...

Page 11: ... Tire 10 5 80 16 6PR OR Performance Travel speed forward reverse Low High 0 9 0 km h 0 5 6 mile h 0 12 0 km h 0 7 5 mile h Vibrating power Frequency Centrifugal force Gradability Rolling width Minimum turning radius 21 degrees 1 300 mm 51 4 3 m 169 Low 55 Hz 26 5 kN 5 955 lbs High 55 Hz 34 3 kN 7 710 lbs Engine Model Total displacement Rated output Max torque KUBOTA D1503 T K2A Diesel Engine With ...

Page 12: ...MEMO ...

Page 13: ...STRUCTURE AND OPERATION ...

Page 14: ......

Page 15: ...W502 2 017 2 2 Propulsion line 2 2 1 Hydraulic piping front 2 018 2 2 2 Hydraulic piping rear 2 019 2 2 3 Hydraulic piping rear 2 020 2 2 4 Propulsion motor cam motor assembly front 2 021 2 2 5 Propulsion motor cam motor assembly rear 2 022 2 2 6 Description and operation of cam motor 2 023 2 2 7 Rear axle assembly TW352 TW502 2 027 2 2 8 Propulsion controls 2 028 2 2 9 Propulsion circuit diagram ...

Page 16: ...operation of steering circuit 2 052 3 Brake System 3 1 Brake pedal 2 053 3 2 Description and operation of parking brake negative brake circuit 2 054 4 Sprinkler 4 1 Sprinkler piping 2 055 5 Liquid Sprayer 5 1 Liquid sprayer piping 2 056 6 Electric System 6 1 Location of instrument panel and key units 2 057 6 2 Location of key units 2 058 6 3 Electric wiring diagram SW352 2 059 6 4 Electric wiring ...

Page 17: ...Location of Engine related Units 2 003 1 Location of Engine related Units 1 1 Engine mount 2 1 TW5022001 1 Engine mount front 2 Engine mount rear Above illustrations show the engine mount of TW502 ...

Page 18: ...Location of Engine related Units 2 004 Above illustrations represent the intake items of SW352 TW352 1 2 Intake system 3 2 1 TW5022003 1 Intake hose 2 Air cleaner 3 Intake hose ...

Page 19: ...Location of Engine related Units 2 005 1 Intake hose 2 Air cleaner 3 Intake pipe 4 Intake hose 5 Intake hose Above illustrations are the intake items of TW502 1 3 Intake system 4 3 2 1 5 TW5022002 ...

Page 20: ...Location of Engine related Units 2 006 1 4 Exhaust system TW5022005 1 2 3 1 Exhaust pipe 2 Muffler 3 Exhaust pipe Above drawings ilustrate the exhaust items of SW352 TW352 ...

Page 21: ...2 007 Location of Engine related Units 1 5 Exhaust system TW5022004 3 2 1 1 Exhaust pipe 2 Muffler 3 Exhaust pipe Above figures represent the exhaust items of TW502 ...

Page 22: ...on of Engine related Units 2 008 1 6 Cooling piping and radiator TW5022057 1 2 3 7 6 5 4 8 1 Radiator 2 Radiator fan motor 3 Radiator fan 4 Radiator inlet hose 5 Sub tank 6 Pipe 7 Hose 8 Radiator outlet hose ...

Page 23: ...Units 2 009 1 7 Fuel piping and fuel tank TW5022006 3 4 5 3 1 2 6 7 1 Fuel tank 2 Hose fuel tank to filter 3 Hose filter to fuel pump 4 Hose fuel pump to injection pump 5 Hose injection pump to fuel tank 6 Fuel filter 7 Fuel pump ...

Page 24: ...Location of Engine related Units 2 010 1 8 Fuel controls TW5022007 3 A 1 2 VIEW A 1 Throttle lever 2 Knob 3 Throttle cable ...

Page 25: ...ort B 5 High pressure gauge port port A 6 High pressure gauge port port B 7 Servo pressure gauge port 8 Servo pressure gauge port 9 Charge port 10 Control lever 11 Case drain port 12 Case drain port 13 Brake release pressure port 14 Speed shift pressure port 15 Brake release solenoid valve 16 Speed selector solenoid valve Technical data SW352 TW352 Model PVM28 608 Displacement 28 0 cm3 rev 1 7 cu ...

Page 26: ...ion of Hydraulic system 2 1 2 Rear vibrator pump assembly SW352 SW502 1 A 2 1 SW5022009 VIEW A 1 Inlet port 2 Outlet port Technical data Model YP15A13A Displacement 12 87 cm3 rev 0 8 cu in rev Pressure setting 12 7 MPa 130 kgf cm3 ...

Page 27: ...ort 2 Outlet port No 1 pump Front vibrator 3 Outlet port No 2 pump Steering charge Technical data No 1 pump Model DDG1A15 12 Displacement 15 cm3 rev 0 9 cu in rev Pressure setting 12 7 MPa 130 kgf cm3 SW352 TW352 14 4 MPa 147 kgf cm3 SW502 TW502 Technical data No 2 pump Displacement 12 5 cm3 rev 0 8 cu in rev Pressure setting 3 5 MPa 138 kgf cm3 ...

Page 28: ...25 1 1 16 12UN 1 1 16 12UN 1 5MPa 10μ 3 4 16UNF D A B φ0 7 φ0 7 φ0 7 φ0 7 28 0 cm 3 rev 34 5MPa 3 8 5 6L min 34 5MPa 3 8 5 6L min 1 9MPa 20L min L2 1 1 16 12UN 5 0MPa 14 0 cm 3 rev 1 1 16 12UN 7 8 14UNF Front propulsion motor Rear propulsion motor Bypass valve Front vibrator pump steering charge pump Suction filter Tank capacity 43 liters Engine KUBOTA D1503 KA 20 1 kw 27 3 PS 2300 rpm Steering va...

Page 29: ...1 75 L30 Brake release bolt M12 1 75 L30 1 5MPa B A X 105μ 12 5 cm 3 rev 15 0 cm 3 rev B A 0 6MPa 0 6MPa 1 67 1 86MPa X L1 L2 1 1 16 12UN 1 1 16 12UN 1 5MPa 10μ 3 4 16UNF A B 31 5 cm 3 rev 34 5MPa 3 8 5 6L min 34 5MPa 3 8 5 6L min 1 8MPa 18 9L min 1 1 16 12UN φ0 7 φ0 7 φ0 7 φ0 7 Front propulsion motor Rear propulsion motor Bypass valve Front vibrator pump steering charge pump Suction filter Tank c...

Page 30: ...1 1 16 12UN 1 5MPa 10μ 3 4 16UNF A B 28 0 cm 3 rev 34 5MPa 3 8 5 6L min 34 5MPa 3 8 5 6L min 1 9MPa 20L min L2 L1 1 1 16 12UN 5 0MPa 14 0 cm 3 rev 1 1 16 12UN 7 8 14UNF φ0 7 φ0 7 φ0 7 φ0 7 Rear propulsion motor RH Rear propulsion motor LH Bypass valve Front vibrator pump steering charge pump Diff lock valve Suction filter Tank capacity 43 liters Engine KUBOTA D1503 KA 20 1 kw 27 3 PS 2300rpm Steer...

Page 31: ...B A 0 6MPa 0 6MPa 1 67 1 86MPa X Brake release bolt M12 1 75 L30 1 1 16 12UN 1 1 16 12UN 1 5MPa 10μ 3 4 16UNF A B 31 5 cm 3 rev 34 5MPa 3 8 5 6L min 34 5MPa 3 8 5 6L min 1 8MPa 18 9L min L2 L1 1 1 16 12UN φ0 7φ0 7 φ0 7φ0 7 Rear propulsion motor RH Rear propulsion motor LH Bypass valve Front vibrator pump steering charge pump Diff lock valve Suction filter Tank capacity 49 liters Engine KUBOTA D150...

Page 32: ...es illustrate the hydraulic piping of TW502 1 Propulsion pump 2 Propulsion motor front 3 High pressure hose forward travel 4 High pressure hose reversing 5 Drain hose front motor 6 Brake release hose 7 Speed selector hose 8 Charge hose 9 Drain hose pump 10 Oil cooler outlet hose 11 Oil cooler inlet hose 12 Oil cooler 13 Hydraulic tank 14 Drain hose hydraulic tank ...

Page 33: ... 2 Hydraulic piping rear TW5022016 6 2 5 1 4 3 1 Rear propulsion motor 2 High pressure hose forward travel 3 High pressure hose reversing 4 Rear motor drain hose 5 Brake release hose 6 Bypass valve Above illustrations represent the hydraulic piping of SW502 ...

Page 34: ...or L H 2 High pressure hose forward travel 3 High pressure hose reversing 4 Rear motor drain hose 5 Brake release hose 6 Rear propulsion motor R H 7 High pressure hose forward travel 8 High pressure hose reversing 9 Rear motor drain hose 10 Brake release hose 11 Bypass valve 12 Diff lock valve Above illustrations show the hydraulic piping of TW502 ...

Page 35: ...Speed selector port 5 Brake release port 6 Charge relief valve 7 Brake release port Technical data front of SW352 TW352 Model DCM0280 536 Max displacement 465 cm3 rev 28 4 cu in rev Min displacement 232 cm3 rev 14 2 cu in rev Pressure setting 34 3 MPa 350 kgf cm3 Technical data front of SW502 TW502 Model DCM0560 548 Max displacement 745 cm3 rev 45 4 cu in rev Min displacement 372 cm3 rev 22 7 cu i...

Page 36: ...Brake release port Technical data rear of SW352 Model DCM0280 541 Displacement 465 cm3 rev 28 4 cu in rev Pressure setting 34 3 MPa 350 kgf cm2 Technical data rear of TW352 Model DCM0280 540 Displacement 224 cm3 rev 13 7 cu in rev Pressure setting 34 3 MPa 350 kgf cm2 Technical data rear of SW502 Model DCM0560 549 Displacement 745 cm3 rev 45 4 cu in rev Pressure setting 34 3 MPa 350 kgf cm2 Techni...

Page 37: ...0 has twelve oil ports which align with corresponding ports of distributor 11 Distributor 11 fitted to end cap 5 with a dowel pin feeds oil fed from port A or port B of end cap 5 to cylinder block 10 and also displaces oil from cylinder block 10 For this purpose there are twelve oil ports in distributor 11 to negotiate the six cam shapes of cam ring 4 Front propulsion motor Speed selector valve 12...

Page 38: ... 0 2 MPa 2 kgf cm2 Pump flow into port A of end cap 5 is distributed from two ports of speed selector valve 12 into six ports of distributor 11 Remaining six ports act as exhaust ports Pistons 3 moving together with rollers 15 along the cam profiles make cylinder block 10 create a rotary force This force is conveyed to outpu flange 1 spline fitted to cylinder block 10 At the same time pistons 3 le...

Page 39: ...hree ports connect to the low pressure ports with the remaining six ports leading to the charge pressure circuit This action feeds high pressure oil into three of twelve ports of cylinder block 10 As a result only a half of ports feeds the pressurized oil to pistons 3 This drives pistons 3 faster with the pump delivery remaining constant The motor runs more rapidly Main high pressure Main low pres...

Page 40: ...outward Because pistons 3 move along the cam profiles together with rollers 15 rotary force is generated in cylinder block 10 This rotary force is transmitted to output flange 1 spline fitted to cylinder block 10 Output flange 1 is driven Simultaneously pistons 3 leading to the exhaust port port B move along the cam profiles and at the same time outward to exhaust oil from port A If pump flow is f...

Page 41: ...2 027 Description and Operation of Hydraulic System TW5022027 5 6 4 3 6 1 2 2 2 7 Rear axle assembly TW352 TW502 Wide tire version 1 Hub bolt 2 Hub nut 3 Tire 4 Disc wheel 5 Disc 6 Propulsion motor ...

Page 42: ...f Hydraulic System 2 028 TW5022028 A A 7 1 4 1 2 5 6 2 3 SECTION A A 2 2 8 Propulsion controls 1 Forward reverse F R lever 2 Vibrator on off switch 3 Shaft 4 Control cable 5 Interlock switch 6 Reverse alarm switch 7 Control lever ...

Page 43: ...ion valve d Charge relief valve e Brake release solenoid valve f Speed selector solenoid valve 4 Steering charge pump 5 Bypass valve 6 Front propulsion motor assembly cam motor g Speed selector valve h Spring applied hydraulically released brake i Flushing valve j Low pressure relief valve k Brake release bolt 7 Front drum 8 Rear propulsion motor assembly cam motor 9 Rear drum 10 Suction filter 11...

Page 44: ...alve f Speed selector solenoid valve 4 Steering charge pump 5 Front propulsion motor assembly cam motor g Speed selector valve h Spring applied hydraulically released brake i Flushing valve j Low pressure relief valve k Brake release bolt 6 Front drum 7 Left hand rear propulsion motor assembly cam motor 8 Left hand rear wheel 9 Right hand rear propulsion motor assembly cam motor 10 Right hand rear...

Page 45: ...8 and right hand rear wheels 10 Brake release solenoid valve e and speed selector valve f are built into the propulsion pump Fundamental function of propulsion pump and propulsion motor Propulsion pump A piston pump shifts speed and selects forward travel neutral drive and backing by varying the angular position of swashplate and thus varying the piston stroke Front propulsion motor A radial pisto...

Page 46: ...ort of motors drives the motors flowing out from the opposite side ports and joins again to flow into inlet port B of propulsion pump 3 At the same time part of oil in the circuit connecting to port A of front motor 6 passes through flushing valve i opens low pressure relief valve j and is drained into the tank through the motor casing Flushing valve i makes part of oil in the circuit return to th...

Page 47: ...ne leading to forward drive port B of rear motor L H 7 and another line going to forward drive port A of rear motor R H 9 Because front motor 5 left hand rear motor 7 and right hand rear motor 9 are cam motors they have a speed reducing characteristic directly driving front drum 6 left hand rear wheels 8 and right hand rear wheels 10 Because the propulsion circuit is a closed loop circuit the suct...

Page 48: ... the amount if High Speed is selected This doubles the rotating speed of the motor output shaft The pump is feeding constant quantity of fluid Upon selecting High speed the front motor runs faster because amount of oil fed to the front motor per shaft rotation decreases increasing the amount of oil to the rear motor to let it run faster As a result the whole motors gain speed so that the amount of...

Page 49: ...rge pump 4 flow is fed into steering valve Orbitrol 11 then the full flow goes to propulsion pump 3 via line filter 12 irrespective of the steering wheel operation When the F R lever is in the neutral position charge relief valve d opens to make the steering line lead to the tank When travelling the pressure in the high pressure line actuates flushing valve i so that the oil in the low pressure li...

Page 50: ...0 8 1 2 10 5 5 12 3 6 7 6 7 4 VIEW A 1 Front vibrator pump steering charge pump 2 Suction hose 3 Pump outlet hose 4 Front vibrator motor 5 High pressure hose 6 Return hose 7 Drain hose 8 Front vibrator on off solenoid valve 9 Front check valve 10 Rear vibrator on off solenoid valve 11 Rear charge valve 12 Rear vibrator motor ...

Page 51: ... vibrator pump steering charge pump 2 Suction hose 3 Front pump outlet hose 4 Front vibrator motor 5 High pressure hose high amp 6 High pressure hose low amp 7 Drain hose 8 Front amplitude selector solenoid valve 9 Rear vibrator pump 10 Rear pump outlet hose 11 Rear amplitude selector solenoid valve 12 Rear vibrator motor 13 Check valve ...

Page 52: ...em 2 3 3 Hydraulic piping TW352 TW5022035 1 2 A 3 6 7 4 5 9 8 VIEW A 1 Vibrator pump steering charge pump 2 Suction hose 3 Pump outlet hose 4 Vibrator motor 5 High pressure hose 6 Return hose 7 Drain hose 8 Vibrator on off solenoid valve 9 Check valve ...

Page 53: ...m 2 3 4 Hydraulic piping TW502 TW5022036 5 4 7 6 3 1 2 8 1 Vibrator pump steering charge pump 2 Suction hose 3 Pump outlet hose 4 Vibrator motor 5 High pressure hose high amp 6 High pressure hose low amp 7 Drain hose 8 Amplitude selector solenoid valve ...

Page 54: ...Vibrator motor assembly 3 2 1 2 TW5022037 1 Port A inlet outlet port 2 Port B inlet outlet port 3 Drain port Technical data Model SNM2 11 Displacement 10 8 cm3 rev 0 7 cu in rev Pressure setting 12 7 MPa 130 kgf cm2 SW352 TW352 14 4 MPa 141 kgf cm2 SW502 TW502 ...

Page 55: ...raulic system 2 041 2 3 6 Radiator fan motor assembly 2 3 1 A TW5022038 VIEW A 1 Inlet port 2 Outlet port 3 Pressure relief valve Technical data Model WM09A1C Displacement 14 0 cm3 rev 0 9 cu in rev Pressure setting 5 0 MPa 51 kgf cm2 ...

Page 56: ...9 Disc 10 Shim 11 O ring 12 Vibrator motor 13 Cover 14 Cover 15 Spring pin 16 Sleeve 17 O ring 18 Breather 19 Taper roller bearing 20 Side plate 21 Plug 22 Boss 23 O ring 24 Roller bearing 25 O ring 26 O ring 27 O ring 28 Holder 2 3 7 Vibrator SW352 TW352 TW5022039 2 1 3 3 4 5 6 7 8 9 10 11 13 12 14 16 15 3 17 19 20 21 22 23 24 24 26 27 28 25 18 ...

Page 57: ...5 Sleeve 16 Vibrator motor 17 O ring 18 Breather 19 Taper roller bearing 20 Side plate 21 Plug 22 Boss 23 O ring 24 Roller bearing 25 Shaft 26 Fixed weight 27 Movable weight 28 O ring 29 O ring 30 Holder 2 3 8 Vibrator SW502 TW502 TW5022040 1 2 3 3 4 5 6 7 A A 8 9 10 11 12 13 14 15 16 3 17 18 19 20 21 22 23 24 25 24 26 27 28 29 30 Counterclockwise rotation High amp Clockwise rotation Low amp SECTI...

Page 58: ...ne 2 Vibrator pump 3 Suction filter 4 Vibrator on off solenoid valve with pressure relief valve 5 Front vibrator motor 6 Front vibrator 7 Check valve 8 Radiator fan motor with check valve and relief valve 9 Oil cooler 10 Rear vibrator pump 11 Vibrator on off solenoid valve 12 Rear vibrator motor 13 Rear vibrator 14 Check valve TW352 has vibrating unit in the front drum only ...

Page 59: ...t vibrator pump 3 Suction filter 4 Amplitude selector solenoid valve with pressure relief valve 5 Front vibrator motor 6 Front vibrator 7 Radiator fan motor with check valve and relief valve 8 Oil cooler 9 Rear vibrator pump 10 Amplitude selector solenoid valve with pressure relief valve 11 Rear vibrator motor 12 Rear vibrator 13 Check valve TW502 has vibrating unit in the front drum only ...

Page 60: ...ctor solenoid valve 4 while radiator fan motor 7 has check valve d and pressure relief valve e The rear vibrator circuit consists of rear vibrator pump 9 amplitude selector solenoid valve 10 rear vibrator motor 11 rear vibrator 12 and check valve 13 Amplitude selector solenoid valve 10 has pressure relief valve c built in it TW502 has front vibrator alone Fundamental function of vibrator pump and ...

Page 61: ...l cooler 8 Energizing of amplitude selector solenoid a or b selects Low amplitude or High amplitude respectively by reversing rotating direction of gear motor 5 A choice of amplitude is made as follows Oil drawn from port B of gear motor 5 High amplitude Oil drawn from port A of gear motor 5 Low amplitude SW502 rear vibrator See hydraulic circuit diagrams on page 2 045 Operation is same as the fro...

Page 62: ...22043 3 6 7 4 5 8 2 1 9 6 7 11 10 1 Steering charge pump 2 Suction hose 3 Pump outlet hose 1 4 Charge circuit hose 1 5 Line filter charge circuit 6 High pressure hose right turn 7 High pressure hose left turn 8 Steering valve Orbitrol 9 Steering cylinder 10 Pump outlet hose 2 11 Charge circuit hose 2 ...

Page 63: ...10 End cover 11 Bolt 12 Spacer 13 Bolt 14 Washer 15 O ring 16 Bush 17 Check valve 18 Ball 19 Plug 20 Washer 21 Plug 22 Spring 23 Plunger 24 O ring 25 O ring Technical data Valve system Open center non load reaction Displacement 100 cm3 rev 6 1 cu in rev SW352 TW352 160 cm3 rev 9 8 cu in rev SW502 TW502 Relief valve setting 13 5 MPa 138 kgf cm2 TW5022044 19 20 21 22 23 17 24 6 5 1 25 8 7 10 14 11 1...

Page 64: ... Operation of Hydraulic system SW5002040 2 10 11 7 8 3 9 6 4 5 1 10 11 1 Cylinder 2 Piston rod 3 End cap 4 Piston 5 Nut 6 Seal 7 Dust seal 8 U ring 9 O ring 10 Spherical bearing 11 Lock ring 2 4 3 Steering cylinder assembly ...

Page 65: ...draulic system 2 4 4 Steering circuit diagram TW5022045 8 7 1 2 3 5 A 4 6 B R T P a L 1 Engine 2 Coupling 3 Propulsion pump 4 Steering charge pump 5 Line filter 6 Suction filter 7 Steering valve Orbitrol a Relief valve 8 Steering cylinder ...

Page 66: ...7 Then the valve feeds an amount of oil into cylinder 8 in accordance with the direction and speed in and at which the steering wheel is rotated The steering fluid fed into steering cylinder 8 moves the piston rod to achieve steering The fluid displaced from the opposite side of the piston flows through steering valve 7 and line filter 5 to the charge circuit of the propulsion pump Relief valve a ...

Page 67: ...2 053 Brake System 3 Brake System 3 1 Brake pedal TW5022047 A A 4 3 1 2 5 SECTION A A 1 Brake pedal 2 Brake pedal switch 3 F R lever rod centering rod 4 F R lever rod centering rod 5 Spring ...

Page 68: ...ndicator lamp comes on The parking brakes 8 9 and 10 are applied The brake release solenoid valve becomes deenergized Parking brake switch set to RELEASE position The contact points of parking brake switch 5 close the circuit to the brake release solenoid valve 7 and open the brake indicator lamp circuit The indicator lamp comes off Parking brakes 8 9 and 10 are released The brake release solenoid...

Page 69: ...ing TW5022049 5 1 3 6 10 2 7 8 4 9 1 Sprinkler tank 2 Sprinkler pump 3 Sprinkler filter 4 Hose tank to filter 5 Hose filter to pump 6 Hose pump to rear pipe 7 Hose pump to front pipe 8 Sprinkler pipe rear 9 Sprinkler pipe front 10 Sprinkler nozzle ...

Page 70: ...050 1 4 2 3 6 8 9 7 A A 5 SECTION A A 1 Liquid tank 2 Liquid filter 3 Hose tank to filter 4 Hose filter to pump 5 Liquid spray pump 6 Hose pump to pipe 7 Hose pipe to pump 8 Liquid pipe 9 Liquid nozzle Above illustrations represent liquid spray system for TW352 and TW502 ...

Page 71: ... C B 20 VIEW A VIEW C VIEW B 1 Fuse box 2 Control box 3 Horn relay 4 Vibrator lamp relay 5 Interlock relay 6 Brake lamp relay 7 Flasher unit 8 Vibrator relay 9 Glow lamp timer 10 Combination meter 11 Turn signal switch 12 Sprinkler relay 13 Reverse alarm 14 Head lamp 15 Turn signal lamp 16 Battery 17 Horn 18 Combination lamp 19 Work lamp 20 Battery relay ...

Page 72: ...el unit 3 Alternator 4 Thermo unit 5 Amplitude selector solenoid valve front 6 Amplitude selector solenoid valve rear 7 Brake release solenoid valve 8 Speed selector solenoid valve 9 Hydraulic oil filter switch 10 Glow plug 11 Tachometer sensor 12 Engine stop solenoid 13 Starter Above figures illustrate location of electric key units of SW502 ...

Page 73: ...OP ENGINE STOP SOL B 5 RG LW HEAD LAMP 55W HEAD LAMP 55W HORN GY STARTER SWITCH E L B FLASHER UNIT G FLOOD LAMP 55W R R R GY RY BY INTERLOCK SWITCH BACKUP SWITCH GLOW PLUGS 3LY 3R RL 3W RY RB RG 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A OIL PRESSURE SWITCH TACHO METER SENSOR THERMO UNIT FUEL UNIT WATER SPRAY RELAY TURN SIGNAL SWITCH BATTERY RELAY AV60 ALTERNATOR 12V 80AH 95D31R BATTERY 3 1 4 PARKING...

Page 74: ...OR 5R 3G REVERSE FORWARD STOP ENGINE STOP SOL B 5 RG LW HEAD LAMP 55W HEAD LAMP 55W HORN GY HORN SWITCH STARTER SWITCH E L B FLASHER UNIT G FLOOD LAMP 55W R R R GY RY BY INTERLOCK SWITCH BACKUP SWITCH GLOW PLUGS 3LY 3R 2BrR RL 3W RY RB RG 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A OIL PRESSURE SWITCH TACHO METER SENSOR THERMO UNIT FUEL UNIT WATER SPRAY RELAY TURN SIGNAL SWITCH BATTERY RELAY AV60 ALTE...

Page 75: ...OP ENGINE STOP SOL B 5 RG LW HEAD LAMP 55W HEAD LAMP 55W HORN GY STARTER SWITCH E L B FLASHER UNIT G FLOOD LAMP 55W R R R GY RY BY INTERLOCK SWITCH BACKUP SWITCH GLOW PLUGS 3LY 3R RL 3W RY RB RG 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A OIL PRESSURE SWITCH TACHO METER SENSOR THERMO UNIT FUEL UNIT WATER SPRAY RELAY TURN SIGNAL SWITCH BATTERY RELAY AV60 ALTERNATOR 12V 80AH 95D31R BATTERY 3 1 4 PARKING...

Page 76: ...LW L R YG YW YR Y B WR STARTER MOTOR 5R 3G REVERSE FORWARD STOP ENGINE STOP SOL B 5 RG LW HEAD LAMP 55W HEAD LAMP 55W HORN GY HORN SWITCH STARTER SWITCH E L B FLASHER UNIT G FLOOD LAMP 55W R R R GY RY BY INTERLOCK SWITCH BACKUP SWITCH GLOW PLUGS 3LY 3R 2BrR RL 3W RY RB RG 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A OIL PRESSURE SWITCH TACHO METER SENSOR THERMO UNIT FUEL UNIT WATER SPRAY RELAY TURN SIG...

Page 77: ...INSPECTION AND ADJUSTMENT ...

Page 78: ......

Page 79: ...hen the machine leaves the factory They should be used for estimation of parts wear after extended operation and for guidance of repair 2 Vaules in the chart are ones based on various test results etc They should be used for a guide tor fault finding practice in due consideration of the past repair frequency and operating record of the machine 3 Values in the chart should not be used as standard f...

Page 80: ...el speed SW352 0 12 0 1 0 km h 0 9 0 1 0 Main circuit 0 9 0 1 0 Hi Charge circuit Lo 0 12 0 1 0 0 9 0 1 0 TW352 0 9 0 1 0 Hydraulic Oil pressure Propulsion Engine at full throttle Hydraulic oil working temperature 50 5 C See measurement procedure of pressure in each circuit MPa kgf cm2 34 5 1 350 10 31 7 323 1 9 0 2 19 4 2 1 8 18 4 Vibrator circuit 12 7 0 5 130 5 11 3 115 Steering circuit 13 5 0 5...

Page 81: ...10 0 1 0 km h 0 7 5 1 0 Main circuit 0 7 5 1 0 Hi Charge circuit Lo 0 12 0 1 0 0 9 0 1 0 TW502 0 9 0 1 0 Hydraulic Oil pressure Engine at full throttle Hydraulic oil working temperature 50 5 C See measurement procedure of pressure in each circuit MPa kgf cm2 34 5 1 350 10 31 7 323 1 8 0 2 18 4 2 1 6 16 3 Vibrator circuit 14 4 0 5 147 5 13 2 135 Steering circuit 13 5 0 5 138 5 12 4 127 Speed select...

Page 82: ...Apply the parking brake by pressing the parking brake switch button Set the speed selector switch to the HIGH speed range 3 Start the engine and move the F R lever slowly in either direction forward or back ward as required until the engine reaches its rated speed Then take the pressure gauge reading at the rated speed When the measurement is complete return the F R lever to the neutral position i...

Page 83: ... from servo pressure gauge points 1 and 2 of the propulsion pump Attach a pressure gauge with adapter w Servo pressure gauge port 9 16 18UNF 2B Pressure gauge 0 4 9 MPa 0 50 kgf cm2 2 Start the engine and set the throttle lever to the high idle position 3 Make sure that the F R lever is in the neutral position Take the gauge reading 2 Adjustment If the measured value falls outside the permissible ...

Page 84: ... correctly since oil is fed from the steering charge pump 1 Disconnect hose 1 in the speed selecting line from the propulsion motor Attach a pressure gauge with adapter e Pressure gauge 0 4 9 MPa 0 50 kgf cm2 These procedures should not apply to the rear motors 2 Start the engine and set the throttle lever to the high idle position 3 Set the speed selector switch to the High speed range and take t...

Page 85: ...as oil is supplied from the steering circuit 1 Disconnect hoses 1 to 4 in the brake release line from the relevant propulsion motors Attach a pressure gauge with adapter r Pressure gauge 0 4 9 MPa 0 50 kgf cm2 2 Making sure that the F R lever is in the neutral position start the engine and put the throttle lever in the high idle position 3 Take the gauge reading with the parking brake switch set t...

Page 86: ...ocated on top of the F R lever Take the gauge reading Use the similar procedures for the rear vibrator motor 2 Adjustment If measured values fall outside the specified range adjust as follows 1 Slacken locknut 3 of the relief valve Make adjustment by turning adjusting screw 4 Clockwise rotation raises the pressure Counterclockwise rotation lowers the pressure Make the adjustment with the solenoid ...

Page 87: ...plitude or HIGH amplitude by actuating the amplitude selector switch Operate the vibrator mode selector switch from OFF to MANUAL mode Then switch on the vibrator on off switch located on top of F R lever and take the pressure gauge reading Use similar procedure for the measurement of the rear vibrating unit 2 Adjustment If the measured valve falls outside the permissible range renew the relief va...

Page 88: ...ge to adapter u 3 Start the engine Ensuring that the F R lever is in the neutral position operate the throttle lever to select the high idle position 4 Rotate the steering wheel clockwise or counterclockwise to full lock in order to allow the pressure relief valve to release the pressure Take the gauge reading When rotating the steering wheel do not allow anyone to enter the pinch area of the arti...

Page 89: ...50 rpm for SW352 TW352 950 50 rpm for SW502 TW502 4 With throttle lever 1 moved to the full throttle position loosen locknut 7 and adjust stop bolt 8 so that governor lever 3 makes contact with stopper 6 on the full throttle side 5 Start the engine Check that the high idle rpm is to specification High idle 2450 50 rpm for SW352 TW352 2450 50 rpm for SW502 TW502 If high idle is lower than specified...

Page 90: ...Because the neutral position of F R levers 1 and 2 in the driver s station are positively set by a notch ball check for the stroke of the lever on the pump side 1 Connect control cable 3 to arm 4 Check that the F R lever is moved smoothly 2 Connect control cable 5 to arm 4 Arm 4 fixed to pump control lever 5 keeps the pump control lever in the exact neutral position Ensure that the stroke of contr...

Page 91: ...FAULT DIAGNOSIS ...

Page 92: ......

Page 93: ...2 2 How to Make a Fault Diagnosis 4 003 3 How to Use Fault Diagnosis Flow Chart 4 004 4 Precautions for Fault Diagnosis of Electric System 4 006 5 Fault Diagnosis of Electric System Mode E 4 201 6 Fault Diagnosis of Hydraulic and Mechanical Systems Mode H 4 401 ...

Page 94: ...are parts or expendables like oil or grease To make matters worse such a careless practice will invite operator s customer s distrust For these reasons a full investigation and a prudent diagnosis in accordance with fault diagnosis procedures recommended are essential for efficient fault finding proctices 2 Questions to be addressed to the operator customer 1 Are there any trouble other than the o...

Page 95: ...g to site where the faulty machine stays idle Procedure 7 Fault diagnosis Determination of remedy 1 Before diagnosis find out and correct simple failures Do the following Daily inspections Other inspections required 2 With reference to FAULT DIAGNOSIS in this manual make a diagnosis by following proper diagnosis flow chart best applicable to correct the trouble Procedure 5 Getting detailed informa...

Page 96: ... subclassified Ex a Starter does not run r How to make diagnosis Each box contains a diagnosis procedure Depending upon the result inspection or measurement proceed to YES or NO line Normally if the result is YES then proceed to the upper line If NO then go to the lower line The number above each box is a reference number It does not mean a sequence in which diagnosis procedure should proceed Exam...

Page 97: ...ive answer to the question adressed in the box or agrees with the value indicated under the box then go to YES line Otherwise go to NO line The standard values have been taken from the standard value list For the location of component parts such as relays mentioned in the flow chart see the drawing which shows the location of key units The line colors mentioned in the flow charts are indicated in ...

Page 98: ...ce is connected with the connectors disconnected unusual indication will be given 4 When making diagnosis of circuit troubles while performing measurement of voltage resistance and current or continuity test etc check to see if the tester readings vary by shaking connectors or harneses If readings vary a possible cause is a poor connection of the circuit 5 For voltage measurement turn the starter ...

Page 99: ...stripe W White YL Yellow Blue stripe BR Black Red stripe G Green LR Blue Red stripe R Red WB White Black stripe YR Yellow Red stripe BW Black White stripe GB Green Black stripe LW Blue White stripe RB Red Black stripe WL White Blue stripe YW Yellow White stripe BY Black Yellow stripe GL Green Blue stripe LY Blue Yellow stripe RG Red Green stripe WR White Red stripe Gy Gray Br Brown GR Green Red st...

Page 100: ...ied voltage fed to battery relay terminal BR that carries wire LgW 10 14V Is stated voltage present at starter terminal S that carries wire BR NO 5 Is stated voltage present at interlock relay terminal that carries wire BR Is stated voltage present at battery relay terminal NO that carries wire GW Is specified voltage fed to starter switch terminal BR that carries wire LgR 10 14V 10 14V 10 14V 10 ...

Page 101: ...orrectly connected Repair or renew wire Repair or renew wire Repair or renew wire Repair or renew wire Charge or renew battery Interlock relay faulty F R lever interlock switch faulty Wire W from starter switch terminal C to interlock relay termianl not connected or incorrectly connected including fuse Starter switch faulty between B and C Cable from battery relay terminal NO to starter not connec...

Page 102: ... terminal COM that carries wire W 10 14V Starter switch faulty between B and BR Cable from battery plus terminal to battery relay terminal COM not connected or incorrectly connected Repair or renew wire Renew fuse Repair or renew cable A Electric wiring diagram for modes E 01 and E 02 BR Battery relay COM B LgR LgW 3BY 5WR 5W NO AV60 AV60 E C BR SOL Engine stop solenoid GY B 3BR 3W Interlock relay...

Page 103: ...Is resistance of engine stop solenoid as specified Engine stop solenoid earth wire faulty Wire BY from starter switch terminal C to engine stop solenoid terminal C not connected or incorrectly connected Renew Wire WR from Battery relay terminal NO to engine stop solenoid terminal BR via fuse box not connected or incorrectly connected Repair or renew wire Repair or renew wire Renew fuse E 02 Engine...

Page 104: ...ries wire WG Glow plugs faulty Renew Wire WG from starter switch terminal R1 to glow plugs not connected or incorrectly connected 10 14V Turn starter switch ON Heating Lower than 1V Starter switch faulty between B and R1 10 14V Turn starter switch to HEAT Possible cause Remedy 10 14V 10 14V 4 206 Fault Diagnosis of Electric System Mode E E 03 Glow Plugs do not become red hot difficult starting It ...

Page 105: ...the voltage with the starter switch ON YES NO YES NO 2 Possible cause Remedy Alternator faulty Wire WY from alternator terminal B to starter terminal B not connected or incorrectly connected Regulator faulty 1 Does specified voltage appear at alternator terminal IG that carries wire Y 13 5 14 5V Run engine at above medium speed 10 14V Renew Renew Does specifed voltage appear at alternator terminal...

Page 106: ...lenoid resistance as specified About 5 5 Ω Disconnect wire 10 14V 3 Is resistance of wire BrR from vibrator solenoid to vibrator relay terminal B as specified 9 A Is specified voltage present at F R lever switch terminal NO carrying wire B YES 4 YES Is stated voltage present at vibration mode selector switch terminals 2 that carry wire RW Is resistance of wire RW from vibration mode selector switc...

Page 107: ...or renew wire Repair or renew wire Vibrator relay faulty Wire Br from F R lever switch terminal C to vibrator relay terminal H not connected or incorrectly connected Wire RW from vibration mode selector switch terminal 2 to vibrator relay terminal F not connected or incorrectly connected Vibration mode selector switch faulty Wire BrR from vibrator solenoid to vibrator relay terminal B not connecte...

Page 108: ...which carry wires LgR and LgB 2 High amplitude Is stated voltage present at high amp vibrator solenoid terminals 1 and amplitude selector switch terminals 2 and 5 which carry wires LgY and LgW YES 2 10 14V NO 1 Low amplitude Is stated voltage present at amplitude selector switch terminals 3 and 6 which carry wires LgR and LgB 2 High amplitude Is stated voltage present at amplitude selector switch ...

Page 109: ... 2 to vibrator relay terminal F not connected or incorrectly connected Vibration mode selector switch faulty Wire RL from vibration mode selector switch terminal 1 to fuse not connected or incorrectly connected Wire BrR from Low amp solenoid terminal 2 to vibrator relay terminal B not connected or incorrectly connected F R lever switch faulty Vibrator relay faulty Vibrator relay earth wire B not c...

Page 110: ...ries wire BrY Possible cause Remedy Wire BrY from vibration mode selector switch terminal 5 to vibrator relay terminal G not connected or incorrectly connected Repair or renew wire Repair or renew wire Repair or renew wire About 1 Ω Disconnect wire 10 14V 10 14V To A Vibration mode selector switch faulty Renew Renew Wire RL from vibration mode selector switch terminal 4 to fuse to branch point not...

Page 111: ...ion meter Electric wiring diagram for mode E 6 SW502 TW502 C C NO NO NC NC 6 2 4 1 3 5 G E H F D B NC NO COM f e c b a HI LOW 4 1 1 6 2 2 1 2 HI LOW 1 2 1 2 3 5 RL F R lever switch R F R lever switch L Br Br B B G G Br Br RL BrY RW Fuse 15A Amplitude selector switch Fuse 15A Vibration mode selector switch BrR RL RL Br BrR Vibrator indicator lamp relay B Br RW BrY GY Vibrator relay W B GY RY Interl...

Page 112: ... stated voltage fed to sprinkler motor that carries wire LB 10 14V Operate sprinkler switch Lower than 1 Ω Disconnect wire at motor Is stated voltage fed to sprinkler relay that carries wire LY Sprinkler motor faulty Wire LB from sprinkler relay to sprinkler motor not connected or incorrectly connected Renew Renew Renew To A Wire LY from fuse to sprinkler relay not connected or incorrectly connect...

Page 113: ... to speed selector solenoid that carries wire LgW 10 14V Operate speed selector switch About 8 5 Ω Disconnect wire at solenoid Is resistance of solenoid earth wire as specified Hydraulic system faulty See H 03 Speed selector solenoid faulty Renew Renew Wire LgW from solenoid to speed selector switch terminal 2 not connected or incorrectly connected Speed selector switch faulty Wire RY from fuse to...

Page 114: ... is solenoid insulated from chassis Possible cause Remedy Solenoid earth wire not connected or incorrectly connected Repair or renew wire Repair or renew wire Repair or renew wire Repair or renew wire Lower than 1 Ω Disconnect wire at solenoid 1 Is stated voltage present at brake release solenoid terminal that carries wire WB 10 14V Set parking brake switch to RELEASE About 8 5 Ω Disconnect wire a...

Page 115: ...c wiring diagram for mode E 09 RY RG RG RG BrY B f e c b a Brake lamp relay BrY W R B WB RY Brake pedal switch COM NO NC 6 2 STOP 5 3 1 4 Parking brake switch B RW RY YL Parking brake indicator lmap Combination meter Parking brake solenoid Fuse 15A Stoplamp ...

Page 116: ...MEMO ...

Page 117: ... H 02 Speed not Gained or Low Traction 4 406 H 03 Speed Range not Selected 4 406 H 04 Vibrator Inoperative 4 407 H 05 Low Vibration Intensity 4 408 H 06 Steering not Achieved 4 408 H 07 Heavy or Slow Steering 4 409 H 08 Parking Brake not Released 4 409 H 09 Poor Parking Brake Function 4 410 See STANDARD VALUE CHART for hydraulic pressure measurement ...

Page 118: ...e brake Motor body Negative brake Flushing valve Speed selector valve or selector piston Speed selector solenoid valve Brake release solenoid valve Engine Diagnosis code H 01a H 03 H 01b H 02a H 02b Pump Vibrator on off solenoid valve Amplitude selector solenoid valve Pressure relief valve Front motor Front vibrator Rear motor Rear vibrator Steering charge pump Steering valve Orbitrol Steering cyl...

Page 119: ...TW352 Inoperative SW TW502 Low vibration intensity a Front and rear b Either front or rear a Front and rear b Either front or rear Either front or rear Steering Not achieved Heavy or slow Parking brake not released Poor parking brake function H 04a H 04b H 04a H 04b H 05 H 09 H 08 H 07 H 06 ...

Page 120: ...front propulsion motor run if ports A and B of rear motor blocked Does rear propulsion motor run if ports A and B of front motor blocked Is machine propelled after releasing negative brake with release bolt screwed into it See Standard Value Chart 8 B See Standard Value Chart See Standard Value Chart NO YES 10 To B Brake release solenoid valve is malfunctioning Low pressure relief valve built in f...

Page 121: ...n valves are exchanged with each other Does control valve spool move smoothly NO YES 3 YES YES NO Possible cause Remedy Servo piston is malfunctioning Renew propulsion pump Adjust NO 1 Does F R lever move smoothly Multi function valve faulty Foreign matter is present or valve is defective Control valve is malfunctioning Repair or renew Renew F R lever linkage incorrectly adjusted ...

Page 122: ...Repair or renew engine Repair or renew Repair or renew motor Repair or renew pump Adjust Renew Repair or renew Renew propulsion pump Adjust Propulsion pump performance degraded Main circuit pressure lowered Charge circuit pressure lowered Increased internal leak Flushing valve faulty Control valve is malfunctioning F R lever linkage incorrectly adjusted Multi function valve is malfunctioning Forei...

Page 123: ...erate running sound Repair or renew Repair or renew Repair or renew Either front or rear amplitude selector solenoid valve faulty Vibrator faulty Front or rear vibrator motor faulty Is travelling normal Is fault corrected if engine is cranked with front or rear amplitude selector solenoid valve disassembled and cleaned 2 YES NO NO 1 YES Operate starter motor to crank engine with wire disconnected ...

Page 124: ... Chart H 05 Low Vibration Intensity Inspect electric systems first If normal then use procedure as described below Low vibration intensity either in front or rear drum Is vibration intensity low either in front or in rear vibrator or in both NO YES 2 1 Is relief pressure as specified with hose blocked at vibrator motor inlet port Either in front drum or in rear drum In both drums Vibrator pump per...

Page 125: ...enew pump See NOTE NOTE Move steering cylinder piston to end of stroke disconnect hose at stroke end side and put pressure from reverse side Oil can leak if seal is faulty Exert pressure from here Disconnect hose here See Standard Value Chart See Standard Value Chart H 08 Parking Brake not Released Make a diagnosis of electric systems first If they are normal use procedures as below NO 1 YES Possi...

Page 126: ...ative brake faulty Is brake release pressure lower than 1 6MPa Repair or renew Repair or renew H 09 Poor Parking Brake Function Make a diagnosis of electric systems first If they are normal then use the flow chart below Fault Diagnosis of Hydraulic and Mechanical Systems Mode H ...

Page 127: ...DISASSEMBLY AND ASSEMBLY ...

Page 128: ......

Page 129: ...ge pump assembly 5 104 4 2 Installation of engine and propulsion vibration steering charge pump assembly 5 107 5 Removal and Installation of Coupling 5 1 Removal of coupling 5 108 5 2 Installation of coupling 5 108 6 Removal and Installation of Front Drum Assembly 6 1 Removal of front drum assembly 5 109 6 2 Installation of front drum assembly 5 111 7 Disassembly and Assembly of Front Drum Assembl...

Page 130: ...or assembly 5 127 13 Disassembly and Assembly of Propulsion Motor Negative Brake 13 1 Disassembly of propulsion motor negative brake 5 128 13 2 Assembly of propulsion motor negative brake 5 130 14 Removal and Installation of Steering Cylinder Assembly 14 1 Removal of steering cylinder assembly 5 138 14 2 Installation of steering cylinder assembly 5 139 15 Disassembly and Assembly of Steering Cylin...

Page 131: ...d gaskets O rings cotter pins and lock plates When installing bend cotter pins and lock plates positively If a sealant is coated clean and remove residual oil or grease from thread portions Apply two or three drops of bond to the threaded portions When applying a sealant clean and remove residual oil or grease from the mating surfaces Spread the sealnat smoothly after making sure that the surfce i...

Page 132: ...MEMO ...

Page 133: ...ulley 1 4 Alternator assembly Remove fixing bolts 3 and remove alternator assembly 6 For installation reverse the removal pro cedure 1 Adjust the fan belt with the adjust bolt so that the slack at the center between the fan and alterna tor puleys is 10 to 15 mm 0 39 to 0 59 in with a push of about 10 kgf 98 N Disconnect the negative cable from the battery 1 2 Instration of alternator assembly 1 Re...

Page 134: ...ct connector 1 and feed wire 2 from the starter 3 Starter assembly Remove two fixing bolts 3 and detach starter assembly 4 2 Removal and Installation of Starter Assembly 2 1 Removal of starter assembly 2 2 Instration of starter assembly Use the removal procudure in the reverse sequence Disconnect the negative cable from the battery TW5025004 3 2 4 1 ...

Page 135: ...aulic tank oil level 5 Radiator piping work Disconnect radiator inlet hose 4 and outlet hose 5 at the radiator 6 Radiator oil cooler assembly 1 Remove bolts 9 that secure the radiator oil cooler assembly 2 Remove radiator oil cooler assembly 8 3 2 Installation of radiator oil cooler assembly 3 Removal and Installation of Radiator Oil Cooler Assembly 3 1 Removal of radiator oil cooler assembly Reve...

Page 136: ...res at the engine that carry oil pressure sensor thermo sensor tachometer sensor and glow plugs 3 Disconnect wires at the alternator and starter See procedures under Electric wiring of alternator page 5 101 and Electric wiring of starter page 5 102 3 Air cleaner Disconnect air cleaner intake hose 4 4 Radiator hose 1 Drain the coolant from the radiator 2 Remove upper hose 5 and lower hose 6 1 Remov...

Page 137: ...Disconnect hydraulic hoses 27 28 at the vibrator steering charge pump Blank the open ends of hoses and elbos 8 Propulsion pump hydraulic hose Disconnect hydraulic hoses 16 23 at the propoulsion pump Blank the open ends of hoses and elbos 10 Vibrator pump hose SW352 SW502 Disconnect vibrator pump hoses 27 28 on the engine side Blank the open ends of hoses and elbos TW5025011 20 21 22 23 19 18 17 16...

Page 138: ...sembly 31 of engine propulsion vibrator charge steering pump 2 Remove fixing nuts at front engine mounts 32 and rear mounts 33 on both right and left sides 3 Lift the whole assembly 34 off the machine TW5025016 33 34 TW5025015 31 32 32 TW5025014 30 29 11 Engine oil drain hose and earth wire 1 Drain engine oil from the engine 2 Disconnect drain hose 29 at the frame 3 Disconnect earth wire 30 at the...

Page 139: ...stment page 3 108 Apply lithium grease to splined portions Bleed air from the fuel line Fill the radiator with a 35 long life coolant to the specified level Run the engine for coolant to circulate through the engine Then recheck the coolant Add oil to the hydraulic tank to the specified level for compensation of a leak Run the engine to allow oil to circulate through the piping Then recheck the oi...

Page 140: ...r engine mount fixing bolts 1 on right and left sides 3 Remove eight flywheel securing bolts 2 and remove the flywheel cover together with propulsion vibrator steering charge pump assembly 3 3 Coupling Remove six retaining bolts 4 and remove coupling 5 5 Removal and Installation of Coupling 5 1 Removal of coupling 5 2 Installation of coupling Installation is the reverse of removal procedure Torque...

Page 141: ...et the plate fall forward 2 Release the negative brake by removing the plug at the center of the front propulsion motor first and then screw ing the brake release bolt into the plug hole Take care when removing the plate It will fall free the moment the whole bolts are taken off Remove the plate on the opposite side by using the same procedure 2 Propulsion motor piping 1 Disconnect hoses 1 5 at th...

Page 142: ... lift side plate 12 take off twelve retaining bolts 15 and separate plate 12 from shockmounts 1 Use the same procedure to separate the side plate on the opposite side 3 On a hoist lift and hold front frame 11 Place a wooden block under the front frame and disengage the hoist hook TW5025023 11 TW5025024 12 15 14 ...

Page 143: ...in the reverse order of removal 1 Tightening torque of bolts 265 N m 27 kgf m 2 Tightening torque of nuts 108 N m 11 kgf m Add oil to the hydraulic tank to the specified level for compensation of a leak during removal Start the engine Allow oil to circulate through the piping then recheck the oil level ...

Page 144: ...uring bolts 2 and remove vibrator motor assembly 1 3 Remove four retaining bolts 6 and remove cover 7 2 Remove six securing bolts 4 and remove cover 5 from the disc 2 Sleeve Remove sleeve 3 3 Disc vibrator motor side 1 Using a hoist stand drum assembly with the vibrator motor up 7 Disassembly and Assembly of Front Drum Assembly 7 1 Disassembly of front drum assembly TW5025025 1 2 TW5025026 3 TW502...

Page 145: ...nd stand with the propulsion motor up See Disassembly of front drum assembly page 5 112 2 Remove elbos 10 14 3 Remove six securing bolts 15 Using lift ing bolts remove disc 16 from the propul sion motor 4 Axle shaft 1 Remove eight fixing bolts from axle shaft 9 2 Allow axle shaft 9 to float by screwing pull bolts into the axle shaft 3 Replace the pull bolts with lifting bolts On a hoist lift off a...

Page 146: ...les of holder 20 and separate it from the drum 3 Using lifting bolts and shuckles lift off holder 20 5 Remove lock ring 24 and take off bearing 23 from holder 20 4 While holding vibrator shaft 21 remove lock ring 22 and pull off vibrator shaft 21 from holder 20 TW5025035 20 21 21 22 TW5025036 20 23 24 TW5025033 TW5025034 19 20 20 Lifting bolt ...

Page 147: ...in position 2 Propulsion motor assembly Using lifting bolts lift the propulsion motor assembly 18 and install it to the drum Tighten eight fixing bolts 17 Tightening torque 343 N m 35 kgf m Thoroughly clean the parts and remove burrs etc 5 Using lifting bolts mount holder 20 to the drum 4 With vibrator shaft 21 standing assemble holder 20 onto the shaft and install lock ring 22 TW5025036 20 23 24 ...

Page 148: ...sing lifting bolts assemble axle shaft 9 onto the vibrator shaft Tighten the eight fixing bolts Tightening torque 265 N m 27 kgf m 4 Vibrator shaft end float Make sure that the vibrator shaft has an end float of about 2 5 mm 0 1 in 2 Assemble bearing 12 onto axle shaft 9 Apply lithium grease to the bearing TW5025031 15 10 11 12 13 14 16 About 2 5mm 0 1 in TW5025038 TW5025039 9 Lifting bolt Lifting...

Page 149: ...que 4 2 After that measure the clearnce between cover 7 and axle shaft 9 with a thickness gauge Fit shims with their thickness equivalent to the clearance Retighten the four bolts to 59 N m 6 0 kgf m 4 3 Then spin disc 8 two turns clockwise and counterclockwise each hook a spring balance to a shockmount fastening bolt and measure the force when the disc starts spinning disc drag Disc drag 64 N m 6...

Page 150: ... to the vibrator shaft 8 Vibrator motor assembly Install propoulsion motor assembly 1 to sleeve 3 Tighten two fixing bolts 2 Tightening torque 49 N m 5 kgf m 5 Fit cover 5 and tighten six fixing bolts 4 Tightening torque 108 N m 11 kgf m TW5025026 3 TW5025025 1 2 TW5025027 5 4 ...

Page 151: ...6 and position it close to the front frame 3 Remove F R cable 7 and position it close to the front frame 2 Electric wiring Detach connectors 4 and place the hoses close to the front frame so that they may not interfere with the work 3 Sprinkler Disconnect hoses 5 and put them close to the front frame 8 Removal and Installation of Center Pin Assembly 8 1 Removal of center pin assembly Disconnect ba...

Page 152: ...y 1 Using a jack support the rear frame from below 2 Release the front propulsion motor negative brake 3 On a hoist lift front frame 10 at the position close to the center pin 4 Remove eight center pin bracket fixing bolts 11 1 5 Roll out the drum off front frame 10 and lower the frame on a stand 7 Center pin assembly 1 Temporarily lift and hold center pin assembly 12 2 Remove twelve fixing bolts ...

Page 153: ...stallation of center pin assembly Reverse the removal procedure 1 2 Torque setting of bolts 265 N m 27 kgf m Add oil to the tank to the specified level for compensation of a leak Start and run the engine to circulate oil through the piping Recheck the oil level ...

Page 154: ...nnect hoses 5 8 Blank the open ends of hoses and elbos 5 Rear motor assembly 1 Remove six propulsion motor securing bolts 9 2 Move the propulsion motor inward and pull off rearward 2 3 Rear wheels left 1 Remove twelve inner bolts 2 from wheel 3 3 2 Using a fork lift pull off the left hand two tire assembly to the left Withdraw the right hand two tire assem bly in the same manner 9 Removal and Inst...

Page 155: ...lsion Motor Assembly and Wheels TW352 TW502 6 Removal and installation of wheels 1 Remove six hub nuts 10 from wheel 3 1 2 On a hoist lift off wheel 3 3 Turn the wheel assembly upside down and remove six hub nuts 10 TW5025054 3 10 TW5025055 3 10 ...

Page 156: ...d wheels Install by reversing the removal sequence 1 Torque setting of bolts 186 N m 19 kgf m 2 Torque setting of bolts 265 N m 27 kgf m 3 Torque setting of bolts 167 N m 17 kgf m Add hydraulic oil to the tank to the speci fied level for compensation of a leak Start and run the engine to circulate oil through the piping Recheck the oil level ...

Page 157: ...late through the piping Recheck the oil level Remove the assembly referring to steps 7 to 9 in Removal of engine and propulsion vibration steering charge pump assembly page 5 104 1 Temporarily lift and hold the propulsion vibration steering charge pump assembly and remove two bolts 2 that fasten the clutch housing to propulsion pump 1 1 2 Lift off the propulsion vibration steerig charge pump assem...

Page 158: ...ibrator hoses 1 and 2 at the engine Blank the open ends of hoses and elbos 3 Vibrator pump assembly Remove two fixing nuts 3 and remove the TW5025057 1 3 2 Install in the reverse order of removal 1 1 Tightening torque of vibrator pump fixing bolts 49 N m 5 kgf m Add oil to the tank to the specified level for compensation of a leak Start and operate the engine to allow oil to circulate through the ...

Page 159: ...f hoses and elbos 2 Vibrator motor ass y Remove two fixing bolts and remove vibrator motor assembly 1 1 Reverse the removal sequence 1 Tightening torque of vibrator pump fixing bolts 49 N m 5 kgf m Add oil to the tank to the specified level for compensation of a leak Start and run the engine to circulate oil through the piping Recheck the oil level 12 2 Installation of vibrator motor assembly TW50...

Page 160: ...e cover 1 If the screws are not slackend evenly the last screw is likely to break Screw size DCM0280 M6X20L 5 mm DCM0560 M8X25L 6 mm Width across flats 2 Brake spring When brake cover 1 is removed brake spring 3 will appear Remove the spring 3 Preparation for brake piston removal After removing O ring and socket head plugs with O ring fitted from the forced brake release port position brake cover ...

Page 161: ...ct the O ring Screw DCM0280 M10X25L 1 5 mm For M10 screw 19 23 mm 2 5 3 5 mm For M12 screw 22 27 mm 2 5 3 5 mm DCM0560 M12X30L 1 75 mm Washer Outer diameter Thickness Pitch Screw and washer for forced brake releasing 5 Brake piston removal After fully screwing in the brake release screw loosen it once and place block 6 between the brake housing and brake cover to lift the brake piston further Incr...

Page 162: ...ke shaft spring Brake shim Quantity Item A R 15 14 Friction disc Separate disc TW5025065 8 7 TW5025073 Separate disc Friction disc Brake shaft 1 Brake disc Assemble the brake shaft into the brake housing Install separate discs 7 and friction discs 8 alternately paying attention to the quantitity and sequence of the discs to assemble Push the brake shaft fully home If the brake discs are assembled ...

Page 163: ...have been removed should be used but if the stroke of brake piston Inspection after replacement page 5 134 is not to specification increase or decrease shim 9 thickness Drawing No Brake shim package Upon request of spare parets above set is supplied as package DCM0280 1745162 S 0 8 mmX1 piece 0 4 mmX1 piece 0 2 mmX1 piece 0 1 mmX1 piece 0 4 mmX1 piece 0 2 mmX1 piece 0 1 mmX1 piece DCM0560 1745280 ...

Page 164: ...y brake is fitted from the side apply a slightly high viscous grease to steel ball 11 to prevent falling free 10 11 TW5025075 Apply grease If the brake is fitted with the cam motor placed horizontally ensure that the brake shaft has been driven fully home The dis tance between the brake housing spline end and brake shaft end should fall within the range as specified below Distance L DCM0280 1 2 2 ...

Page 165: ...ring and big O ring to brake piston 12 Assemble brake piston 12 into the brake housing Drive the brake piston fully home by tapping it with a soft faced hammer Apply a coat of mineral oil jelly to the O rings to prevent scratching 6 Brake cover Tighten socket head screws 2 that fix brake cover 1 Tighten the eight screws evenly Failure to tighten the screws evenly can break the first bolt Screw siz...

Page 166: ...distance L1 between the brake cover surface and the screw head with the brake release pilot port open to the atmosphere brake is applied DCM0280 M10X25L 1 5 mm DCM0560 M12X30L 1 75 mm Brake release screw size pitch L2 TW5025078 2 Checking for brake stroke Using a depth gauge measure dimension L2 from the brake cover surface to the brake release screw head with the brake release pressure applied to...

Page 167: ...ement standard If unusual signs are noticeable as stated below renew the whole friction discs and sep arate discs 1 The braking force is lower than the tractive force of the propulsion motor When the propulsion motor is powered the motor starts running although the brake stays applied 2 Any of the friction discs or separate discs are seized 3 The brake piston stroke exceeds 3 5 mm 0 14 in Refer to...

Page 168: ...rake release pilot port open to the atmosphere brake is applied DCM0280 M10X25L 1 5 mm DCM0560 M12X30L 1 75 mm Brake release screw size pitch 3 Checking for brake stroke Using a depth gauge measure distance L2 from the brake cover surface to the screw head with the brake release pressure applied to the pilot port brake is released Brake piston stroke L2 L1 If the brake piston stroke with used brak...

Page 169: ...14934 01 1714935 01 1733702 1733703 1745653 HKW04 AAM0802501 M8X25 12 9T HP11020 3 KP1B014 1B P14 15 1 1 1 1 1 1 1 1 1 1 8 1 1 Separate disc Brake shim set O ring O ring O ring Brake cover Brake piston Brake shaft Brake spring Brake shaft spring Steel ball ø12 7 Socket head screw Socket head plug O ring Parts given in parentheses are for reference only and not necessary to replace D13 D14 D51 D52 ...

Page 170: ...ne and fully retract the piston rod of the steering cylinder 2 Disconnect hoses 4 and 5 from the cylinder Blank the open ends of the elbows on the cylinder 3 Hydraulic hoses 1 Support the cylinder assembly from below 2 Pull off the pin and remove the cylinder assembly Engage the steering lock bar securely for safe work in the articulated area of the machine 1 Cylinder rod Pull pin 1 and remove cyl...

Page 171: ...Installation of steering cylinder assembly For installation reverse the removal procedure Fit spacer between the rod and bracket on top and bottom locations Add oil to the specified level Start the engine Allow oil to circulate through the piping Recheck the oil level ...

Page 172: ...piston rod assembly 1 Loosen end cap 2 and pull off the assem bly from cylinder 3 Hold the cylinder in a vice 2 Pull off piston piston rod assembly 4 from cylinder 3 SW5005081 4 2 3 SW5005082 3 6 5 SW5005083 2 9 8 6 SW5005084 12 10 2 13 2 Remove U ring 10 and dust seal 12 from end cap 2 3 Remove O ring 13 from end cap 2 2 Piston 1 Remove nut 5 and withdraw piston 6 from the rod Clamp the piston ro...

Page 173: ...ing 10 to end cap 2 SW5005084 12 10 2 13 SW5005083 2 9 8 6 SW5005082 3 6 5 SW5005081 4 2 3 2 Tighten nut 5 Tightening torque 30 5 kgf m 294 49 N m Mount the piston rod on a vice 3 Fit end cap 2 on piston rod 9 2 Piston 1 Assemble seal ring 8 onto piston 6 and fit the assembly onto piston rod 9 3 Piston piston rod ass y 1 Assemble piston piston rod assembly 4 into cylinder 3 2 Screw end cap 2 into ...

Page 174: ...l of steering wheel 1 Contact plate Remove horn cap 1 from the steering wheel and remove contact plate 2 lock spring 3 and spring 4 SV5005213 1 2 4 3 5 6 SV5005214 2 Steering wheel Remove nut 5 and remove steering wheel 6 16 2 Instration of steering wheel Installation is the reverse of the removal procedure ...

Page 175: ...rect reconnection Plug the open ends of the hoses and openings of Orbitrol 2 Remove four bolts 3 and remove steering wheel assembly 4 together with Orbitrol 5 Hold Orbitro by hand as it can fall free when the steering wheel is detached SW5005085 4 5 2 3 17 2 Installation of Orbitrol Reverse the removal instructions Add oil to the tank to make up for a leak Start the engine and let oil circulate th...

Page 176: ...Printed in Japan 2006 7 100 0 C D Head office 1 4 8 Shiba Daimon Minato ku Tokyo Japan Telephone Tokyo 03 3431 9971 Facsimile 03 3431 6212 No 98084 0 ...

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