Sakai SW354 Shop Manual Download Page 11

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SW/TW354,SW/TW504

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0-007

. ELECTRICAL COMPONENT SPECIFICATION

S (SW504)

9-1. Fuse Box

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

5-088

-2. Combination Meter

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

5-089

6. VIBRATORY DRUM • REAR WHEEL

1. PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY

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

6-001

VIBRATORY DRUM

2-1.

Removal and Installation of Vibratory Drum

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

6-003

2-1-1. Removal of vibratory drum

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

6-003

2-1-2. Installation of vibratory drum

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

6-006

VIBRATORY DRUM ASSEMBLY

3-1. Vibratory Drum Assembly (SW/TW354)

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

6-007

3-2. Vibratory Drum Assembly (TW504)

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

6-008

3-3. Disassembly and Reassembly of Vibratory Drum

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

6-009

3-3-1. Disassembly of vibratory drum

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

6-009

3-3-2. Reassembly of vibratory drum

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

6-020

4. REAR AXLE

4-1. Rear Axle Assembly (TW types)

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

6-039

4-2. Removal and Installation of Rear Axle (TW types)

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

6-040

4-2-1. Removal of rear axle



6-041

4-2-2. Installation of rear axle

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

6-044

VIBRATORY DRUM (SW504)

-1. Removal and Installation of Vibratory Drum

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

6-045

-2. Disassembly and Reassembly of Vibratory Drum

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

6-045

7. BRAKE

1. BRAKE PEDAL

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

7-001

2. BRAKE SYSTE

2-1. Brake System (SW354)

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

7-002

2-2. Brake System (TW354, 504)

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

7-003

8. WATER SPRAY SYSTEM

1. WATER SPRAY PIPIN

1-1. Water Spray Piping (

SW354)

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8-001

1-2. Water Spray Piping (

TW354, 504)

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

8-002

LIQUID SPRAY SYSTEM

-1. Liquid Spray Piping (TW354,504)

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

8-003

○

Summary of Contents for SW354

Page 1: ...SW TW354 SW TW504 SHOP MANUAL 3498 6446A 1 ...

Page 2: ......

Page 3: ...he machine Improper operation is dangerous and can result in injury or death Sakai Heavy Industries cannot foresee all possible circumstances or varying conditions to which the operator serviceman or machine may be exposed to that might lead to a potential hazard Therefore the warnings and cautions listed in this manual and those placed on the machine are not intended to be all inclusive and liabi...

Page 4: ......

Page 5: ... 004 1 9 Stopping 1 004 1 10 Maintenance 1 005 1 11 Transporting the Machine 1 007 2 SPECIFICATIONS 1 SPECIFICATION DATA 1 1 SW354 2 001 1 2 SW354 ROPS 2 003 1 3 TW354 2 005 1 4 TW354 ROPS 2 007 1 5 TW504 2 009 1 6 TW504 ROPS 2 011 1 7 Common Specifications 2 013 2 TABLE OF STANDARD VALUES 2 1 Engine 2 014 2 2 Propulsion 2 014 2 3 Hydraulic System 2 015 2 4 Steering 2 015 2 5 Brakes 2 016 2 6 Capa...

Page 6: ...commended Lubricants 2 026 3 ENGINE AND CONTROLS 1 ENGINE 1 1 Engine Mount 3 001 2 CONTROL SYSTEM 2 1 Throttle Control 3 002 2 2 Forward reverse Control 3 003 3 PUMP MOUNT 3 1 Pump Mount 3 004 3 1 1 Installation of pump 3 005 4 ENGINE SW504 4 1 Engine Mount 3 006 5 FUEL SYSTEM SW504 3 007 6 CONTROL SYSTEM SW504 6 1 Throttle Control 3 009 6 2 Forward reverse Control 3 010 7 PUMP MOUNT SW504 7 1 Pum...

Page 7: ...ropulsion hydraulic motor R SW354 4 015 2 2 5 Propulsion hydraulic motor R TW354 504 4 016 2 2 6 Differential lock valve TW354 504 4 017 3 VIBRATOR HYDRAULIC SYSTEM 3 1 Vibrator Hydraulic Piping 4 018 3 1 1 Vibrator hydraulic piping SW354 4 018 3 1 2 Vibrator hydraulic piping TW354 4 019 3 1 3 Vibrator hydraulic piping TW504 4 020 3 2 Hydraulic Component Specifications 4 021 3 2 1 Hydraulic pump a...

Page 8: ...TEERING SYSTEM SW504 8 1 Steering Hydraulic Piping 4 041 8 2 Hydraulic Component Specifications 4 042 8 2 1 Orbitrol 4 042 5 ELECTRICAL SYSTEM 1 Precautions for work 1 1 Wire Numbers Wire Sizes Wire Colors and Connectors Shown in Electrical Circuit Diagram Wiring Harness Layout and Wiring Harnesses 5 001 2 SYSTEM CIRCUIT DIAGRAM 2 1 Electrical Circuit Diagram SW354 5 003 2 2 Electrical Circuit Dia...

Page 9: ...itch Harness 5 030 4 9 1 Short harness SW TW354 except SW354 ROPS 5 030 4 9 2 Vibration Lo Hi change switch harness TW504 5 031 4 10 Vibrator Solenoid R Harness 5 032 4 10 1 Vibrator solenoid R harness SW354 5 032 4 10 2 Cap TW354 504 5 033 4 11 Hazard Switch Harness 5 034 4 11 1 Cap except ROPS 5 034 4 11 2 Hazard switch harness ROPS 5 035 4 12 Mihaalu Harness 5 036 4 13 Liquid Spray Switch Harne...

Page 10: ...itch harness except ROPS 5 068 8 11 Vibration Switch Harness 5 069 8 11 1 Vibration switch harness ROPS 5 069 8 11 2 Vibration Lo Hi change switch harness except ROPS 5 070 8 12 Vibrator Solenoid F Harness 1 5 071 8 13 Vibrator Solenoid F Harness 2 5 072 8 14 Vibrator Solenoid R Harness 1 5 073 8 15 Vibrator Solenoid R Harness 2 5 074 8 16 Vibrator Solenoid R Harness 3 5 075 8 17 Vibrator Solenoid...

Page 11: ...atory Drum 6 009 3 3 1 Disassembly of vibratory drum 6 009 3 3 2 Reassembly of vibratory drum 6 020 4 REAR AXLE 4 1 Rear Axle Assembly TW types 6 039 4 2 Removal and Installation of Rear Axle TW types 6 040 4 2 1 Removal of rear axle 6 041 4 2 2 Installation of rear axle 6 044 5 VIBRATORY DRUM SW504 5 1 Removal and Installation of Vibratory Drum 6 045 5 2 Disassembly and Reassembly of Vibratory Dr...

Page 12: ...ELEASE PRESSURE 5 1 Measurement 9 007 5 1 1 SW types front and rear TW types front 9 007 5 1 2 TW types rear 9 008 6 MEASUREMENT OF VIBRATOR CIRCUIT PRESSURE 6 1 Measurement 9 009 7 MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE 7 1 Measurement 9 010 7 2 Inspection 9 011 8 MEASUREMENT OF HYDRAULIC PUMP CASE PRESSURE 8 1 Measurement of Propulsion Pump Case Pressure 9 012 9 MEASUREMENT OF P...

Page 13: ...TEERING CIRCUIT PRESSURE SW504 19 1 Measurement 9 028 19 2 Inspection 9 029 20 MEASUREMENT OF HYDRAULIC PUMP CASE PRESSURE SW504 20 1 Measurement of Propulsion Pump Case Pressure 9 030 21 ADJUSTMENT OF THROTTLE LEVER SW504 21 1 Adjustment of Potentiometer 9 031 21 2 Adjustment of Operating Force 9 032 22 ADJUSTMENT OF F R LEVER SW504 22 1 Adjustment of Linkage 9 033 10 TROUBLESHOOTING 1 TROUBLESHO...

Page 14: ...hed F R lever vibration switch does not work 10 034 2 4 3 Vibratory drum cannot be switched SW354 ROPS 10 036 2 4 4 Amplitude does not change Remains either low or high TW504 10 038 2 5 Water Spray 10 040 2 5 1 Continuous water spray does not operate 10 040 2 5 2 Continuous water spray works but auto water spray does not operate 10 042 2 5 3 Liquid cannot be sprayed TW354 504 10 044 2 6 Lighting 1...

Page 15: ...force 1 2 10 075 3 2 3 Slow machine speed or small drive force 2 2 10 076 3 2 4 Machine speed cannot be switched 10 076 3 2 5 Machine does not stop completely with F R lever in N 10 076 3 2 6 Driving not possible with differential locked TW354 504 10 077 3 2 7 Propulsion system is overheating 10 077 3 2 8 Abnormal noise from propulsion system 10 077 3 3 Vibrator System 10 078 3 3 1 No vibration 10...

Page 16: ... 10 103 4 4 1 No vibration occurs 1 3 10 103 4 4 1 No vibration occurs 2 3 10 105 4 4 1 No vibration occurs 3 3 10 107 4 4 2 Vibratory drum cannot be switched ROPS 10 109 4 5 Water Spray 10 110 4 6 Lighting 10 112 4 6 1 Illumination of combination meter does not light 10 112 4 6 2 Combination meter warning lamp or indicator lamp is abnormal 10 114 4 6 3 Tachometer reading is abnormal 10 114 4 6 4 ...

Page 17: ...SAFETY ...

Page 18: ......

Page 19: ...machine if you fail to observe or important point to maintain of quality in maintenance works Indicates standard value to judge whether measured value is good or not Items that indicate the weight of a part or equipment and require attention in wire selection and operating posture for slinging operation N m In the assembly operation tightening torque in locations that require particular attention ...

Page 20: ... guidance of a skilled electrician and according to electrical engineering rules and regulations Work on the frame brakes hydraulic and steering systems must be performed by skilled personnel with special knowledge and training for such work 1 4 Safety Practices and Policies Keep the manuals in the container provided on the machine Manuals must always be available at the site where the machine is ...

Page 21: ...readable Never fill the fuel tank with the engine running or while near an open flame or while smoking Always clean up any spilled fuel Check for any warning tags placed on the machine do not operate the machine until all repairs have been made and warning tags have been removed by authorized personnel Check the seat belt for wear or damage inspect the belt hardware and fabric Replace if hardware ...

Page 22: ...to slide or roll over Avoid any areas that may be a risk to machine stability Avoid side hill travel Always operate up and down the slope Always keep the propulsion travel control lever in low speed range when climbing or descending hills or steep grades Make sure there is sufficient clearance when crossing underpasses bridges and tunnels or when passing under overhead power lines Never allow anyo...

Page 23: ... to avoid the risk of accident Use lifting devices that are in perfect condition and of sufficient lifting capacity Never stand under suspended loads Always use the proper tools and workshop equipment in good condition when performing maintenance or repairs on the machine Always use specially designed safety ladders and working platforms when working above floor level Never use machine parts as a ...

Page 24: ...g or grinding operations Inspect hydraulic hoses at regular intervals and immediately replace if they show signs of chafing cracking brittleness deformation blistering fitting separation leakage corrosion or other damage which may affect their function or strength Do not work on hydraulic system while the engine is running and the system is under pressure The hydraulic system remains pressurized e...

Page 25: ...ake sure that the compactor does not slide off the edge of the ramp Keep the deck clear of mud oil ice or snow or other materials that can make the deck slippery Position the compactor on the trailer or transport vehicle centered from side to side and apply the brake Shut off the engine and lock all lockable compartments Block the drums or tires and lock the articulation lock bar Chain the machine...

Page 26: ......

Page 27: ...SPECIFICATIONS ...

Page 28: ......

Page 29: ......

Page 30: ...nt axle with operating weight 1 470 kg 3 240 lbs Load on rear axle with operating weight 1 430 kg 3 155 lbs Dimensions Overall length 2 675 mm 105 in Overall width 1 290 mm 51 in Overall height 1 575 mm 62 in Wheelbase 2 000 mm 79 in Compaction width 1 200 mm 47 in Front drum width dia thickness 1 200 mm 675 mm 13 mm 47 in 27 in 0 5 in Rear drum width dia thickness 1 200 mm 675 mm 13 mm 47 in 27 i...

Page 31: ...ting weight 117 N cm 65 lbf in Dynamic linear pressure Front drum Operating weight 362 N cm 205 lbf in Rear drum Operating weight 358 N cm 205 lbf in Traveling speed Number of speed shifts 2 speed Speed range 1st 0 to 7 km h 0 to 4 3 mile h 2nd 0 to 10 km h 0 to 6 2 mile h Gradeability without vibration 38 21 Turning radius Machine clearance radius inside 2 5 m 99 in Machine clearance radius outsi...

Page 32: ...ront axle with operating weight 1 470 kg 3 240 lbs Load on rear axle with operating weight 1 490 kg 3 285 lbs Dimensions Overall length 2 675 mm 105 in Overall width 1 290 mm 51 in Overall height with ROPS 2 455 mm 97 in without ROPS 1 575 mm 62 in Wheelbase 2 000 mm 79 in Compaction width 1 200 mm 47 in Front drum width dia thickness 1 200 mm 675 mm 13 mm 47 in 27 in 0 5 in Rear drum width dia th...

Page 33: ...g weight 121 N cm 70 lbf in Dynamic linear pressure Front drum Operating weight 362 N cm 205 lbf in Rear drum Operating weight 363 N cm 205 lbf in Traveling speed Number of speed shifts 2 speed Speed range 1st 0 to 7 km h 0 to 4 3 mile h 2nd 0 to 10 km h 0 to 6 2 mile h Gradeability without vibration 38 21 Turning radius Machine clearance radius inside 2 5 m 99 in Machine clearance radius outside ...

Page 34: ...ht 1 470 kg 3 240 lbs Load on rear axle with operating weight 1 130 kg 2 490 lbs Dimensions Overall length 2 675 mm 105 in Overall width 1 290 mm 51 in Overall height 1 575 mm 62 in Wheelbase 2 000 mm 79 in Compaction width 1 200 mm 47 in Front drum width dia thickness 1 200 mm 675 mm 13 mm 47 in 27 in 0 5 in Rear tyres outer shell width dia 1 199 mm 671 mm 47 in 26 in Size 9 5 65 15 6PR Inflation...

Page 35: ...weight N A N cm N A lbf in Dynamic linear pressure Front drum Operating weight 292 N cm 165 lbf in Rear drum Operating weight N A N cm N A lbf in Traveling speed Number of speed shifts 2 speed Speed range 1st 0 to 7 km h 0 to 4 3 mile h 2nd 0 to 10 km h 0 to 6 2 mile h Gradeability without vibration 38 21 Turning radius Machine clearance radius inside 2 5 m 99 in Machine clearance radius outside 3...

Page 36: ...operating weight 1 470 kg 3 240 lbs Load on rear axle with operating weight 1 190 kg 2 625 lbs Dimensions Overall length 2 675 mm 105 in Overall width 1 290 mm 51 in Overall height with ROPS 2 455 mm 97 in without ROPS 1 575 mm 62 in Wheelbase 2 000 mm 79 in Compaction width 1 200 mm 47 in Front drum width dia thickness 1 200 mm 675 mm 13 mm 47 in 27 in 0 5 in Rear tyres outer shell width dia 1 19...

Page 37: ...ght N A N cm N A lbf in Dynamic linear pressure Front drum Operating weight 292 N cm 165 lbf in Rear drum Operating weight N A N cm N A lbf in Traveling speed Number of speed shifts 2 speed Speed range 1st 0 to 7 km h 0 to 4 3 mile h 2nd 0 to 10 km h 0 to 6 2 mile h Gradeability without vibration 38 21 Turning radius Machine clearance radius inside 2 5 m 99 in Machine clearance radius outside 3 8 ...

Page 38: ...ht 1 980 kg 4 365 lbs Load on rear axle with operating weight 1 460 kg 3 220 lbs Dimensions Overall length 3 105 mm 122 in Overall width 1 390 mm 55 in Overall height 1 705 mm 67 in Wheelbase 2 300 mm 91 in Compaction width 1 300 mm 51 in Front drum width dia thickness 1 300 mm 800 mm 17 mm 51 in 31 in 0 7 in Rear tyres outer shell width dia 1 295 mm 812 mm 51 in 32 in Size 10 5 80 16 6PR Inflatio...

Page 39: ... linear pressure Front drum Operating weight 149 N cm 85 lbf in Rear drum Operating weight N A N cm N A lbf in Dynamic linear pressure Front drum Operating weight Low amplitude 353 N cm 202 lbf in High amplitude 413 N cm 236 lbf in Rear drum Operating weight Low amplitude N A N cm N A lbf in High amplitude N A N cm N A lbf in Traveling speed Number of speed shifts 2 speed Speed range 1st 0 to 7 km...

Page 40: ...rating weight 1 980 kg 4 365 lbs Load on rear axle with operating weight 1 530 kg 3 375 lbs Dimensions Overall length 3 105 mm 122 in Overall width 1 390 mm 55 in Overall height with ROPS 2 565 mm 101 in without ROPS 1 705 mm 67 in Wheelbase 2 300 mm 91 in Compaction width 1 300 mm 51 in Front drum width dia thickness 1 300 mm 800 mm 17 mm 51 in 31 in 0 7 in Rear tyres outer shell width dia 1 295 ...

Page 41: ...near pressure Front drum Operating weight 149 N cm 85 lbf in Rear drum Operating weight N A N cm N A lbf in Dynamic linear pressure Front drum Operating weight Low amplitude 353 N cm 202 lbf in High amplitude 413 N cm 236 lbf in Rear drum Operating weight Low amplitude N A N cm N A lbf in High amplitude N A N cm N A lbf in Traveling speed Number of speed shifts 2 speed Speed range 1st 0 to 7 km h ...

Page 42: ...tem Alternator 12 V 60 A Starter 12 V 2 0 kW Battery 12 V 78 Ah CCA N A 1 pc 12 V Dry weight 169 kg 373 lbs Drive system Transmission Type Hydrostatic Speeds 2 speed shifts Reverser Switching the direction of flow delivered from the variable pump Differential type Front N A Rear N A Final drive Front Direct drive Rear Direct drive Vibration system Power transmission type Hydraulic Vibrator type SW...

Page 43: ...ng torque 24 to 27 N m 18 to 20 lbf ft Fan belt tension 7 0 to 9 0 mm 0 28 to 0 35 in When midpoint of 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 2 95 to 3 23 MPa 427 to 469 psi 290 min 1 Allowable limit 2 35 MPa 341 psi 290 min 1 2 2 Propulsion Item Standard ...

Page 44: ...otor R More than 1 5 MPa 218 psi Drainage Motor F 3 7 L min 1 0 gal min 4 9 L min 1 3 gal min Motor R 3 7 L min 1 0 gal min 1 8 L min 0 5 gal min Vibration High pressure relief valve pressure setting 12 7 MPa 1 842 psi 14 0 MPa 2 030 psi Case pressure Motor F 0 5 MPa 72 5 psi or less Motor R 0 5 MPa 72 5 psi or less N A Drainage Motor F 3 4 L min 0 9 gal min Motor R 3 4 L min 0 9 gal min N A Steer...

Page 45: ...nt standard brake stroke length More than 3 5 mm 0 14 in L2 L1 SW300 1 02001 L1 L2 Bolt Brake lock condition Brake releasing condition 2 6 Capacities Item Standard value Remarks SW354 TW354 TW504 Engine oil pan 7 0 L 1 8 gal Fuel tank 40 L 10 6 gal 50 L 13 2 gal Coolant 5 8 L 1 5 gal 6 5 L 1 7 gal Hydraulic oil tank 43 L 11 4 gal Vibrator case 5 0 L 2 1 3 gal 2 5 0 L 1 3 gal 6 0 L 1 6 gal Water sp...

Page 46: ...GI 2 Fuel Ambient temp 15 to 10 C Ambient temp 10 to 55 C Diesel fuel ASTM D975 NO 1 D S15 or S500 1 Diesel fuel ASTM D975 NO 2 D S15 or S500 2 1 For EPA regulation Diesel fuel ASTM D975 NO 1 D S15 only 2 For EPA regulation Diesel fuel ASTM D975 NO 2 D S15 only 3 2 Recommended Lubricants Lubricant Oil company Engine oil API CF Gear oil API GL 5 Hydraulic oil VG 46 Grease NLGI 2 Chevron DELO 400 RP...

Page 47: ...43 253 343 253 20 2 5 294 217 392 289 539 398 539 398 22 2 5 441 325 539 398 686 506 686 506 24 3 0 539 398 637 470 883 651 883 651 27 3 0 785 579 981 724 1324 977 1324 977 30 3 5 1079 796 1324 977 1765 1302 1765 1302 Metric fine screw 10 1 25 39 29 49 36 69 51 69 51 12 1 25 69 51 88 65 118 87 118 87 14 1 5 108 80 137 101 186 137 186 137 16 1 5 167 123 206 152 284 209 284 209 18 1 5 245 181 294 21...

Page 48: ...n front axle with operating weight 1 990 kg 4 390 lbs Load on rear axle with operating weight 2 000 kg 4 410 lbs Dimensions Overall length 3 100 mm 122 in Overall width 1 390 mm 55 in Overall height 1 705 mm 67 in Wheelbase 2 300 mm 91 in Compaction width 1 300 mm 51 in Front drum width dia thickness 1 300 mm 800 mm 17 mm 51 in 31 in 0 7 in Rear drum width dia thickness 1 300 mm 800 mm 17 mm 51 in...

Page 49: ...ure Static linear pressure Front drum Operating weight 150 N cm 85 lbf in Rear drum Operating weight 151 N cm 85 lbf in Dynamic linear pressure Front drum Operating weight Low amplitude 354 N cm 200 lbf in High amplitude 414 N cm 235 lbf in Rear drum Operating weight Low amplitude 355 N cm 205 lbf in High amplitude 415 N cm 235 lbf in Traveling speed Number of speed shifts 2 speed Speed range 1st ...

Page 50: ...d on front axle with operating weight 1 990 kg 4 390 lbs Load on rear axle with operating weight 2 070 kg 4 565 lbs Dimensions Overall length 3 100 mm 122 in Overall width 1 390 mm 55 in Overall height with ROPS 2 565 mm 101 in without ROPS 1 705 mm 67 in Wheelbase 2 300 mm 91 in Compaction width 1 300 mm 51 in Front drum width dia thickness 1 300 mm 800 mm 17 mm 51 in 31 in 0 7 in Rear drum width...

Page 51: ...e Static linear pressure Front drum Operating weight 150 N cm 85 lbf in Rear drum Operating weight 156 N cm 90 lbf in Dynamic linear pressure Front drum Operating weight Low amplitude 354 N cm 200 lbf in High amplitude 414 N cm 235 lbf in Rear drum Operating weight Low amplitude 360 N cm 205 lbf in High amplitude 420 N cm 240 lbf in Traveling speed Number of speed shifts 2 speed Speed range 1st 0 ...

Page 52: ...ed water forced circulation Cooling fan type Inhale Electrical system Alternator 12 V 60 A Starter 12 V 2 0 kW Battery 12 V 72 Ah CCA 750 A 1 pc 12 V Dry weight 200 kg 441 lbs Drive system Transmission Type Hydrostatic Speeds 2 speed shifts Reverser Switching the direction of flow delivered from the variable pump Differential type Front N A Rear N A Final drive Front Direct drive Rear Direct drive...

Page 53: ...ard value 2 95 to 3 23 MPa 427 to 469 psi 290 min 1 Allowable limit 2 35 MPa 341 psi 290 min 1 6 2 Propulsion Item Standard value Remarks Travel speed Forward reverse 1st 0 to 7 5 km h 0 to 4 7 mph 2nd 0 to 10 km h 0 to 6 2 mph 6 3 Hydraulic System Item Standard value Remarks Propulsion High pressure relief valve pressure setting 34 5 MPa 5 003 psi Charge relief valve pressure setting 1 8 0 7 MPa ...

Page 54: ...eased Note 1 119 mm 4 7 in SW354 02002 Note 1 Note 2 Clearance between brake pedal and floorboard when pressed down Note 2 79 mm 3 1 in Replacement standard brake stroke length More than 3 5 mm 0 14 in L2 L1 SW300 1 02001 L1 L2 Bolt Brake lock condition Brake releasing condition 6 6 Capacities Item Standard value Remarks Engine oil pan 7 0 L 1 8 gal Fuel tank 50 L 13 2 gal Coolant 6 5 L 1 7 gal Hy...

Page 55: ... NLGI 2 Fuel Ambient temp 15 to 10 C Ambient temp 10 to 55 C Diesel fuel ASTM D975 NO 1 D S15 or S500 1 Diesel fuel ASTM D975 NO 2 D S15 or S500 2 1 For EPA regulation Diesel fuel ASTM D975 NO 1 D S15 only 2 For EPA regulation Diesel fuel ASTM D975 NO 2 D S15 only 7 2 Recommended Lubricants Lubricant Oil company Engine oil API CJ 4 Gear oil API GL 5 Hydraulic oil VG 46 Grease NLGI 2 Chevron DELO 4...

Page 56: ......

Page 57: ...ENGINE AND CONTROLS ...

Page 58: ......

Page 59: ... Bracket 9 Spacer 16 Bracket 3 Nut M12 10 Bolt M10 20 17 Nut M12 4 Rubber isolator 11 Bracket 18 Bolt M10 20 5 Bolt M12 30 P 1 25 12 Bolt M12 30 19 Bracket 6 Bracket 13 Engine 20 Rubber isolator 7 Bracket 14 Bolt M12 35 P 1 25 21 Bolt M12 35 P 1 25 N m 3 Nut M12 88 N m 65 lbf ft 17 Nut M12 88 N m 65 lbf ft 14 Bolt M12 35 P 1 25 118 N m 87 lbf ft 21 Bolt M12 35 P 1 25 118 N m 87 lbf ft 15 Bolt M10 ...

Page 60: ...2 7 8 17 1 Control cable 10 Stopper bolt FULL M8 35 2 Throttle lever 11 Washer Apply grease 3 ECO lamp switch 2 Apply grease 12 Nut M14 4 ECO lamp switch 1 Apply grease 13 Disc spring 5 Lock nut M8 14 Bush 6 Stopper bolt IDLE M8 35 15 Washer Apply grease 7 Lock nut M6 16 Lock nut M6 8 Rod end Apply grease 17 Rod end Apply grease 9 Lock nut M8 Lithium based grease ...

Page 61: ...14 C DETAIL C 1 Control cable 8 Friction plate 14 Lock nut M12 2 F R lever L 9 Bush 15 Set screw M12 22 3 F R lever R 10 Holder Apply grease 16 Rod end 4 Backup buzzer switch 11 Disc spring Apply grease 17 Lock nut M6 5 F R lever switch 12 Lock nut M12 18 Rod end 6 Spring Fill grease 13 Set screw M12 22 19 Lock nut M6 7 Steel ball Apply grease Lithium based grease ...

Page 62: ...UMP MOUNT 3 1 Pump Mount 0446 36804 0 20215 B 1 2 6 4 7 5 1 2 VIEW A A 3 Weep hole 1 Cover 5 Coupling 2 Bolt M10 35 P 1 25 6 Bolt M12 40 3 Pin 7 Pump 4 Bolt M 8 20 N m 4 Bolt M 8 20 23 N m 17 lbf ft 6 Bolt M12 40 108 N m 80 lbf ft ...

Page 63: ...to engine flywheel with six bolts 4 spring washers and washers N m 4 Bolt M8 20 23 N m 17 lbf ft Install pins 3 to flywheel housing Position cover 1 as shown in the figure and secure to flywheel housing with seven bolts 2 and washers Engage spline of pump 7 with coupling 5 Secure pump 7 to cover 1 with two bolts 6 and washers N m 6 Bolt M12 40 108 N m 80 lbf ft NOTICE Bolts 4 is treated with threa...

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Page 65: ... Engine 21 Bolt M10 25 4 Rubber isolator 13 Bolt M12 35 P 1 25 22 Stopper 5 Bolt M14 30 P 1 25 14 Bolt M10 30 P 1 25 23 Bracket 6 Bracket 15 Base 24 Bolt M12 25 7 Bracket 16 Bracket 25 Rubber isolator 8 Bolt M14 30 P 1 25 17 Nut M12 P 1 25 26 Bolt M12 35 P 1 25 9 Bolt M10 20 18 Bolt M10 20 N m 3 Nut M12 P 1 25 88 N m 65 lbf ft 17 Nut M12 P 1 25 88 N m 65 lbf ft 13 Bolt M12 35 P 1 25 118 N m 87 lbf...

Page 66: ...3 007 ENGINE AND CONTROLS SW504 5 FUEL SYSTEM SW504 0448 02806 0 10621 A 1 A 2 4 3 5 6 7 8 9 3 10 11 12 24 23 22 13 14 12 20 21 18 19 17 16 B C 3 14 15 13 11 DETAIL A ...

Page 67: ... Check valve 2 Cap 19 IN check valve 3 Hose 9 27 20 Hose 21 19 4 Fuel tank 21 VENT main filter 5 Return fuel tank 22 IN sedimenter 6 Hose 7 22 23 Sedimenter 7 Suction fuel tank 24 OUT sedimenter 8 Hose 25 29 25 OUT fuel cooler 9 Return engine 26 Fuel cooler 10 Suction engine 27 IN fuel cooler 11 Hose 13 10 28 Hose 33 29 12 Main filter 29 Tee 13 OUT main filter 30 Hose 24 31 14 IN main filter 31 IN...

Page 68: ... B 1 A 4 5 2 3 6 7 8 9 10 11 12 14 13 15 SECTION B B VIEW A 1 Throttle lever 9 Key 2 Lock nut M8 10 Nut M14 3 Stopper bolt FULL M8 35 11 Disc spring 4 Potentiometer 12 Bush Apply grease 5 Screw M4 20 13 Shaft 6 Wire 14 Base 7 Washer Apply grease 15 Bush Apply grease 8 Washer Apply grease Lithium based grease ...

Page 69: ...B VIEW D DETAIL C 1 Control cable 8 Friction plate 14 Lock nut M12 2 F R lever L 9 Bush 15 Set screw M12 22 3 F R lever R 10 Holder Apply grease 16 Rod end 4 Backup buzzer switch 11 Disc spring Apply grease 17 Lock nut M6 5 F R lever switch 12 Lock nut M12 18 Lock nut M6 6 Spring Fill grease 13 Set screw M12 22 19 Rod end 7 Steel ball Apply grease Lithium based grease ...

Page 70: ...0 20631 0 1 2 7 4 8 6 5 2 A 3 5 B B 1 1 1 1 4 4 SECTION B B VIEW A Weep hole Engine flywheel 1 Bolt M 8 16 5 Cover 2 Bolt M10 35 6 Coupling 3 Pin 7 Bolt M12 35 4 Bolt M 8 20 8 Pump N m 1 Bolt M 8 16 23 N m 17 lbf ft 4 Bolt M 8 20 23 N m 17 lbf ft 7 Bolt M12 35 108 N m 80 lbf ft ...

Page 71: ... four bolts 1 two bolts 4 spring washers and washers 1 Bolt M8 16 23 N m 17 lbf ft N m 4 Bolt M8 20 23 N m 17 lbf ft Install pins 3 to flywheel housing Position weep hole of cover 5 with bottom and secure to flywheel housing with eight bolts 2 and washers Engage spline of pump 8 with coupling 6 Secure pump 8 to cover 5 with two bolts 7 and washers N m 7 Bolt M12 35 108 N m 80 lbf ft NOTICE Bolts 1...

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Page 73: ...HYDRAULIC SYSTEMS ...

Page 74: ......

Page 75: ......

Page 76: ...Reservoir vented Filter or strainer Heat exchanger lines in dicate flow of coolant Quick disconnect Connected with mechan ically opened checks Disconnected Sloping arrow through a symbol at 45 indicates that a component can be adjusted or varied Pump Motors and Cylinders DESCRIPTION SYMBOL Hydraulic pumps Fixed displacement Unidirectional Bidirectional Variable displacement Unidirectional Bidirect...

Page 77: ...es providing various flow path options for the fluid The multiple square moves to represent how flow paths change when the valving element is shifted within the compo nent Valves with infinite posi tioning between certain limits are symbolized with lines parallel to the squares Methods of Operation DESCRIPTION SYMBOL Spring Manual Pressure compensated Reversing motor Pilot pressure Internal supply...

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Page 79: ...200min 1 X 1 2 10μ 1 1 4 3 4 Reverse Forward 5 0MPa 0 4MPa 29 0kN 4000min 1 12 7MPa 1 67to 0 6MPa 0 6MPa 465 cm3 rev 12 5 cm3 rev 16 2 cm3 rev 28 0 cm3 rev 13 9 cm3 rev 8 4 cm3 rev 29 0kN 4000min 1 0 7MPa 12 7MPa 13 5MPa 50X 25X220ST 1 5MPa 105μ 1 5MPa 1 86MPa 0 7 0 7 0 7 0 7 34 5MPa 34 5MPa 1 9MPa 675 1200 1200 675 100cm3 rev 8 4 cm3 rev 14 4 cm3 rev 232 cm3 rev 232 cm3 rev VPS VPD T7 T6 T9 T8 T5...

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Page 81: ...5 2PS KUBOTA D1703M DI MAX min 1 2400min 1 SET min 1 2200min 1 Wheel R R Differential lock valve Bypass valve Propulsion motor R R Wheel R L Propulsion pump ENGINE Suction filter Propulsion motor R L Orbitrol Hydraulic oil filter Steering cylinder Oil cooler Cooling fan drive motor Cooling fan Vibrator solenoid valve Check valve Vibrator motor Propulsion motor F Drum Vibrator F steering charge pum...

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Page 83: ... 2200min 1 25 2PS KUBOTA D1703M DI MAX min 1 2400min 1 SET min 1 2200min 1 1 0 815 1 5MPa 5 0MPa 13 5MPa 10μ 14 0MPa LOW HIGH 0 6MPa 0 6MPa 1 5MPa 1300 LOW 26 5kN 3120min 1 HIGH 34 3kN 3120min 1 280 cm3 rev 1 5MPa 0 034MPa 0 034MPa 280 cm3 rev 12 5 cm3 rev 16 2 cm3 rev 34 5MPa 34 5MPa 1 9MPa 105μ 28 0 cm3 rev 0 7 0 7 0 7 0 7 160cm3 rev 63X 30X250ST 14 4 cm3 rev 10 8 cm3 rev 800 372 cm3 rev 372 cm3...

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Page 85: ...T5 Hose Hose Hose Hose PFB PA Hose The letters and numbers in the figure such as PFA and FMA show each port Arrow symbols show the hose connection and the direction of the flow of the oil PFA FMA PFB FMB TOS CS FD AFD P5 FM4 TF4 FM3 C C D D SECTION C C PFA PB SECTION D D PD T7 Hose FMD T9 B B T10 FM3 PD T9 Hydraulic oil tank E F CO T5 CS CO Drain hose SECTION B B T7 VIEW E PC Speed change solenoid...

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Page 87: ...symbols show the hose connection and the direction of the flow of the oil FD AFD Hose PD T3 Hose CO T5 TOS CS Drain hose Hose PFB FMB Hose PFA FMA B B C C Hose Hose P5 FM4 TF4 FM3 Hose FMD T9 PFB PA SECTION B B PFA PB SECTION C C PD FMA FMB FMD FM4 FM3 T9 Hydraulic oil tank CS CO E D VIEW D PC Speed change solenoid valve AFD Parking brake solenoid valve P5 P4 TF4 VIEW E TOS CMD 2 1 2 Propulsion hy...

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Page 89: ... B B A A B B Hose Hose PRA TPA PRB TPB Propulsion pump T6 Hose TT6 T6 Hose TV2 BV2 Propulsion motor R RMD Hose AD1 RMB Hose Hose AD4 RMA Hose Hose TR4 AP4 Hydraulic oil tank Bypass valve BV2 BV1 TV1 AP4 TPA TPB TV2 AD1 AD3 AD2 TPB Hose TT6 T6 Hose Hose PRB AD1 PRA TPA Hose TR4 AP4 AD2 RM3 RMD AD3 Hose TV1 BV1 RMB RMA RM3 C DETAIL C AD4 TT6 TT6 E VIEW E TR4 2 1 3 Propulsion hydraulic piping R SW354...

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Page 91: ...e B2 RLB Hose RLD LDR Hose TLA RLA Bypass valve BV2 BV1 Hydraulic oil tank T6 Propulsion pump Hose Hose PRA TDA PRB FPB Hose TR4 PR Hose Hose OTK T6 E E SECTION E E Hose OTK T6 Hose ADC DC ADC DC Hose TR4 PR Hose PRB FPB Hose PRA TDA VIEW G G Differential lock valve F F B B A A C DETAIL C Hose TV2 BV2 Hose TV1 BV1 D DETAIL D TLA RDR RM3 B1 B2 TRB TV2 FPB OTK PR DC TDA DA TV1 PRA PA SECTION A A PRB...

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Page 93: ...ose OTK T6 Hose ADC DC Hose TR4 PR Hose PRB FPB Hose PRA TDA The letters and numbers in the figure such as TLA and RLA show each port Arrow symbols show the hose connection and the direction of the flow of the oil F F C D PRA PA SECTION A A PRB PB SECTION B B SECTION F F Bypass valve BV2 BV1 DETAIL C Hose TV2 BV2 Hose TV1 BV1 Differential lock valve B B A A DETAIL D FPB OTK PR DC TDA DA TV1 LM3 LD...

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Page 95: ......

Page 96: ...HYDRAULIC SYSTEMS 2 2 Hydraulic Component Specifications 2 2 1 Propulsion hydraulic pump SW354 04001 A 2 1 Hydraulic circuit diagram 3 7 9 4 8 5 16 3 2 6 1 4 12 10 11 16 6 5 B VIEW A VIEW B 11 8 7 12 13 14 15 ...

Page 97: ...16 18UNF 9 Speed change solenoid valve 10 Parking brake solenoid valve 11 Servo pressure gauge port 9 16 18UNF 12 Charge pressure suction port PC 3 4 16UNF 13 High pressure relief valve For port B 14 High pressure relief valve For port A 15 Charge relief valve 16 Drain port 1 1 16 12UN Specifications Displacement 28 0 cm3 rev 1 7 cu in rev High pressure relief valve pressure setting 34 5 MPa 5 003...

Page 98: ...t B FMB G1 2 5 Parking brake pilot port FM3 G1 4 2 Parking brake pilot port G1 4 6 Speed change port FM4 G1 4 3 Drain port FMD G3 8 7 Manual brake release port M10 4 Port A FMA G1 2 8 Charge relief valve Specifications Displacement 465 cm3 rev 28 cu in rev Maximum working pressure 34 3 MPa 4 974 psi Charge relief valve pressure setting 1 67 to 1 86 MPa 242 to 270 psi Allowable motor case pressure ...

Page 99: ...lve 6 Parking brake pilot port FM3 G1 4 2 Parking brake pilot port G1 4 7 Speed change port FM4 G1 4 3 Port B FMB G1 2 8 Manual brake release port M12 4 Drain port FMD G1 2 9 Drain port G1 2 5 Port A FMA G1 2 Specifications Displacement 745 cm3 rev 45 cu in rev Maximum working pressure 34 3 MPa 4 974 psi Charge relief valve pressure setting 1 67 to 1 86 MPa 242 to 270 psi Allowable motor case pres...

Page 100: ... is when viewed in direction of arrow A 3 6 X 1 Port B RMB G1 2 4 Port A RMA G1 2 2 Parking brake pilot port G1 4 5 Parking brake pilot port RM3 G1 4 3 Drain port RMD G3 8 6 Manual brake release port M10 Specifications Displacement 465 cm3 rev 28 cu in rev Maximum working pressure 34 3 MPa 4 974 psi Allowable motor case pressure 0 3 MPa 43 5 psi Brake release pressure 1 5 MPa 218 psi Weight 42 kg ...

Page 101: ...n of arrow A 4 X 6 1 Port B RLB RRB G1 2 4 Port A RLA RRA G1 2 2 Parking brake pilot port RLP G1 4 5 Parking brake pilot port RRP G1 4 3 Drain port RLD RRD G3 8 6 Manual brake release port M10 Specifications Displacement TW354 224 cm3 rev 13 7 cu in rev TW504 280 cm3 rev 17 0 cu in rev Maximum working pressure 41 2 MPa 5 974 psi Allowable motor case pressure 0 3 MPa 43 5 psi Brake release pressure...

Page 102: ... 6 Check valve 2 Port C DC 9 16 18UNF 7 Port B1 B1 3 4 16UNF 3 Port A DA 3 4 16UNF 8 Port B2 B2 3 4 16UNF 4 Orifice 9 Flow control valve 5 Check valve 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 Weight 4 6 kg 10 lbs ...

Page 103: ...w symbols show the hose connection and the direction of the flow of the oil VFP VPF VIEW C C TCS TVR TCC Hose VPD VAR Hose TT8 TVR A Hose TO8 TCC Hose TCS TVT D VIEW D Check valve TFA VTF TCS SECTION A A Hose Hose TT8 TVR VPD VAR RVA TRA RVD TVD VBR RVB Vibrator motor F Hydraulic oil tank CMS C C TRS E T8 TVT CMD VIEW E TO8 RVD RVB RVA Vibrator motor R Hose Hose Hose VIEW F B Cooling fan drive mot...

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Page 105: ...Cooling fan drive motor Hose TCS TVT Hose TO8 T8 A VIEW A Check valve TFA VTF TCS The letters and numbers in the figure such as FVA and TFA show each port Arrow symbols show the hose connection and the direction of the flow of the oil Hydraulic oil tank FVD FVB FVA Vibrator motor B CMD VIEW B TO8 3 1 2 Vibrator hydraulic piping TW354 4 019 HYDRAULIC SYSTEMS ...

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Page 107: ...ection of the flow of the oil Vibrator F steering charge pump T2 Hose VT TVT Hose VD VP VD T8 CMS Cooling fan drive motor Hose TO8 T8 Hose Hose FVD T2 Hose VB FVB Hydraulic oil tank A FVD FVB FVA Vibrator motor VA FVA B VIEW B TO8 DETAIL A VA VB VT VP Vibrator solenoid valve CMD TVT 3 1 3 Vibrator hydraulic piping TW504 4 020 HYDRAULIC SYSTEMS ...

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Page 109: ... 2 1 2 3 3 VIEW A A Hydraulic circuit diagram 1 Suction port VVS G1 2 Discharge port steering SD G1 2 3 Discharge port vibration VD G1 2 Specifications Displacement vibration 16 2 cm3 rev 0 99 cu in rev steering 12 5 cm3 rev 0 76 cu in rev Rated pressure vibration 20 6 MPa 2 987 psi steering 20 6 MPa 2 987 psi Weight 7 2 kg 15 9 lbs ...

Page 110: ...hydraulic pump R SW354 SW354 04005 1 2 1 2 VIEW A A Hydraulic circuit diagram 1 1 Suction port RVS G3 4 2 Discharge port RVD G1 2 Specifications Displacement 13 9 cm3 rev 0 85 cu in rev Rated pressure 17 2 MPa 2 494 psi Weight 2 3 kg 5 1 lbs ...

Page 111: ...direction is when viewed in direction of arrow B 1 Drain port FVD RVD 9 16 18UNF 2 Port B FVB RVB 7 8 14UNF 3 Port A FVA RVA 7 8 14UNF Specifications Displacement SW354 8 4 cm3 rev 0 51 cu in rev TW354 504 10 8 cm3 rev 0 66 cu in rev Rated pressure 25 MPa 3 625 psi Allowable motor case pressure 0 5 MPa 72 5 psi Weight SW354 2 5 kg 5 5 lbs TW354 504 2 7 kg 6 0 lbs RVD RVA RVB SW354 only ...

Page 112: ...cuit diagram VIEW A 1 Suction port CMS 7 8 14UNF 2 Discharge port CMD 1 1 16 12UN 3 Relief valve Specifications Displacement 14 4 cm3 rev 0 88 cu in rev Rated pressure 5 0 MPa 725 psi Relief valve pressure setting 5 0 MPa 725 psi Allowable motor case pressure 0 5 MPa 72 5 psi Weight 3 14 kg 6 9 lbs ...

Page 113: ...rt B G3 4 1 Port B VBR G3 4 2 Solenoid valve 2 Solenoid valve 3 Port A G3 4 3 Port A VAR G3 4 4 Port T VTF G3 4 4 Port T VTR G3 4 5 Port P VPF G3 4 5 Port P G3 4 Specifications Maximum flow 75 L min 19 8 gal min Maximum pressure 21 0 MPa 3 045 psi Relief valve pressure setting 12 7 MPa 1 842 psi Weight 1 30 kg 2 9 lbs R SW354 only ...

Page 114: ...7 6 5 6 1 Port B VB 3 4 16UNF 5 Port P VP 3 4 16UNF 2 Port A VA 3 4 16UNF 6 Port M 7 16 20UNF 3 Relief valve 7 Solenoid valve a 4 Port T VT 3 4 16UNF 8 Solenoid valve b Specifications Rated flow 50 L min 13 2 gal min Rated pressure 25 MPa 3 625 psi Relief valve pressure setting 14 MPa 2 030 psi Weight 2 9 kg 6 4 lbs ...

Page 115: ...SRL SBR SSP STF A DETAIL A C Hose T STF Hose L SRL Hose R SBR VIEW C Hose STF FS B B Hose SD SSP Hose SSP P Hose Hose T STF Hose STF FS Arrow symbols show the hose connection and the direction of the flow of the oil Coupling Charge pressure gauge port SECTION B B Hose SD SSP Hose STF FS Hose SD SSP SSP P Hose STF FS T STF Hose SD SSP 4 STEERING SYSTEM 4 1 Steering Hydraulic Piping 4 1 1 Steering h...

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Page 117: ...lic oil tank VSS Hose T1 VSS Hydraulic oil filter T1 SRL SBR Steering cylinder The letters and numbers in the figure such as R and SBR show each port Arrow symbols show the hose connection and the direction of the flow of the oil Coupling Charge pressure gauge port SECTION B B Hose SD SSP Hose STF FS Hose Hose Hose SD SSP SSP P Hose STF FS T STF Hose SD SSP 4 1 2 Steering hydraulic piping TW504 4 ...

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Page 119: ...DRAULIC SYSTEMS 4 2 Steering Wheel 0446 32803 0 20620 A 4 5 3 2 1 1 Nut M12 P 1 25 2 Steering wheel 3 Column shaft 4 Bolt M10 35 5 Orbitrol N m 1 Nut M12 P 1 25 64 N m 47 lbf ft 4 Bolt M10 35 39 2 N m 29 lbf ft ...

Page 120: ...c circuit diagram 1 Port L L 3 4 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 SW TW354 100 cm3 rev 6 1 cu in rev TW504 160 cm3 rev 9 8 cu in rev Maximum pressure 17 5 MPa 2 538 psi Relief valve pressure setting 13 5 MPa 1 958 psi Weight 5 2 kg 11 5 lbs ...

Page 121: ...3 CR TE4B MAX min 1 2550min 1 MIN min 1 1000min 1 ENGINE SET NO LOAD 前進後進 Suction filter Bypass valve Drum R Propulsion motor R Drum F Propulsion motor F Vibrator solenoid valve F Cooling fan drive motor Cooling fan Oil cooler Vibrator motor F Orbitrol Steering cylinder Vibrator motor R Vibrator solenoid valve R Hydraulic oil filter PD PB PA PC P5 P4 VPS VFD VRD SPS SD PRB PFA PRA PFB TPA AD4 TV1...

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Page 123: ...ic oil tank CS CO F Speed change solenoid valve PC Parking brake solenoid valve P5 P4 TF6 TOS CMD E T3 T5 B B P 4 014 T10 P 4 034 Propulsion motor F VIEW A SECTION B B SECTION C C SECTION D D VIEW E VIEW F The letters and numbers in the figure such as PFB and FMA show each port Arrow symbols show the hose connection and the direction of the flow of the oil P 4 039 SW504 4 032 HYDRAULIC SYSTEMS 6 P...

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Page 125: ...2 TPB Hose TT6 T6 Hose Hose PRB TPA PRA TPB Hose TR5 AP4 AD2 RM5 RMD AD3 Hose TV1 BV1 RMB RMA RM5 D D 詳細 AD4 TT6 TT6 TR5 G C T6 E E A Hose Hose PRB TPA PRA TPB P 4 034 P 4 036 VIEW G VIEW A SECTION B B SECTION C C SECTION E E SECTION F F The letters and numbers in the figure such as PRA and TPA show each port Arrow symbols show the hose connection and the direction of the flow of the oil 6 1 2 Pro...

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Page 128: ...RAULIC SYSTEMS 6 2 Hydraulic Component Specifications 6 2 1 Propulsion hydraulic pump SW354 04001 A 2 1 Hydraulic circuit diagram 3 7 9 4 8 5 16 3 2 6 1 4 12 10 11 16 6 5 B VIEW A VIEW B 11 8 7 12 13 14 15 SW504 ...

Page 129: ...6 18UNF 9 Speed change solenoid valve 10 Parking brake solenoid valve 11 Servo pressure gauge port 9 16 18UNF 12 Charge pressure suction port PC 3 4 16UNF 13 High pressure relief valve For port B 14 High pressure relief valve For port A 15 Charge relief valve 16 Drain port 1 1 16 12UN Specifications Displacement 31 5 cm3 rev 1 9 cu in rev High pressure relief valve pressure setting 34 5 MPa 5 003 ...

Page 130: ...tion of arrow A Motor circuit diagram X 1 Parking brake pilot port G1 4 4 Port A RMA G1 2 2 Port B RMB G1 2 5 Parking brake pilot port RM5 G1 4 3 Drain port RMD G1 2 6 Manual brake release port M12 Specifications Displacement 745 cm3 rev 45 cu in rev Maximum working pressure 34 3 MPa 4 974 psi Allowable motor case pressure 0 3 MPa 43 5 psi Brake release pressure 1 5 MPa 218 psi Weight 77 kg 170 lb...

Page 131: ... TVR VFD Hose TO8 TCC TO8 VTF VPF VBF VAF Hose VFD VPF T2 B B Hose VTF TVT Hose VRD VPR Hose VRD VPR T1 Hose AVS VPS AVS VAF FVA VBF FVB VAR RVA VBR RVB CMS CMD D P 4 023 P 4 023 P 4 038 Pump assembly vibrator steering charge VIEW F VIEW A DETAIL D DETAIL E SECTION B B SECTION C C The letters and numbers in the figure such as VBR and RVB show each port Arrow symbols show the hose connection and th...

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Page 133: ...ump R 6 Discharge port steering SD G1 2 3 Steering charge pump 7 Discharge port vibrator R VRD G1 2 4 Suction port vibrator VPS G1 8 Discharge port vibrator F VFD G1 2 Specifications Displacement vibrator F 11 23 cm3 rev 0 69 cu in rev vibrator R 11 23 cm3 rev 0 69 cu in rev steering 11 23 cm3 rev 0 69 cu in rev Rated pressure vibrator F 25 MPa 3 626 psi vibrator R 25 MPa 3 626 psi steering 25 MPa...

Page 134: ...t diagram VIEW A 1 Suction port CMS 7 8 14UNF 2 Discharge port CMD 1 1 16 12UN 3 Relief valve Specifications Displacement 10 8 cm3 rev 0 66 cu in rev Rated pressure 5 0 MPa 725 psi Relief valve pressure setting 5 0 MPa 725 psi Allowable motor case pressure 0 5 MPa 72 5 psi Weight 3 14 kg 6 9 lbs SW504 ...

Page 135: ...uit diagram 1 Solenoid valve b 5 Port A VAF VAR G1 2 2 Solenoid valve a 6 Port T VTF VTR G1 2 3 Relief valve G3 4 7 Port P VPF VPR G1 2 4 Port B VBF VBR G1 2 Specifications Maximum flow 35 L min 9 2 gal min Maximum pressure 17 9 MPa 2 595 psi Relief valve pressure setting 14 4 MPa 2 088 psi Valve assembly weight 3 5 kg 7 7 lbs SW504 ...

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Page 137: ...STF FS T STF Hose SD SSP L SRL R SBR FS B B D Hose SD SSP Hose STF FS ASS P 4 038 P 4 042 Orbitrol DETAIL A Steering cylinder Pump assembly vibrator steering charge Coupling Charge pressure gauge port The letters and numbers in the figure such as R and SBR show each port Arrow symbols show the hose connection and the direction of the flow of the oil SECTION B B SECTION C C VIEW D 8 STEERING SYSTEM...

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Page 139: ... 3 4 1 2 Hydraulic circuit diagram 1 Port L L 3 4 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 159 cm3 rev 9 7 cu in rev Maximum pressure 17 2 MPa 2 494 psi Relief valve pressure setting 13 5 MPa 1 958 psi Weight 6 2 kg 13 7 lbs SW504 ...

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Page 141: ...ELECTRICAL SYSTEM ...

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Page 143: ...50 Corrugate Ǟ70 GB 100 CB104 58X 2F 200 Ǟ13 770 63 CorrugateǞ10 Brw 9 GB 63 LY 38 SWP 4㧲 Mark S Starter relay harness P 5 017 J P 5 005 BrR GL Fuel sensor Wire color Reference page Marking Reference page 24 1 25 BR Wire color AVS wire size Wire number 7 28 LgW R2 BR R1 C B ACC 24 1 25BR 4 26 Lg STARTER SWITCH 26 Lg 5G 5BY The pin or socket layout of mating connectors are symmetrical either vertic...

Page 144: ...e YW Yellow White stripe Br Brown BrW Brown White stripe BrR Brown Red stripe BrY Brown Yellow stripe BrB Brown Black stripe BrG Brown Green stripe BrL Brown Blue stripe L Blue LW Blue White stripe LR Blue Red stripe LY Blue Yellow stripe LB Blue Black stripe LG Blue Green stripe Lg Light green LgR Light green Red stripe LgY Light green Yellow stripe LgB Light green Black stripe LgW Light green Wh...

Page 145: ...B LgR BrR 3LB 3G 3LY 3R 3BY RB 3BY 5WG 8WY 3GW 5WR G GR Or 2GB 2GB Or 1 R 2 3 Or B B B B AV60 G 1 4 2 3 6 5 R B R LgW B R R B R 13 14 12 11 5 2 10 9 8 7 6 4 3 1 RL 2Y B RG 5R 5WR 3GW C C NO NO NC NC Br Br B B G G Br Br B RL RL Br BrR B B Sb 1 6 2 RL B 3BR LgW Br RW BrY BrY RW RL GY Lg RG LW LY WL 8WY 2Y 5BR 3W Y WR 5WR 3W 3W WL YW L g W LgR WG 5WG 5WR 5W BrB NO BR COM B GY GR G G E H F D B 4 1 3 5...

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Page 147: ...R 13 14 12 11 5 2 10 9 8 7 6 4 3 1 RL 2Y B RG 5R 5WR 3GW C C NO NO NC NC Br Br B B G G Br Br B RL RL Br BrR B B Sb 1 6 2 RL B 3BR LgW Br RW BrY BrY RW RL GY Lg RG LW LY WL 8WY 2Y 5BR 3W Y WR 5WR 3W 3W WL YW L g W LgR WG 5WG 5WR 5W BrB NO BR COM B GY GR G G E H F D B 4 1 3 5 L R B B E L B IG S B 3 4 5 6 B BR ACC R2 R1 C 5R 3G STOP RG LW GY E L B G G R R R GY RY RY RB RG AV60 12V 80AH 95D31R RG B RW...

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Page 149: ...B GR 2GB 2GB G AV60 B B L g W 4 NO AV60 BR COM AV60 12V 80AH 95D31R 28 26 3 4 2 1 LgR LgW 8WY 5BR 5WR 5W S B 5WR 3GW 5R 3G 1 25B 1 25Br 3 4 5 6 g B G e BrW Br B LAMP CHECK WATER SPRAY GROUND WR Y YL YR YW FUEL METER TEMPERATURE METER ENGINE OIL PRESSURE WARNING G REV RATIO SEL 2 TURN SIGNAL R PARKING BRAKE HYDRAULIC OIL FILTER WARNING PREHEATING VIBRATOR LIQUID SPRAY REV RATIO SEL 4 TURN SIGNAL L ...

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Page 151: ...R 2GB 2GB G AV60 B B L g W 4 NO AV60 BR COM AV60 12V 80AH 95D31R 28 26 3 4 2 1 LgR LgW 8WY 5BR 5WR 5W S B 5WR 3GW 5R 3G 1 25B 1 25Br 3 4 5 6 g B G e BrW Br B LAMP CHECK WATER SPRAY GROUND WR Y YL YR YW FUEL METER TEMPERATURE METER ENGINE OIL PRESSURE WARNING G REV RATIO SEL 2 TURN SIGNAL R PARKING BRAKE HYDRAULIC OIL FILTER WARNING PREHEATING VIBRATOR LIQUID SPRAY REV RATIO SEL 4 TURN SIGNAL L FLO...

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Page 153: ...B G AV60 B B L g W 4 NO AV60 BR COM AV60 12V 80AH 95D31R 28 26 3 4 2 1 LgR LgW 8WY 5BR 5WR 5W S B 5WR 3GW 5R 3G 1 25B 1 25Br 3 4 5 6 g B G e BrW Br B LAMP CHECK WATER SPRAY GROUND WR Y YL YR YW FUEL METER TEMPERATURE METER ENGINE OIL PRESSURE WARNING G REV RATIO SEL 2 TURN SIGNAL R PARKING BRAKE HYDRAULIC OIL FILTER WARNING PREHEATING VIBRATOR LIQUID SPRAY REV RATIO SEL 4 TURN SIGNAL L FLOOD LAMP ...

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Page 155: ...W 8WY 5BR 5WR 5W S B 5WR 3GW 5R 3G 1 25B 1 25Br 3 4 5 6 g B G e BrW Br B LAMP CHECK WATER SPRAY GROUND WR Y YL YR YW FUEL METER TEMPERATURE METER ENGINE OIL PRESSURE WARNING G REV RATIO SEL 2 TURN SIGNAL R PARKING BRAKE HYDRAULIC OIL FILTER WARNING PREHEATING VIBRATOR LIQUID SPRAY REV RATIO SEL 4 TURN SIGNAL L FLOOD LAMP REV PULSE INPUT 1 REV RATIO SEL 3 STARTER SWITCH ACC COOLANT TEMP SEL 2 REV R...

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Page 157: ...y Ground Vibrator lamp relay Parking interlock relay B DETAIL E DETAIL D Water spray relay Backup buzzer Frame F harness P 5 019 CA104 CB104 Vibrator solenoid F Vibrator solenoid F BY Cap Cap Cap Cap Cap Fuel pump H to Vibrator solenoid R harness P 5 032 A Cap Battery C P 5 010 H H P 5 010 VIEW A Battery relay DETAIL B Engine harness P 5 015 Parking brake solenoid upper position Speed change solen...

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Page 159: ...5 to ECO lamp H to Starter switch harness P 5 025 Starter switch N Fuse 5A 10A 15A J J Dashboard harness P 5 017 F R lever switch Backup buzzer switch SECTION J J Flasher unit Horn relay Grow lamp relay DETAIL K ECO lamp switch 2 Insulation protection DETAIL L ECO lamp switch 1 Insulation protection VIEW H H J E F Parking brake switch harness P 5 029 Working switch harness P 5 027 Control switch h...

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Page 161: ...ame F harness P 5 019 CA104 CB104 Vibrator solenoid Vibrator solenoid BY Cap Cap Cap Cap Cap A Cap Battery C H VIEW A Battery relay DETAIL B Engine harness P 5 015 Parking brake solenoid upper position Speed change solenoid lower position VIEW C Fusible link 65A black Fusible link 45A red P 5 038 K to Liquid spray pump harness B G GB B Lg GB B GR B YG Sb Or Engine oil pressure switch G Ground Vibr...

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Page 163: ... J J Flasher unit Horn relay Grow lamp relay DETAIL K ECO lamp switch 2 Insulation protection DETAIL L ECO lamp switch 1 Insulation protection VIEW H H TW354 VIEW H H TW354 ROPS DETAIL N DETAIL P Dashboard harness P 5 017 Insulation protection CA104 CA104 P 5 041 DETAIL R Dashboard harness P 5 017 Insulation protection CA104 CA104 P 5 042 Sub power 12V 120W P 5 037 Insulation protection Insulation...

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Page 165: ...ine stop solenoid Tachometer sensor Vibrator relay Ground Vibrator lamp relay Parking interlock relay B DETAIL E DETAIL D Water spray relay Backup buzzer BY Cap Cap Cap Cap Cap Fuel pump A Cap Battery C P 5 014 H H P 5 014 VIEW A Battery relay DETAIL B Engine harness P 5 015 Parking brake solenoid upper position Speed change solenoid lower position VIEW C Fusible link 65A black Fusible link 45A re...

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Page 167: ... Insulation protection DETAIL L ECO lamp switch 1 Insulation protection VIEW H H TW504 VIEW H H TW504 ROPS DETAIL N DETAIL P Dashboard harness P 5 017 Insulation protection CA104 CA104 P 5 041 DETAIL R Dashboard harness P 5 017 Insulation protection CA104 CA104 P 5 042 P 5 037 Insulation protection Insulation protection P 5 031 D to Vibration Lo Hi chang switch harness L Short harness P 5 039 Sub ...

Page 168: ...r Terminal cover 5BR 80 5BR 50 3BR 50 1 0 0 VB5 5 LE104 Thermo unit Glow plugs LE304 Sb 100 6189 0443 Parking brake solenoid Speed change solenoid 50 50 LA108 PB104 Engine oil pressure switch YB 50 33 40 X X LgW B B WB B L RB X 57 22 3BR 26 2BY 2Y B L LR YB WB LgW WR RB 32 13 57 X Sb 59 53 54 33 40 17 22 50 50 LA308 RB1B SL 7283 8732 40 Tachometer sensor LE104 Ground Hydraulic oil filter switch 2B...

Page 169: ...Alternator RB 3 B Engine stop solenoid Tachometer sensor 3BR 5BR 2 B Starter motor S 8WY 2 Alternator B Starter motor B NO SIZE COLOR CONTACT POINTS CONNECTION 2BY 2 B Engine stop solenoid LgW 2 B 2 WB 2 B 2 LR 2 B Hydraulic oil filter switch YB 2 B 2 L 2 B Tachometer sensor Sb 2 B Thermo unit 5 016 ELECTRICAL SYSTEM ...

Page 170: ...Y 50 RY 50 CA104 CB104 2B 100 LA208 CA104 CA104 RW 50 BrY 50 100 100 RG RG Lg LgW WG WL YW B RL RL Br BrR 21 21 30 31 10 14 52 X 23 23 51 46 3BR B LgR 3BW 26 X 302 300 RG B GY 21 X 34 LCT RL 1A 3W 100 Fuse box LCR RL 1B LCR RL 1B SWP 2M 24 22 LCR RL 1B LCT RL 1A LCT RL 1A LCT RL 1A SWP 2M 15A 7124 9681 Y 40 WR 40 5A 7124 9681 Fuse Fuse LgR 40 LgW 40 Fuse 3W 100 5R 100 RB RG RL RY 23 21 3G 100 2BrR...

Page 171: ... Horn switch 3BY 2 A 3F H LgW 2 A 4F F No SIZE COLOR CONTACT POINTS CONNECTION GY 4 G 2 Flasher unit Turn signal switch G 5 A 8F C G Combination meter 12F Turn signal switch GR 5 A 8F C G Combination meter 12F Turn signal switch GB 2GB 4 A 2F C F Combination meter 12F Or 3 C F Combination meter 12F LW 3 C J Combination meter 12F WB 2 A 4F E RW 2 E Foot brake switch RW 2 J Vibrator relay BrY 2 J Vi...

Page 172: ...GR 90 B 50 G 90 Lg 320 50 22 RB X B Fuel pump RB2B SL 2B 250 Ground LA210 CA104 BrR 50 LgR 50 LCT RL 1A SWP 4F SWP 6F 58X 3F 7322 4123 30 7322 4125 50 45A red 7322 4123 30 65A black 65A black 100 50 100 5WG 80 80 80 80 B 150 LgW 150 5WR 140 3GW 140 5W 140 2GB 100 YG 50 B 50 5R 8 5RW 7 3G 6 3GW 5 5WR 2 5W 1 2Y 13 3BY 32 Sb 59 B X L 57 YB 54 LR 53 WB 40 LgW 33 RB 22 WR 17 BrR 46 LgR 47 LgW 4 Lg 30 G...

Page 173: ...ink 45A 5WR 2 Battery relay NO Fusible link 65A 5R 2 A Fusible link 65A 5WG 2 A B 2Y 2 A 3M B WR 2 A 4M B RB 3 A 4M B Fuel pump 5BR 2 A B Lg 2 A 8M Horn No SIZE COLOR CONTACT POINTS CONNECTION 3BY 2 A 3M B LgW 2 A 4M B G 2 A 8M Turn signal lamp R GR 2 A 8M Turn signal lamp L 2GB 3 A 2M Head lamp L R Or 3 M Drum edge lamp F L option F R option WB 2 A 4M B BrR 2 A 8M Vibrator solenoid F LgR 2 A 8M V...

Page 174: ...Corrugate 10 150 Corrugate 22 250 Corrugate 22 600 Corrugate 10 440 Corrugate 7 160 2GB 130 Corrugate 7 150 630 Corrugate 7 470 Corrugate 7 360 Corrugate 7 250 Corrugate 7 P 5 023 M P 5 017 Dashboard harness Turn signal lamp L CA104 CB104 CB104 Head lamp L Turn signal lamp R Vibrator solenoid Fuel gauge unit B 50 G 90 CA104 YG 50 B 50 CB104 CA104 CB104 700 Corrugate 15 320 Corrugate 10 Engine harn...

Page 175: ...ery relay NO Fusible link 65A 5R 2 A Fusible link 65A 5WG 2 A B 2Y 2 A 3M B WR 2 A 4M B RB 3 A 4M B Fuel pump 5BR 2 A B Lg 2 A 8M Horn No SIZE COLOR CONTACT POINTS CONNECTION 3BY 2 A 3M B LgW 2 A 4M B G 2 A 8M Turn signal lamp R GR 2 A 8M Turn signal lamp L 2GB 3 A 2M Head lamp L R Or 3 M Drum edge lamp F L option F R option WB 2 A 4M B BrR 3 A 8M Vibrator solenoid Hi Lo LgR 2 A 8M Vibrator soleno...

Page 176: ... 61 GB 37 3LB 42 3B X BrR 46 LgB 49 LgW 50 2BrW 9 3LY 18 LgB 49 LgW 50 LW 39 BrR 46 GB 37 Or 38 RG 61 BY 29 G 35 GR 36 LA208 CB104 Combination lamp L RB6B SL Combination lamp R RB6B SL 58X 2F SWP 3F SW354 Vibrator solenoid R harness H P 5 032 TW354 504 Cap P 5 033 58X 2F SWP 4F SWP 8F Ground Backup buzzer LA208 CB104 PB104 PB104 LE206 LE206 100 Tape 100 Tape 130 Tape 130 Tape 600 Corrugate 10 200 ...

Page 177: ... spray relay B BY 2 C Backup buzzer G 2 C Combination lamp R GR 2 C Combination lamp L GB 3 C Combination lamp L R Or 6 C M Flood lamp Drum edge lamp R L option R R option No SIZE COLOR CONTACT POINTS CONNECTION LW 2 C Water spray relay g 3LB 2 Water spray pump Water spray relay G BrR 2 C J LgB 2 C J LgW 2 C J RG 3 C Combination lamp L R G 2 C Mihaalu harness Br 3 C Mihaalu harness Backup lamp opt...

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Page 179: ...E105 ACC LE305 R1 LE305 B 3BY 100 3W 100 WL 100 LgR 100 2Y 100 BrB 100 5WG 100 5WR 100 H Starter switch Dashboard harness P 5 017 50 Tape 2 10 2 10 11 13 3 14 16 32 No SIZE COLOR CONTACT POINTS CONNECTION 5WR 2 H Starter swich B LgR 2 H Starter swich BR 5WG 2 H Starter swich R1 BrB 2 H Starter swich ACC 2Y 2 H Starter swich ACC WL 2 H Starter swich C 3W 2 H Starter swich C 3BY 2 H Starter swich C ...

Page 180: ...LgW 80 RY 80 2GB 80 2Or 80 50 50 RY LgW 24 33 58X 3M SWP 2M Dashboard harness P 5 017 50 Tape Speed change switch F 5 3 4 1 2 1 24 33 19 19 37 38 No SIZE COLOR CONTACT POINTS CONNECTION 2R 3R 3 F Lighting swich 1 4 RY 2 F Speed change swich 1 LgW 2 F Speed change swich 2 2GB 2 F Lighting swich 3 2Or 2 F Lighting swich 5 ...

Page 181: ...3F Vibration mode select switch Water spray mode select switch 5 2 4 1 5 4 2 1 J 50 Tape Dashboard harness P 5 017 18 39 27 39 23 23 43 44 No SIZE COLOR CONTACT POINTS CONNECTION LY 2 J Water spray mode select switch 1 RL 3 J Vibration mode select switch 1 4 GY 2 J Water spray mode select switch 4 LW 3 J Water spray mode select switch 2 5 RW 2 J Vibration mode select switch 2 BrY 2 J Vibration mod...

Page 182: ... mode select switch 5 2 4 1 5 2 4 1 3 5 0 T a p e 50 50 Tape 5 0 LA108 Ground Dashboard harness P 5 017 J X 18 18 39 70 23 23 43 44 No SIZE COLOR CONTACT POINTS CONNECTION B 2 J Water spray timer LY 3 J Water spray mode select switch 1 4 RL 3 J Vibration mode select switch 1 4 LW 3 J Water spray mode select switch 2 Water spray timer RW 2 J Vibration mode select switch 2 BrY 2 J Vibration mode sel...

Page 183: ...00 SWP 6F 50 301 41 40 Y RW WB YL B 15 X Dashboard harness P 5 017 Parking brake switch 2 4 5 3 1 E 50 Tape 41 40 15 X 301 No SIZE COLOR CONTACT POINTS CONNECTION B 2 E Parking brake switch 4 YL 2 E Parking brake switch 5 WB 2 E Parking brake switch 3 RW 2 E Parking brake switch 1 Y 2 E Parking brake switch 2 ...

Page 184: ...i Change Switch Harness 4 9 1 Short harness SW TW354 except SW354 ROPS 1446 09015 0 40121 0 SWP 6M LgR LgR LgB LgB 49 49 47 47 Dashboard harness P 5 017 No SIZE COLOR CONTACT POINTS CONNECTION LgR 2 Dashboard harness 2 LgB 2 Dashboard harness 2 ...

Page 185: ... SWP 6M LgW 80 LgB 80 RL 80 RL 80 LgR 80 LgY 80 RL LgB LgW LgY LgR RL 50 49 23 48 47 23 50 2 3 4 1 5 6 23 23 47 48 49 50 No SIZE COLOR CONTACT POINTS CONNECTION RL 3 D Vibration Lo Hi change switch 1 4 LgR 2 D Vibration Lo Hi change switch 3 LgY 2 D Vibration Lo Hi change switch 2 LgB 2 D Vibration Lo Hi change switch 6 LgW 2 D Vibration Lo Hi change switch 5 ...

Page 186: ... SW354 1446 09012 0 30118 0 SWP 3M LgW LgB BrR 50 49 46 LgW 50 CA104 CB104 BrR 50 CB104 LgB 50 H Vibrator solenoid R Frame R harness P 5 023 50 50 Tape Not in use 46 49 50 No SIZE COLOR CONTACT POINTS CONNECTION BrR 2 H Vibrator solenoid R LgB 2 H Vibrator solenoid R LgW 2 H CB104 not in use ...

Page 187: ...5 033 ELECTRICAL SYSTEM 4 10 2 Cap TW354 504 1447 09002 0 40043 0 SWP 3M Frame R harness P 5 023 ...

Page 188: ...5 034 ELECTRICAL SYSTEM 4 11 Hazard Switch Harness 4 11 1 Cap except ROPS 1418 09044 0 40589 0 SWP 4F Dashboard harness P 5 017 ...

Page 189: ...09078 0 31116 0 100 G 50 Corrugate 7 Hazard switch 6 6 26 40 GY GY GR GB 5 4 2 1 GY 100 GB 100 GY 100 GR 100 SWP 4F Dashboard harness P 5 017 6 6 40 26 No SIZE COLOR CONTACT POINTS CONNECTION GY 4 G 2 Hazard switch 1 4 GR 2 G Hazard switch 5 GB 2 G Hazard switch 2 ...

Page 190: ...S VCTF 0 75mm 4C 2 SWP 4M SWP 6F Mihaalu option G 304 W 308 R 38 B X 38 X 308 R B W 304 G Frame R harness P 5 023 750 No SIZE COLOR CONTACT POINTS CONNECTION B 2 Frame R harness Mihaalu option R 2 Frame R harness Mihaalu option G 2 Frame R harness Mihaalu option W 2 Frame R harness Mihaalu option ...

Page 191: ...h Harness TW354 504 1442 09001 0 30054 0 9 20 58X 2M 2BrR 130 2BrW 130 2BrR 2BrW D 170 Tape Liquid spray switch Dashboard harness P 5 017 2 1 20 9 No SIZE COLOR CONTACT POINTS CONNECTION 2BrW 2 D Liquid spray switch 2 2BrR 2 D Liquid spray switch 2 ...

Page 192: ...4 14 Liquid Spray Pump Harness TW354 504 1447 09003 1 30081 A 1350 K LCT RL 1A CB104 Liquid spray pump Corrugate 7 Frame R harness P 5 023 2BrW 30 2BrW 30 9 9 No SIZE COLOR CONTACT POINTS CONNECTION 2BrW 2 K Liquid spray pump ...

Page 193: ...5 039 ELECTRICAL SYSTEM 4 15 Short Harness 1446 09080 0 40879 0 SWP 2F 29 29 BY BY Dashboard harness P 5 017 No SIZE COLOR CONTACT POINTS CONNECTION BY 2 Dashboard harness 2 ...

Page 194: ...0 LgY 80 RL 80 RL 80 LgR 80 LgB 80 RL LgB LgW LgY LgR RL 50 49 23 48 47 23 50 3 6 4 1 5 6 Not in use 23 23 47 48 49 50 No SIZE COLOR CONTACT POINTS CONNECTION RL 3 D Vibratory drum select switch 1 4 LgR 2 D Vibratory drum select switch 6 LgY 2 D Vibratory drum select switch 6 not in use LgB 2 D Vibratory drum select switch 3 LgW 2 D Vibratory drum select switch 5 not in use ...

Page 195: ...PVC tube 6 0 5 F R lever vibration switch L Dashboard harness P 5 017 See Wiring Harness Layout 2 DETAIL P P 5 010 P 5 012 P 5 014 No SIZE COLOR CONTACT POINTS CONNECTION Br 2 Dashboard harness F R lever vibration switch L 1 G 2 Dashboard harness F R lever vibration switch L 2 W 2 Dashboard harness F R lever vibration switch L 3 ...

Page 196: ...F R lever vibration switch R Dashboard harness P 5 017 See Wiring Harness Layout 2 DETAIL R P 5 010 P 5 012 P 5 014 PVC tube 6 0 5 No SIZE COLOR CONTACT POINTS CONNECTION Br 2 Dashboard harness F R lever vibration switch R 1 G 2 Dashboard harness F R lever vibration switch R 2 W 2 Dashboard harness F R lever vibration switch R 3 ...

Page 197: ...de select switch Vibrator solenoid F Vibrator solenoid R Vibratory drum select switch ROPS RG 9 8 7 6 5 4 3 2 1 10 Backup buzzer switch Horn relay Flasher unit G Battery relay R Battery relay W Parking interlock relay RY ECO lamp switch 1 Brake lamp relay F R lever switch Speed change switch Foot brake switch Sub power 12V 120W Water spray relay Harness color codes W White RG Red Green stripe R Re...

Page 198: ...ct switch Vibrator solenoid RG 9 8 7 6 5 4 3 2 1 10 Backup buzzer switch Horn relay Flasher unit W Parking interlock relay RY ECO lamp switch 1 Brake lamp relay F R lever switch Speed change switch Foot brake switch W Starter switch G Battery relay R Battery relay Sub power 12V 120W Water spray relay Harness color codes W White RL Red Blue stripe R Red G Green RB Red Black stripe BrR Brown Red str...

Page 199: ...tch Vibration Lo Hi change switch RG 9 8 7 6 5 4 3 2 1 10 Backup buzzer switch Horn relay Flasher unit W Parking interlock relay RY ECO lamp switch 1 Brake lamp relay F R lever switch Speed change switch Foot brake switch W Starter switch G Battery relay R Battery relay Sub power 12V 120W Water spray relay Harness color codes W White RL Red Blue stripe R Red G Green RB Red Black stripe BrR Brown R...

Page 200: ...speed 4 Position lamp Backlight Turn signal R Turn signal L Vibration Liquid spray Water spray Flood lamp Glow plug Parking brake Engine charge warning Engine oil pressure Hydraulic filter Lamp check Coolant temperature 1 Coolant temperature 2 System configuration diagram Harness side Harness side SWP 16F SWP 16F SWP 16M SWP 12M SWP 12M SWP 12F G Engine oil pressure warning GW Hydraulic oil filter...

Page 201: ...A15 137 G_R_GND3 GND COLANT_TMP SEN _1 A14 129 G_R_RAILPS GND RAIL_PRE SEN _1 A09 123 O_T_DCNEG MOTOR INTAKE_THRO VAL _5 A08 124 O_T_DCPOS MOTOR 111 O_V_MEU SCV MPROP _1 A07 EGR VALVE_4 A06 SHIELD_DOREN A05 INTAKE_THRO VAL _6 A04 112 O_V_MEU SCV MPROP _2 A03 X EGR VALVE_3 A02 SHIELD_DOREN A01 238 O_V_12V 242 B_D_CANL2 CAN2 L 230 B_D_CANH2 CAN2 H 225 O_V_SWITCH 12V 239 I_S_REGINH SW 228 I_S_MRGESW ...

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Page 203: ...EN NE _1 A19 141 I_F_CASPOS SIG CAM_ANG SEN G _2 A18 140 G_R_GND8 GND CAM_ANG SEN G _1 A15 137 G_R_GND3 GND COLANT_TMP SEN _1 A14 129 G_R_RAILPS GND RAIL_PRE SEN _1 A09 123 O_T_DCNEG MOTOR INTAKE_THRO VAL _5 A08 124 O_T_DCPOS MOTOR 111 O_V_MEU SCV MPROP _1 A07 EGR VALVE_4 A06 SHIELD_DOREN A05 INTAKE_THRO VAL _6 A04 112 O_V_MEU SCV MPROP _2 A03 X EGR VALVE_3 A02 SHIELD_DOREN A01 238 O_V_12V 242 B_D...

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Page 205: ...s engine Engine Harness ECU harness vehicle Fuel pump Vibrator relay Glow relay P 5 051 Frame F harness P 5 061 P 5 071 Vibrator solenoid F harness 2 P 5 072 Frame R harness P 5 064 Vibrator solenoid R harness 3 P 5 075 Vibrator solenoid R harness 4 P 5 076 Vibrator solenoid R harness 1 P 5 073 Vibrator solenoid R harness 2 P 5 074 DETAIL A DETAIL B Battery relay Engine Harness P 5 051 Parking bra...

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Page 207: ... harness Diagnostic switch Stater relay harness P 5 083 Glow relay Neutral relay DETAIL L H to Stater switch harness P 5 065 Starter switch N Starter relay L Buzzer Potentiometer F R lever switch Backup buzzer switch SECTION J J Flasher unit ECU main relay Insulation protection Horn relay Diagnostic switch harness ROPS P 5 077 Except ROPS P 5 078 J R K K J M P GW 2 B 1 1 2 3 DETAIL M Dashboard har...

Page 208: ...WR 17 2Y 13 50 100 VB5 5 5BR 50 3BR 50 12015792 12015792 50 50 Speed change solenoid 50 50 50 50 Tape 5 0 T a p e B 5 0 T a p e 2Y 13 5WG 10 5BR 26 SWP 8M 58X 1M 58Y 2M WL 82 40 WB 33 LgW 17 WR X 111 110 109 Gr G L B 82 0 5WL 400 100 Parking brake solenoid 26 H COT Corrugate 15 H COT Corrugate 10 H COT Corrugate 15 H COT Corrugate 20 H COT Corrugate 10 H COT Corrugate 7 H COT Corrugate 15 H COT Co...

Page 209: ...B Alternator 26 3BR 5BR 2 B Starter motor S 28 8WY 2 Alternator B Starter motor B NO SIZE COLOR CONTACT POINTS CONNECTION 33 LgW 2 B Speed change solenoid 40 WB 2 B Parking brake solenoid 82 0 5WL WL 2 B Air flow sensor 109 0 5Gr Gr 3 B Air flow sensor 2 110 0 5G G 2 B Air flow sensor 111 0 5L L 2 B Air flow sensor 5 052 ELECTRICAL SYSTEM SW504 ...

Page 210: ...2F SWP 6F BrR LgR LgY 48 47 46 LgW LR Lg 30 53 4 2GB 37 2Y 13 5WG 5BR 26 10 5BY 8WR 312 2 5R 3G 6 8 COMB 100 Corrugate CAN service tool Cap MTL 2PL F Buzzer CAN service tool Frame F harness Combination meter Twist cable processing diagram Twist cable Stater relay harness P 5 083 F R lever vibration switch R harness P 5 085 P 5 089 Twist pair cable AVS 0 85 mm2 x 2C Potentiometer Terminating resist...

Page 211: ...VD 8M Combination meter 24 2 53 LR 2 A 6F Combination meter 16 2 55 YG 2 A 4F Combination meter 18 2 60 BrY 2 Foot brake switch 1 1 61 RG 2 C 8M 1 1 80 WG 2 ECU VD 8M 1 1 82 WL 1 25WL 3WL 5 A 8F ECU VD 8M 2 3 83 WR 2 A 8F 1 1 84 WY 2 ECU VD 8M 1 1 85 LY 2 P ECU VD 8M 2 86 L 2 P 1 1 89 G 2 ECU VD 8M Glow relay 2 90 GW 2 ECU VD 8M Glow relay 2 92 W 2 ECU VD 8M Combination meter 17 2 93 W L 2 ECU VD ...

Page 212: ...9 Vibrator relay F R lever vibration switch L harness P 5 084 Corrugate 32 100 Corrugate 28 Corrugate 7 Corrugate 15 350 Corrugate 25 Corrugate 28 250 Corrugate 15 313 313 3WL 30 3 1 25WL 120 82 82 150 Corrugate 15 6110 4643 100 WY WB 84 82 3WL 313 313 3WB X RY BrY B 24 61 RG 60 RB6B SL L B LgR LR 86 X 302 87 RB6B SL 100 100 Interlock relay ECU main relay Brake lamp relay 100 1 0 0 100 100 46 51 2...

Page 213: ...al switch 4 35 G 5 3 G Turn signal switch 2 36 GR 5 3 G Turn signal switch 2 37 GB 2GB 5 4 F 1 38 Or 3 2 F 1 39 LW 3 2 J 1 40 WB 2 1 E 1 41 RW 2 1 E 1 43 RW 2 J Vibrator relay 2 44 BrY 2 J Vibrator relay 2 45 Br 3 1 F R lever vibration switch L harness Vibrator relay 2 46 BrR 4 2 Vibrator lamp relay Vibrator relay 2 47 LgR 2 1 D 1 48 LgY 2 1 D 1 49 LgB 2 1 D 1 50 LgW 2 1 D 1 No SIZE COLOR CONTACT ...

Page 214: ...6 R 125 LgY 124 W 123 B 122 GR 121 YB 120 B 119 BrW 118 LW 116 Sb 115 RW 113 YR 112 L 111 G 110 Gr 109 GB 150 YB 149 WL 82 LgY 148 1 25B 162 1 25B 161 1 25B 160 G 107 Y 106 Br 105 Y 104 W 103 B 102 G 101 L 100 LY 99 LR 98 Y 301 1 25WL 1 25WL 1 25WL 82 82 82 201 212 248 237 249 250 255 256 156 155 150 149 137 148 112 101 Twist cable ECU VF 100 SWP 3F 100 50 SWP 16M Shield drain 117 Twist shield cab...

Page 215: ...R 2 C2 213 ECU VF 16F 122 B 2 C1 143 ECU VF 16M No SIZE COLOR CONTACT POINTS CONNECTION 123 W 2 C1 141 ECU VF 16M 124 LgY 2 C1 131 ECU VF 16F 125 R 2 C1 102 ECU VF 16M 126 R 2 C1 103 ECU VF 16M 127 Gr 2 C1 108 ECU VF 16F 128 GY 2 C1 144 ECU VF 16F 129 LY 2 C1 132 ECU VF 16F 130 BrY 2 C1 120 ECU VF 16F 131 LgB 2 C1 128 ECU VF 16F 132 RY 2 C1 115 ECU VF 16F 133 RG 2 C1 101 ECU VF 16F 134 W 2 C1 142 ...

Page 216: ...2 ECC 16 8 5 8 9 12 13 17 18 22 23 27 28 32 33 37 38 42 TYCO 0 936421 2 ECA 50 50 80 130 Twist cable BrW 118 123 126 128 BrB 135 131 LgB W RY RY RG 133 132 132 134 106 Y LY 129 130 BrY X WR LW Sb Gr GY 127 G 107 R R 125 124 LgY W B 122 GR 121 119 B YB 120 Twist cable Engine connector B Engine connector C Engine connector A LgW 141 LgR 140 ECB 138 LR BrR 136 BrW 137 139 LW Twist cable Twist cable 1...

Page 217: ... R 2 ECA 24 ECU E 8F 126 R 2 ECA 23 ECU E 8F 127 Gr 2 ECA 32 ECU E 16F No SIZE COLOR CONTACT POINTS CONNECTION 128 GY 2 ECA 28 ECU E 16F 129 LY 2 ECA 37 ECU E 16F 130 BrY 2 ECA 34 ECU E 16F 131 LgB 2 ECA 33 ECU E 16F 132 RY 4 ECA 39 42 ECC 11 ECU E 16F 133 RG 2 ECA 41 ECU E 12M 134 W 2 ECA 40 ECU E 8F 135 BrB 2 ECA 38 ECU E 12M 136 BrR 2BrR 2 ECB 5 ECU E 2F 137 BrW 2BrW 2 ECB 11 ECU E 2F 138 LR 2L...

Page 218: ...4 LE104 X SWP 2F 38 Or RB2B SL CA104 CB104 CB104 Fuel pump Fuel gauge unit Turn signal lamp R Vibrator solenoid F harness 2 Hydraulic oil filter switch Head lamp R Horn Ground PB104 X 55 37 30 LA210 X BrR 100 LgY 100 LgR 100 BrR 100 47 46 48 46 CB104 CA104 CB104 CA104 3 0 0 Lg 320 35 X CA104 CB104 270 320 300 B 150 LgW 150 8W 140 2B 250 600 1 8W 2 8WR 5 3GW 6 3G 311 5BW 312 5BY 130 80 80 80 7322 4...

Page 219: ... B 8F 110 G 2 ECU VF 3M B 8F 111 L 2 ECU VF 3M B 8F 112 YR 2 ECU E 16M ECU VF 16F 113 RW 2 ECU E 16M ECU VF 16F 114 X 2 ECU E 8M ECU VF 16F No SIZE COLOR CONTACT POINTS CONNECTION 115 Sb 2 ECU E 16M ECU VF 16F 116 LW 2 ECU E 16M ECU VF 16F 117 X 2 ECU E 8M ECU VF 16F 118 BrW 2 ECU E 16M ECU VF 16F 119 B 2 ECU E 8M ECU VF 16F 120 YB 2 ECU E 16M ECU VF 16M 121 GR 2 ECU E 16M ECU VF 16M 122 B 2 ECU E...

Page 220: ...38 RG 61 BY 29 G 35 GR 36 LA208 CB104 Combination lamp L RB6B SL Combination lamp R Drum edge lamp R R option Drum edge lamp R L option RB6B SL Water spray pump 58X 2F SWP 3F Vibrator solenoid R harness 3 P 5 075 58X 2F SWP 4F SWP 8F Ground Backup buzzer LA208 CB104 PB104 PB104 LE206 LE206 100 Tape 100 Tape 130 Tape 130 Tape 600 Corrugate 10 200 Corrugate 10 1500 Corrugate 10 600 Corrugate 10 360 ...

Page 221: ...X 2F Water spray relay B 29 BY 2 C 8F Backup buzzer 35 G 2 C 8F Combination lamp R 36 GR 2 C 8F Combination lamp L 37 GB 3 C 8F Combination lamp L R 38 Or 6 C 8F M Flood lamp Mihaalu harness Drum edge lamp R L option R R option 39 LW 2 C 4F Water spray relay g 42 3LB 2 Water spray pump Water spray relay G 46 BrR 2 C 4F J 49 LgB 2 C 4F J 50 LgW 2 C 4F J 61 RG 3 C 8F Combination lamp L R 304 G 2 C 2...

Page 222: ...ch Dashboard harness 2 Not in use Insulation protection P 5 055 50 Tape 2 10 LE305 B 2 LE305 R1 10 LE105 ACC 11 LE205 BR 13 LE105 BR 3 LE105 C 14 LE205 C 16 LE205 C 32 H No SIZE COLOR CONTACT POINTS CONNECTION 2 5WR 2 H Starter swich B 3 LgR 2 H Starter swich BR 10 5WG 2 Starter swich R1 H not in use 11 BrB 2 H Starter swich ACC 13 2Y 2 H Starter swich BR 14 WL 2 H Starter swich C 16 3W 2 H Starte...

Page 223: ...0 RY 80 2GB 80 2Or 80 50 50 RY LgW 24 33 58X 3M SWP 2M Dashboard harness 2 P 5 055 50 Tape Speed change switch F 1 24 2 33 1 19 4 19 3 37 5 38 F No SIZE COLOR CONTACT POINTS CONNECTION 19 3R 3 F Lighting swich 1 4 24 RY 2 F Speed change swich 1 33 LgW 2 F Speed change swich 2 37 2GB 2 F Lighting swich 3 38 2Or 2 F Lighting swich 5 ...

Page 224: ... 1 5 2 4 1 3 5 0 T a p e 50 50 Tape 5 0 LA108 Ground Dashboard harness 2 P 5 055 J X 18 18 39 70 23 23 43 44 J No SIZE COLOR CONTACT POINTS CONNECTION X B 2 J Water spray timer 18 LY 3 J Water spray mode select switch 1 4 23 RL 3 J Vibration mode select switch 1 4 39 LW 3 J Water spray mode select switch 2 Water spray timer 43 RW 2 J Vibration mode select switch 2 44 BrY 2 J Vibration mode select ...

Page 225: ...ect switch Water spray mode select switch 5 2 4 1 5 4 2 1 J 50 Tape 18 39 27 39 23 23 43 44 Dashboard harness 2 P 5 055 J No SIZE COLOR CONTACT POINTS CONNECTION 18 LY 2 J Water spray mode select switch 1 23 RL 3 J Vibration mode select switch 1 4 27 GY 2 J Water spray mode select switch 4 39 LW 3 J Water spray mode select switch 2 5 43 RW 2 J Vibration mode select switch 2 44 BrY 2 J Vibration mo...

Page 226: ... 80 RL LgB LgW LgY LgR RL 50 49 23 48 47 23 50 23 23 62 63 1 4 3 6 RL 90 RL 90 BrB 90 BrW 90 No SIZE COLOR CONTACT POINTS CONNECTION 23 RL 4 D 2 Vibratory drum select switch 1 4 47 LgR 2 D Vibration Lo Hi change switch 3 48 LgY 2 D Vibration Lo Hi change switch 2 49 LgB 2 D Vibration Lo Hi change switch 6 50 LgW 2 D Vibration Lo Hi change switch 5 62 BrB 2 Vibratory drum select switch 6 Vibration ...

Page 227: ... 80 LgR 80 LgY 80 RL LgB LgW LgY LgR RL 50 49 23 48 47 23 50 2 3 4 1 5 6 23 23 47 48 49 50 D Dashboard harness 2 P 5 055 No SIZE COLOR CONTACT POINTS CONNECTION 23 RL 4 D 2 Vibration Lo Hi change switch 1 4 47 LgR 2 D Vibration Lo Hi change switch 3 48 LgY 2 D Vibration Lo Hi change switch 2 49 LgB 2 D Vibration Lo Hi change switch 6 50 LgW 2 D Vibration Lo Hi change switch 5 ...

Page 228: ...brator solenoid F Hi 1 2 Frame F harness P 5 061 W 50 B 50 VCTF 0 75mm2 2C 125 W 25 B 25 CB104 CA104 BrR LgY LgY BrR indicate the connection line color No SIZE COLOR CONTACT POINTS CONNECTION B 2 Vibrator solenoid F Hi 1 Frame F harness LgY W 2 Vibrator solenoid F Hi 2 Frame F harness BrR ...

Page 229: ...50 B 50 VCTF 0 75mm2 2C 125 W 25 B 25 CB104 CA104 1 2 Vibrator solenoid F Lo Frame F harness P 5 061 BrR LgR LgR BrR indicate the connection line color No SIZE COLOR CONTACT POINTS CONNECTION B 2 Vibrator solenoid F Lo 1 Frame F harness LgR W 2 Vibrator solenoid F Lo 2 Frame F harness BrR ...

Page 230: ...TF 0 75mm2 2C 125 W 25 B 25 1 2 Vibrator solenoid R Hi CB104 CA104 BrR LgW LgW BrR indicate the connection line color P 5 075 Vibrator solenoid R harness 4 P 5 076 No SIZE COLOR CONTACT POINTS CONNECTION B 2 Vibrator solenoid R Hi 1 Vibrator solenoid R harness 3 LgW W 2 Vibrator solenoid R Hi 2 Vibrator solenoid R harness 4 BrR ...

Page 231: ...ator solenoid R harness 4 P 5 076 W 50 B 50 VCTF 0 75mm2 2C 125 W 25 B 25 1 2 Vibrator solenoid R Lo CB104 CA104 BrR LgB LgB BrR indicate the connection line color No SIZE COLOR CONTACT POINTS CONNECTION B 2 Vibrator solenoid R Lo 1 Vibrator solenoid R harness 3 LgB W 2 Vibrator solenoid R Lo 2 Vibrator solenoid R harness 4 BrR ...

Page 232: ...ator solenoid R harness 1 P 5 073 SWP 3M LgW LgB BrR 50 49 46 LgW 50 CA104 CB104 BrR 50 CB104 LgB 50 H Frame R harness P 5 063 50 50 Tape 46 49 50 BrR B B J BrR B indicate the connection line color No SIZE COLOR CONTACT POINTS CONNECTION 46 BrR 2 H Vibrator solenoid R harness 4 BrR 49 LgB 2 H Vibrator solenoid R harness 2 B 50 LgW 2 H Vibrator solenoid R harness 1 B ...

Page 233: ...ibrator solenoid R harness 2 P 5 074 CB104 CA104 CA104 BrR 50 BrR 50 BrR 50 Tape 50 46 46 46 W BrR W BrR W indicate the connection line color Vibrator solenoid R harness 3 P 5 075 No SIZE COLOR CONTACT POINTS CONNECTION 46 BrR 3 Vibrator solenoid R harness 1 W Vibrator solenoid R harness 2 W Vibrator solenoid R harness 3 BrR ...

Page 234: ... ROPS 1634 09078 0 31116 A G G Corrugate 7 Hazard switch 6 6 26 40 GY GY GR GB 5 4 2 1 GY 100 GB 100 GY 100 GR 100 SWP 4F Dashboard harness 2 P 5 055 6 6 40 26 100 50 No SIZE COLOR CONTACT POINTS CONNECTION 6 GY 4 G 2 Hazard switch 1 4 26 GR 2 G Hazard switch 5 40 GB 2 G Hazard switch 2 ...

Page 235: ...5 078 ELECTRICAL SYSTEM SW504 8 18 2 Cap except ROPS 1418 09044 0 40589 0 SWP 4F Dashboard harness 2 P 5 055 G ...

Page 236: ... 19 DPF Switch Harness 1448 09021 0 30554 A Dashboard harness 2 P 5 055 SWP 2F 2 1 82 148 WL 100 DPF switch LgY 100 82 148 WL LgY Q 50 Tape 50 Q No SIZE COLOR CONTACT POINTS CONNECTION 82 WL 2 Q DPF switch 1 148 LgY 2 Q DPF switch 2 ...

Page 237: ...tch Harness 1448 09040 0 30777 0 B 50 LA104 DIA SWP 2M Dashbord harness 1 LA104 1 2 GW 50 Diagnostic switch 100 P 5 053 Tape X 315 50 DIA B GW 315 X No SIZE COLOR CONTACT POINTS CONNECTION X B 2 DIA Diagnostic switch 1 315 GW 2 DIA Diagnostic switch 2 ...

Page 238: ... 6F 50 301 41 40 Y RW WB YL B 15 X Dashboard harness 2 P 5 055 Parking brake switch E 50 Tape 1 41 3 40 5 15 4 X 2 301 E No SIZE COLOR CONTACT POINTS CONNECTION X B 2 E Parking brake switch 4 15 YL 2 E Parking brake switch 5 40 WB 2 E Parking brake switch 3 41 RW 2 E Parking brake switch 1 301 Y 2 E Parking brake switch 2 ...

Page 239: ... 0 75mm 4C 2 SWP 4M SWP 6F Mihaalu option G 304 W 308 R 38 B X 38 X 308 R B W 304 G Frame R harness P 5 063 750 50 50 No SIZE COLOR CONTACT POINTS CONNECTION X B 2 Frame R harness Mihaalu option 38 R 2 Frame R harness Mihaalu option 304 G 2 Frame R harness Mihaalu option 308 W 2 Frame R harness Mihaalu option ...

Page 240: ...5 A P P 5 053 SWP 2F 26 5BR 3W 25 L 86 LY 85 30 VCF4 1002 Starter relay Dashboard harness 1 100 25 3W L 86 LY 85 26 5BR 50 58Y 2F 30 Tape P No SIZE COLOR CONTACT POINTS CONNECTION 25 3W 2 P Starter relay 26 5BR 2 P Starter relay 85 LY 2 P Starter relay 86 L 2 P Starter relay ...

Page 241: ...5 G 65 PVC tube 6 0 5 F R lever vibration switch L Dashboard harness 2 P 5 055 See Wiring Harness Layout 2 DETAIL P P 5 050 No SIZE COLOR CONTACT POINTS CONNECTION Br 2 Dashboard harness 2 F R lever vibration switch L 1 G 2 Dashboard harness 2 F R lever vibration switch L 2 W 2 Dashboard harness 2 F R lever vibration switch L 3 ...

Page 242: ...5 G 65 F R lever vibration switch R See Wiring Harness Layout 2 DETAIL R P 5 050 Dashboard harness 1 P 5 053 PVC tube 6 0 5 No SIZE COLOR CONTACT POINTS CONNECTION Br 2 Dashboard harness 1 F R lever vibration switch R 1 G 2 Dashboard harness 1 F R lever vibration switch R 2 W 2 Dashboard harness 1 F R lever vibration switch R 3 ...

Page 243: ...5 086 ELECTRICAL SYSTEM SW504 8 26 Short Harness 1446 09080 0 40879 0 SWP 2F 29 29 BY BY Dashboard harness 2 P 5 055 No SIZE COLOR CONTACT POINTS CONNECTION 29 BY 2 Dashboard harness 2 2 ...

Page 244: ...5 087 ELECTRICAL SYSTEM SW504 8 27 Cord 1745 33006 0 40486 0 150 AV3 B LA208 LA208 ECU Ground No SIZE COLOR CONTACT POINTS CONNECTION B 2 ECU Ground ...

Page 245: ...de select switch Vibratory drum select switch ROPS Vibration Lo Hi change switch except ROPS RG 9 8 7 6 5 4 3 2 1 10 Backup buzzer switch Horn relay Flasher unit G Battery relay R Battery relay W Starter relay RY Brake lamp relay F R lever switch Speed change switch Foot brake switch Sub power 12V 120W Water spray relay Harness color codes W White RG Red Green stripe R Red RL Red Blue stripe G Gre...

Page 246: ... Red DEF Tampering Buzzer Water splay Liquid spray High beam Flood lamp Turn signal R Turn signal L Vibrator Inhibit the DPF Auto vegeneration Inhibit the SCR cleaning 7 Segments LCD Dot Matrix LCD TACHO FUEL TEMP BAT Battery 24V Ground Starter switch ACC Pull down Resistor 4 7KΩ x7 BAT System configuration diagram X 35 37 36 15 17 53 315 17 51 12 37 DESCRIPTION Battery 24V Starter switch ACC Grou...

Page 247: ...VIBRATORY DRUM REAR WHEEL ...

Page 248: ......

Page 249: ...t and other substances from getting in Before removing piping for hydraulic oil or coolant or removing related parts satisfactorily release internal pressure 2 Precautions for installation work Tighten bolts and nuts sleeve nuts to the specified torque screw tightening torque table When installing hoses do not twist them or allow them to interfere with other parts Replace gaskets O rings split pin...

Page 250: ...ng life coolant to the specified level Start the engine and allow the coolant to circulate through the piping Then add coolant again to the specified level If hydraulic equipment has been removed and reinstalled fill with hydraulic oil to the specified level Start the engine and allow the oil to circulate through the piping Then add oil again to the specified level ...

Page 251: ...ing the machine body use an appropriate hoist of sufficient strength Confirm that the surrounding area is safe and work in a natural unstrained posture Also to firmly secure the machine body use a support stand of sufficient strength 2 Supporting frame Lift frame with a crane Place support stands under frame when drum is slightly off ground to support machine body Front axle Rear axle SW354 1 470 ...

Page 252: ...rk 3 Disconnecting piping 3 1 Disconnecting propulsion motor piping Remove bolts 3 Remove cover 2 Disconnect hydraulic hoses 4 5 6 7 and 8 connecting to propulsion motor NOTICE Plug both ends of the disconnected hoses or implement other actions to prevent entry of foreign matter 3 2 Disconnecting vibrator motor piping Remove bolts 10 Remove cover 9 Disconnect hydraulic hoses 11 12 and 13 connectin...

Page 253: ...1 565 lbs TW504 1 060 kg 2 337 lbs 5 Removal of plates TW504 Hold drum 18 with chocks Remove nuts 20 and bolts 19 left and right sides Remove plate 15 16 15 Front left plate 80 kg 176 lbs 16 Front right plate 85 kg 187 lbs 6 Removal of plates SW TW354 Hold drum 23 with chocks Remove nuts 24 left and right sides Remove plate 21 22 21 Front left plate 60 kg 132 lbs 22 Front right plate 65 kg 143 lbs...

Page 254: ...45 lbf ft 2 Upon installing vibratory drum pay particular attention to items mentioned below Fill hydraulic oil tank to specified level to make up for any oil leakage Start engine and circulate oil through piping Then check oil level again ensuring that oil is at specified level NOTICE If the engine is run at high speed or the cylinder is operated to full stroke when the engine is started for the ...

Page 255: ...ing 5 Eccentric shaft 6 Drum 7 Vibrator bearing 8 Boss 9 O ring 10 Bolt M16 40 11 Plug 12 Bolt M16 50 13 Plug 14 Plate 15 Roller bearing 16 Breather 17 Bolt M16 40 18 O ring 19 Nut M16 20 Damper 21 Sleeve 22 Spring pin 23 Bolt M10 35 24 Cover 25 Bolt M10 25 26 Cover 27 O ring 28 Shim 29 Disc 30 Oil seal 31 Bolt M16 40 32 Snap ring 33 Bolt M16 45 34 Disc 35 Bolt M16 40 36 Damper 37 Nut M16 38 Bolt ...

Page 256: ......

Page 257: ... Holder 3 O ring 4 Vibrator bearing 5 Eccentric shaft 6 Drum 7 Vibrator bearing 8 Boss 9 O ring 10 Bolt M16 40 11 Plug 12 Bolt M16 50 13 Plug 14 Plate 15 Roller bearing 16 Breather 17 Bolt M12 30 18 O ring 19 Bolt M12 50 20 Damper 21 Sleeve 22 Spring pin 23 Bolt M10 35 24 Cover 25 Bolt M10 25 26 Cover 27 O ring 28 Shim 29 Disc 30 Oil seal 31 Bolt M16 40 32 Snap ring 33 Bolt M18 50 34 Disc 35 Bolt ...

Page 258: ......

Page 259: ...th chocks Drum assembly SW TW354 590 kg 1 301 lbs TW504 890 kg 1 962 lbs 2 Remove plugs 11 1 and 11 3 Drain gear oil Quantity of gear oil SW TW354 5 0 L 1 3 gal TW504 6 0 L 1 6 gal WARNING When standing the vibratory drum use wooden blocks of sufficient strength to securely support the drum Carry out the work in an unstrained posture using a work stool or the like 3 Stand drum assembly with its vi...

Page 260: ...RATORY DRUM REAR WHEEL 4 Remove adapters 5 Remove bolts 44 Remove vibrator motor 43 Remove breather 16 43 Vibrator motor 5 kg 11 lbs 6 Remove sleeve 21 SW300 1 06016 Adapter SW300 1 06017 16 43 44 SW354 06040 21 ...

Page 261: ...WHEEL 7 Remove bolts 25 8 Lift cover 26 using two pulling bolts M10 40 Remove cover 9 Remove bolts 17 17 Bolts SW TW354 four bolts TW504 eight bolts Remove dampers 20 SW354 06047 25 SW354 06048 Pulling bolt 26 SW354 06076 17 20 ...

Page 262: ...oss 8 Set a puller on disc 29 Remove disc subassembly with roller bearing from boss subassembly WARNING When installing lifting bolts screw in the threads fully before using 12 Install lifting bolts SW TW354 M16 TW504 M12 to disc subassembly SW354 06035 23 24 28 SW300 1 06023 Wooden board Puller 8 29 SW354 06049 Lifting bolt ...

Page 263: ...ith roller bearing from boss subassembly Disc subassembly SW TW354 35 kg 77 lbs TW504 45 kg 99 lbs 14 Remove bolts 10 15 Lift boss subassembly using two pulling bolts M16 40 SW354 06050 Boss subassembly Disc subassembly SW354 06028 10 SW354 06051 Pulling bolt ...

Page 264: ...ARNING Be careful because reversing the vibratory drum involves risk Confirm that the surrounding area is safe and work in a natural unstrained posture 18 Reverse drum subassembly Drum subassembly SW TW354 500 kg 1 102 lbs TW504 790 kg 1 742 lbs SW354 06052 Lifting bolt SW354 06077 Boss subassembly SW354 06059 Drum subassembly Wooden block ...

Page 265: ...HEEL 19 Remove dampers 36 and bolts 35 35 Bolts SW TW354 six bolts TW504 twelve bolts 20 Remove adapters 21 Install lifting bolts SW TW354 M16 TW504 M12 to disc 34 SW354 06019 35 36 SW354 06018 Adapter SW354 06078 Lifting bolt 34 ...

Page 266: ...isc 34 Remove bolts 38 23 Remove disc 34 34 Disc SW TW354 15 kg 33 lbs TW504 20 kg 44 lbs 24 Install lifting bolts SW TW354 M16 TW504 M18 to propulsion motor 39 Remove bolts 33 SW300 1 06036 39 33 Lifting bolt SW354 06015 34 SW354 06054 38 34 ...

Page 267: ...emove propulsion motor 39 39 Propulsion motor SW TW354 45 kg 99 lbs TW504 85 kg 187 lbs 26 Remove bolts 31 27 Lift holder subassembly using two pulling bolts M16 40 SW354 06011 39 SW354 06008 31 SW354 06055 Pulling bolt Holder subassembly ...

Page 268: ...TW504 M18 to holder subassembly 29 Remove holder subassembly Holder subassembly SW TW354 50 kg 110 lbs TW504 60 kg 132 lbs 30 Remove snap ring 32 while supporting eccentric shaft 5 SW354 06079 32 5 SW354 06007 Holder subassembly SW354 06056 Lifting bolt Holder subassembly ...

Page 269: ...emove holder subassembly Holder subassembly 30 kg 66 lbs 32 Put holder subassembly on wooden blocks 33 Remove vibrator bearing 4 SW354 06003 Holder subassembly 5 SW354 06058 4 Holder subassembly SW354 06057 Wooden block Holder subassembly ...

Page 270: ...n an unstrained posture using a work stool or the like 1 Stand drum 6 with its propulsion motor side facing up 6 Drum SW TW354 380 kg 838 lbs TW504 605 kg 1 334 lbs NOTICE Propulsion motor side dimension a SW TW354 363 5 mm 14 3 in TW504 379 5 mm 14 9 in 2 Reassembly of holder subassembly Apply a coat of gear oil to holder 2 at where bearing will be press fitted Drive in vibrator bearing 4 NOTICE ...

Page 271: ...When installing lifting bolts screw in the threads fully before using 4 Install lifting bolts SW TW354 M16 TW504 M18 to holder subassembly 5 Lift holder subassembly Holder subassembly 30 kg 66 lbs SW354 06061 Holder subassembly SW354 06080 Holder subassembly Lifting bolt SW354 06002 Holder subassembly ...

Page 272: ... 5 to holder subassembly 7 Hold eccentric shaft 5 with snap ring 32 NOTICE Make sure that the snap ring is fitted completely in its groove 8 Apply grease to O ring 3 Install O ring to holder 2 SW354 06063 Holder subassembly 5 SW354 06081 32 5 SW354 06005 3 2 ...

Page 273: ...SW TW354 50 kg 110 lbs TW504 60 kg 132 lbs 10 Secure holder subassembly with eight bolts 31 and washers N m 31 Bolts M16 40 265 N m 195 lbf ft 11 Install lifting bolts SW TW354 M16 TW504 M18 to propulsion motor 39 SW354 06065 31 Holder subassembly SW354 06064 Holder subassembly 6 SW300 1 06048 Lifting bolt 39 ...

Page 274: ...Apply grease to O ring 1 Install O ring to propulsion motor 13 Lower propulsion motor 39 on mounting surface of holder subassembly 14 Secure propulsion motor 39 with six bolts 33 and washers N m 33 Bolts SW TW354 M16 45 265 N m 195 lbf ft TW504 M18 50 343 N m 253 lbf ft SW300 1 06049 39 1 SW354 06066 39 SW300 1 06050 39 33 ...

Page 275: ...stall lifting bolts SW TW354 M16 TW504 M12 to disc 34 16 Lift disc 34 34 Disc SW TW354 15 kg 33 lbs TW504 20 kg 44 lbs 17 Lower disc 34 on mounting surface of propulsion motor 39 SW354 06013 34 Lifting bolt SW354 06014 34 SW354 06067 34 39 ...

Page 276: ... propulsion motor port A 18 Secure disc 34 with six bolts 38 and washers N m 38 Bolts SW TW354 M16 40 265 N m 195 lbf ft TW504 M18 40 343 N m 253 lbf ft 19 Apply grease to O rings for adapters Install adapters SW354 06017 34 38 SW354 06016 Propulsion motor port A Longer direction of disc SW354 06018 Adapter ...

Page 277: ...use reversing the vibratory drum involves risk Confirm that the surrounding area is safe and work in a natural unstrained posture 21 Reverse drum subassembly Drum subassembly SW TW354 500 kg 1 102 lbs TW504 790 kg 1 742 lbs 22 Reassembly of boss subassembly 22 1 Apply a coat of gear oil to boss 8 at where bearing will be press fitted Drive in vibrator bearing 7 SW354 06019 35 36 SW300 1 06054 Drum...

Page 278: ...earing 15 inner race by using a ring heater or the like Apply a coat of gear oil to boss 8 at where bearing inner race will be press fitted Drive in heated roller bearing inner race 22 4 Apply grease to O rings for plugs 11 Install plugs Apply sufficient amount of lithium based grease to rollers of roller bearing 15 inner race SW354 06022 Boss subassembly SW354 06023 15 8 SW354 06024 11 15 ...

Page 279: ... kg 77 lbs Apply grease to O ring 9 Install O ring to boss 8 25 Lower boss subassembly on mounting surface of drum subassembly slowly NOTICE Support the eccentric shaft 5 with a pipe or the like to prevents tilting of vibrator bearing inner race during installation SW354 06025 Lifting bolt SW300 1 06062 9 8 SW354 06027 5 Pipe ...

Page 280: ...washers N m 10 Bolts M16 40 265 N m 195 lbf ft 27 Install lifting bolts M5 to end of eccentric shaft 5 28 Slowly lift eccentric shaft 5 with a crane and check that there is an axial play of 2 to 4 mm 0 08 to 0 16 in SW354 06068 10 Boss subassembly SW354 06029 Lifting bolt SW354 06030 ...

Page 281: ...ply liquid packing to periphery of oil seal 30 Drive in oil seal Apply grease to lip of oil seal 30 Install lifting bolts SW TW354 M16 TW504 M12 to disc subassembly 31 Lower disc subassembly on mounting surface of boss subassembly Disc subassembly 35 kg 77 lbs SW300 1 06067 29 15 30 15 SW354 06032 Lifting bolt Disc subassembly SW354 06033 Disc subassembly Boss subassembly ...

Page 282: ...ly with four bolts 23 and washers A gap will remain between end of boss subassembly and inside of cover 24 Tighten bolts 23 to a torque of 12 7 N m 9 4 lbf ft Give disc subassembly two to three turns Tighten bolts to a torque of 12 7 N m 9 4 lbf ft again Repeat this work several times until tightening torque of bolts no longer fluctuates NOTICE Tighten the bolts alternately in diagonal directions ...

Page 283: ... will not be seated Remove bolts 23 Remove cover 24 Remove shim NOTICE Do not turn the disc subassembly after the cover is removed Without inserting shim install cover 24 to boss subassembly with four bolts 23 and washers SW800 06080 End of rollers in close contact with inner race shoulder G a p G a p 1 Bearing not seated 2 Bearing correctly seated SW354 06070 23 24 Shim SW354 06036 23 24 Boss sub...

Page 284: ...ess A 0 1 mm 0 004 in Remove bolts 23 Remove cover 24 Install shim 28 of preload adjusting shim thickness A 0 1 mm 0 004 in Secure cover 24 to boss subassembly with four bolts 23 and washers N m 23 Bolts M10 35 59 N m 44 lbf ft SW300 1 06075 A No gap SW354 06071 23 24 SW354 06072 23 24 28 Boss subassembly ...

Page 285: ...g to cover 26 35 Lower cover 26 on mounting surface of disc subassembly NOTICE The recess of the disc must face the same direction as the breather mounting hole in the cover SW300 1 06077 27 26 SW354 06037 26 Disc subassembly SW354 06073 Recess of disc Breather mounting hole ...

Page 286: ...d washers 37 Secure two dampers 20 to disc subassembly with four eight bolts 17 and washers N m 17 Bolts SW TW354 four bolts M16 40 265 N m 195 lbf ft TW504 eight bolts M12 30 108 N m 80 lbf ft 38 Drive two spring pins 22 into sleeve 21 SW354 06038 26 25 SW354 06039 17 20 SW300 1 06080 21 22 ...

Page 287: ...haft end 40 Apply grease to O ring 18 Install O ring to vibrator motor 43 41 Wind seal tape around threaded portion of breather 16 Install breather Secure vibrator motor 43 to cover 26 with two bolts 44 and washers 43 Vibrator motor 5 kg 11 lbs N m 44 Bolts M10 35 49 N m 36 lbf ft SW300 1 06082 43 18 SW354 06074 21 SW300 1 06083 43 44 16 26 ...

Page 288: ...with chocks Drum assembly SW TW354 585 kg 1 290 lbs TW504 885 kg 1 951 lbs 44 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 SW TW354 5 0 L 1 3 gal TW504 6 0 L 1 6 gal Reinstall plugs SW300 1 06084 Adapter SW354 06045 Chock Drum assembly 11 2 11 1 11 3 SW354 06044 Supply port Gauge port 11 1 11 2 ...

Page 289: ...14 45 P 1 5 25 Bracket 6 Adapter 16 Hub nut M14 P 1 5 26 Bolt M16 40 7 Hub bolt M14 45 P 1 5 17 Disc 27 Propulsion motor R L 8 Hub nut M14 P 1 5 18 Propulsion motor R R 28 Adapter 9 Tire 19 Bolt M16 40 29 Hose 10 Disc wheel 20 Adapter 30 Adapter N m 8 Nut M14 P 1 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 lbf ft 22 Bolt M20 80 539 N m 398 lbf ft 16 Nut M14 P ...

Page 290: ...6 040 VIBRATORY DRUM REAR WHEEL 4 2 Removal and Installation of Rear Axle TW types 1 Hold drum with chocks 2 Lock front and rear frames with lock pin 1 TW354 06004 Chock SW354 06075 1 ...

Page 291: ... Confirm that the surrounding 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 stands under frame when tires are slightly off ground to support machine body Flip up scraper blade Rear axle TW354 1 130 kg 2 490 lbs TW354 ROPS 1 190 kg 2 625 lbs TW504 1...

Page 292: ...ediately after the machine is stopped Disconnecting the hydraulic hoses in this condition can cause burns Wait for the hydraulic oil to cool down before starting the work 4 Disconnecting piping 4 1 Disconnect hydraulic hoses 13 21 23 and 29 connecting to rear propulsion motor NOTICE Plug both ends of the disconnected hoses or implement other actions to prevent entry of foreign matter TW354 06003 W...

Page 293: ... 2 3 4 and 5 connecting to rear propulsion motor 5 Hold up propulsion motor subassembly with forklift Remove bolts 22 Remove propulsion motor subassembly Propulsion motor subassembly 130 kg 287 lbs SW300 1 06100 2 3 5 4 TW354 06005 22 Propulsion motor subassembly ...

Page 294: ...talling rear axle pay particular attention to items mentioned below Fill hydraulic oil tank to specified level to make up for any oil leakage Start engine and circulate oil through piping Then check oil level again ensuring that oil is at specified level NOTICE If the engine is run at high speed or the cylinder is operated to full stroke when the engine is started for the first time after the work...

Page 295: ...Removal and Installation of Vibratory Drum P 6 003 Each mass is same as TW 504 except for supporting frame Front axle 2 000 kg 4 410 lbs Rear axle 2 090 kg 4 605 lbs 5 2 Disassembly and Reassembly of Vibratory Drum For disassembly and reassembly refer to 3 3 Disassembly and Reassembly of Vibratory Drum P 6 009 Each mass is same as TW 504 SW504 ...

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Page 297: ...BRAKE ...

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Page 299: ... 9 14 15 SECTION A A 1 Washer 6 Rod end M10 11 Nut M10 P 1 25 2 Split pin 7 Rubber bolt M10 25 P 1 25 12 Rubber bolt M10 25 P 1 25 3 Rod Apply grease to hole 8 Foot brake switch 13 Nut M10 4 Nut M10 P 1 25 9 F R lever 14 Spring 5 Nut M10 10 Shaft 15 Bush Apply grease Lithium based grease ...

Page 300: ... R Parking brake switch Brake OFF condition To combination meter Propulsion motor F Brake Brake ON condition Brake Brake ON condition Parking brake solenoid valve when brake is ON without solenoid excited Parking brake solenoid valve when brake is OFF with solenoid excited Steering charge pump The arrow symbol shows the direction of the hydraulic oil flow ...

Page 301: ...ombination meter Parking brake solenoid valve when brake is ON without solenoid excited Parking brake solenoid valve when brake is OFF with solenoid excited Steering charge pump The arrow symbol shows the direction of the hydraulic oil flow Propulsion motor F Propulsion motor R L Brake Brake ON condition Brake Brake ON condition Propulsion motor R R Brake Brake ON condition ...

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Page 303: ...WATER SPRAY SYSTEM ...

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Page 305: ...Tee 2 Tee 1 Drain valve Hose Tee 1 Pump IN Water spray diagram Water spray pipe F Water spray pipe R OUT IN OUT IN Water spray tank Water spray pump Tee 1 Tee 1 Tee 3 Tee 4 Filter Water spray pipe F Pump From Filter OUT To Tee 4 Water spray pipe R Water spray tank Strainer Tee 2 Tee 3 Tee 4 Drain valve Drain valve 3 way valve Check valve Drain valve Arrow symbols show the hose connection and the d...

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Page 307: ...direction of the flow of the water Pipe R Water spray pipe R Check valve Drain valve Drain valve Tee 2 Tee 3 DETAIL OF WATER SPRAY PUMP Hose Pump OUT Tee 2 Tee 1 Drain valve Hose Tee 1 Pump IN Water spray diagram Water spray pipe F Water spray pipe R OUT IN OUT IN Water spray tank Water spray pump Tee 1 Tee 1 Filter From Filter OUT To Tee 4 Tee 2 Tee 3 Tee 4 Drain valve Drain valve 3 way valve Che...

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Page 309: ...pipe Liquid spray pump Filter IN Filter OUT Tee Drain valve Filter Drain cap Drain valve Drain valve The letters and figures such as Filter IN and Pump OUT show each port Arrow symbols show the hose connection and the direction of the flow of the liquid Pump IN Pump OUT Liquid spray tank Liquid spray pipe A A SECTION A A Pump Liquid spray pump Liquid spray pipe Hose Liquid tank Filter IN Tee Filte...

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Page 311: ...INSPECTION AND ADJUSTMENT ...

Page 312: ......

Page 313: ...an V belt or exhaust system parts while the engine is running may cause serious injury 1 2 Preparation for Inspection and Adjustment Prepare the necessary measuring instruments In addition particularly when measuring pressure values make sure to prepare the appropriate hoses adapters and a plug removal tool for the pressure reading port Make sure that the instruments to be used operate normally Wh...

Page 314: ...y pressing parking brake switch button Set propulsion speed change switch to 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 applied With propulsion load at maximum slowly move F R lever to the side to be measured Read pressure indicated by pressure gauge After measuring prom...

Page 315: ...If pressure still deviates from maximum circuit pressure range after valve is disassembled and cleaned replace high pressure relief valve After inspection measure pressure again and check that pressure reaches maximum circuit pressure range N m Plug 70 N m 52 lbf ft NOTICE Carefully disassemble and reassemble after taking steps to prevent foreign material from getting in High pressure relief valve...

Page 316: ...port 3 and 11 of propulsion pump Attach pressure gauge with adapter ⓗ Adapter ⓗ 9 16 18UNF Pressure gauge 0 to 50 MPa 0 to 7 250 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Start the engine and set throttle lever to Full Read pressure indicated by pressure gauge Standard charge relief valve setting 1 9 0 7 MPa 276 100 psi The numbers 3 and 11 appeari...

Page 317: ...rclockwise Pressure drop Pressure change rate 0 19 MPa turn 27 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 and clean charge relief valve If a scratch is found on seat replace charge relief valve After adjustment measure pressure again and chec...

Page 318: ...asurement 50 5 C 122 9 F Disconnect hose 1 from propulsion motor F Attach pressure gauge through adapter ⓜ Adapter ⓜ G1 4 Pressure gauge 0 to 5 MPa 0 to 725 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Set propulsion speed change switch to Start the engine and set throttle lever to Full Read pressure indicated by pressure gauge Standard charge relief ...

Page 319: ...t 50 5 C 122 9 F Disconnect hose 1 and 2 from propulsion 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 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 Read brake release pressure indicated by pres...

Page 320: ...apter ⓜ Adapter ⓜ G1 4 Pressure gauge 0 to 5 MPa 0 to 725 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Start the engine and set throttle lever to Full Release parking brake by pressing parking brake switch button Read brake release pressure indicated by pressure gauge Brake release pressure 1 5 MPa 218 psi TW354 09001 3 4 m PG002002 ...

Page 321: ...0 to 50 MPa 0 to 7 250 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button SW354 ROPS Set vibratory drum select switch to Set vibration mode change switch to Start the engine and set throttle lever to Full Press F R lever vibration switch ON Slowly move F R lever to forward or reverse side Read pressure gauge for maximum value of vibrator circuit pressure Tu...

Page 322: ...ssure gauge with hose ⓢ and connector ⓤ Coupling 9 16 18UNF M16 Adapter for hose ⓢ M16 P 2 0 Pressure gauge connector ⓤ M16 G3 8 Pressure gauge 0 to 25 MPa 0 to 3 625 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Start the engine and set throttle lever to Full Turn steering wheel to operate relief valve Read pressure indicated by pressure gauge Standar...

Page 323: ...removed relief valve for trapped dirt scratches on its seat and other abnormalities If trapped dirt is present disassemble and clean relief valve If a scratch or any other abnormality is found on seat replace relief valve After inspection measure pressure again and check that pressure reaches standard maximum circuit pressure range NOTICE Carefully disassemble and reassemble after taking steps to ...

Page 324: ...si Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Set propulsion speed change switch to 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 applied With propulsion load at maximum measure pressure when speed change switch is and and F R le...

Page 325: ...onfirm that F R lever is N Apply parking brake by pressing parking brake switch button Set propulsion speed change switch to 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 applied With propulsion load at maximum measure pressure when speed change switch is and and F R lever ...

Page 326: ...parking brake by pressing parking brake switch button Set propulsion speed change switch to 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 applied With propulsion load at maximum measure pressure when speed change switch is and and F R lever is N F and R respectively Allowab...

Page 327: ...ever is N Apply parking brake by pressing parking brake switch button SW354 ROPS Set vibratory drum select switch to Set vibration mode change switch to Start the engine and set throttle lever to Full Press F R lever vibration switch ON Slowly move F R lever to forward or reverse side Read pressure indicated by pressure gauge Press F R lever vibration switch OFF or move back F R lever to N as soon...

Page 328: ...F R lever is N Apply parking brake by pressing parking brake switch button Set vibration mode change switch to Start the engine and set throttle lever to Full Press F R lever vibration switch ON Slowly move F R lever to forward or reverse side Measure pressure when vibration Lo Hi change switch is and respectively Press F R lever vibration switch OFF or move back F R lever to N as soon as measurem...

Page 329: ... throttle lever 1 to IDLE Attach control cable 4 to throttle lever 1 Attach control cable 4 to fuel injection pump s control lever Start the engine Loosen lock nut 3 Using stopper bolt 2 adjust so that standard minimum no load rotational speed is achieved Standard minimum no load rotational speed 1 050 50 rpm Using lock nut 3 firmly secure stopper bolt 2 Set throttle lever 1 to FULL Loosen lock nu...

Page 330: ...7 and set operating force at center of throttle lever 1 knob to standard operating force Do not turn nut to the loosening direction Standard operating force 44 1 6 86 N 9 9 1 5 lbf NOTICE In case of loosen nut 7 replace it with a new one SW354 09031 A A SW354 09017 7 SECTION A A 1 ...

Page 331: ...ribed below N maximum F and maximum R positions of F R lever 1 are positioned by notches Set F R lever in N Attach control cable 2 to F R lever Specified dimension a 208 mm 8 19 in Attach control cable to propulsion pump control lever 3 Specified dimension b 208 mm 8 19 in Confirm the strokes of propulsion pump control lever 3 Specified dimension c 24 mm 0 94 in Specified dimension d 23 mm 0 91 in...

Page 332: ... 3 4 9 N 7 7 1 1 lbf After adjustment fix set screw 6 with lock nut 7 Loosen lock nut 5 and set screw 4 to match operating force of lever to standard operating force 14 7 N when getting over notch at center of F R lever knob Operating force to move lever over notch 49 4 9 N 11 1 1 lbf After adjustment fix set screw 4 with lock nut 5 SW354 09020 1 A A SW354 09021 6 7 B B VIEW A A 4 5 SW354 09022 SE...

Page 333: ... 30 Leave manual brake release port open to atmosphere brake lock state Measure distance L1 between brake cover 2 and bolt 3 head with depth calipers Measure distance L2 up to bolt 3 head with depth calipers when complete release pressure is applied to manual brake release port Quantity of brake stroke L2 L1 NOTICE When brake stroke exceeds replacement standard shown below replace all friction pla...

Page 334: ...by pressing parking brake switch button Set propulsion speed change switch to 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 applied With propulsion load at maximum slowly move F R lever to the side to be measured Read pressure indicated by pressure gauge After measuring pro...

Page 335: ... pressure still deviates from maximum circuit pressure range after valve is disassembled and cleaned replace high pressure relief valve After inspection measure pressure again and check that pressure reaches maximum circuit pressure range N m Plug 70 N m 52 lbf ft NOTICE Carefully disassemble and reassemble after taking steps to prevent foreign material from getting in High pressure relief valve S...

Page 336: ... port 3 and 11 of propulsion pump Attach pressure gauge with adapter ⓗ Adapter ⓗ 9 16 18UNF Pressure gauge 0 to 50 MPa 0 to 7 250 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Start the engine and set throttle lever to Full Read pressure indicated by pressure gauge Standard charge relief valve setting 1 8 0 7 MPa 261 100 psi The numbers 3 and 11 appear...

Page 337: ...lockwise Pressure drop Pressure change rate 0 19 MPa turn 27 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 and clean charge relief valve If a scratch is found on seat replace charge relief valve After adjustment measure pressure again and check ...

Page 338: ...easurement 50 5 C 122 9 F Disconnect hose 1 from propulsion motor F Attach pressure gauge through adapter ⓜ Adapter ⓜ G1 4 Pressure gauge 0 to 5 MPa 0 to 725 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Set propulsion speed change switch to Start the engine and set throttle lever to Full Read pressure indicated by pressure gauge Standard charge relief...

Page 339: ...r ⓟ G1 2 Pressure gauge 0 to 50 MPa 0 to 7 250 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Set vibratory drum select switch to Set vibration mode change switch to Start the engine and set throttle lever to Full Press F R lever vibration switch ON Slowly move F R lever to forward or reverse side Read pressure gauge for maximum value of vibrator circui...

Page 340: ...essure gauge with hose ⓢ and connector ⓤ Coupling 9 16 18UNF M16 Adapter for hose ⓢ M16 P 2 0 Pressure gauge connector ⓤ M16 G3 8 Pressure gauge 0 to 25 MPa 0 to 3 625 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Start the engine and set throttle lever to Full Turn steering wheel to operate relief valve Read pressure indicated by pressure gauge Standa...

Page 341: ...oved relief valve for trapped dirt scratches on its seat and other abnormalities If trapped dirt is present disassemble and clean relief valve If a scratch or any other abnormality is found on seat replace relief valve After inspection measure pressure again and check that pressure reaches standard maximum circuit pressure range NOTICE Carefully disassemble and reassemble after taking steps to pre...

Page 342: ...psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Set propulsion speed change switch to 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 applied With propulsion load at maximum measure pressure when speed change switch is and and F R l...

Page 343: ...CE When fixing potentiometer 1 position the potentiometer in the direction shown mounting the potentiometer parallel to the base 5 Tighten screws 4 with wire 3 Set throttle lever 6 to IDOL Adjust engine rotational speed to standard value Engine rotational speed 1 000 50 min 1 Set throttle lever to FULL Loosen lock nut 7 and adjust engine rotational speed to standard value with stopper bolt 8 Engin...

Page 344: ...2 Adjustment of Operating Force Tighten nut 9 and set operating force at center of throttle lever 6 knob to standard operating force Do not turn nut to the loosening direction Standard operating force 45 10 N 10 2 lbf NOTICE In case of loosen nut 9 replace it with a new one SW504 ...

Page 345: ...th procedure described below N maximum F and maximum R positions of F R lever 1 are positioned by notches Set F R lever in N Attach control cable 2 to F R lever Specified dimension a 210 mm 8 27 in Attach control cable 2 to propulsion pump control lever 3 Specified dimension b 198 mm 7 80 in Confirm the strokes of propulsion pump control lever 3 Specified dimension c 24 mm 0 94 in SW354 09018 R N ...

Page 346: ...KE RELEASE PRESSURE Refer to P 9 007 MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE Refer to P 9 013 MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE Refer to P 9 016 PROCEDURE FOR MEASURING QUANTITY OF BRAKE PISTON STROKE REPLACEMENT STANDARD Refer to P 9 021 SW504 ...

Page 347: ...TROUBLESHOOTING ...

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Page 349: ...ay cause a serious accident When inspecting the engine make sure to exchange the appropriate cues and hand signal with the person at the operator station to avoid any accidents CAUTION Before inspecting inside of the engine compartment always stop the engine Contact with the fan V belt or exhaust system parts while the engine is running may cause serious injury 1 2 Important Information for Troubl...

Page 350: ...r full details of the trouble ask questions 3 Verify the trouble by warming up the machine and operating it Check the problem yourself 4 Identify the problem with either a mechanical hydraulic or electrical system source 5 Isolate the problem to a particular component or circuit 6 Eliminate the simplest or easiest to check possibilities first to prevent unnecessary disassembly of components 7 Foll...

Page 351: ...nal condition Before making a diagnosis check related connectors for faulty connections Check by disconnecting and reconnecting related connectors several times Before proceeding to the next step be sure to return the disconnected connectors to their original condition When diagnosing a circuit measuring the voltage resistance continuity and current move related wiring and connectors several times...

Page 352: ... equipment A measuring resistance between terminals 1 and 3 1 2 3 3 4 2 5 1 2 3 1 2 3 1 TS 10002 Equipment A Connector Harness Equipment A Ohmmeter tester Equipment B Main power source of equipment B Signal from equipment A Power to equipment A Ground of equipment A Inspection procedure Disconnect the connector of equipment A Connect the test probe to connector terminal 1 of equipment A and the te...

Page 353: ...rness such as broken wire 10 Ω or higher measured value 1 3 Measuring resistance of grounding wire measuring resistance between terminal 5 of equipment B and ground 1 2 3 4 5 5 1 TS 10004 Connector A Harness Ohmmeter tester Main power source of equipment B Equipment B Battery Equipment B Inspection procedure Disconnect the connector of equipment B Connect the test probe to connector terminal 5 of ...

Page 354: ...A Power to equipment A Equipment B Equipment B Equipment A TS 10005 Inspection procedure Connect the connectors of equipment A and that of equipment B Connect the test probe to connector terminal 3 of equipment A and the test probe to connector terminal 1 of equipment A and measure the voltage Note that reversing the connector terminals between the probes and changes the result of the measurement ...

Page 355: ...onnected in position contact the tester probes to the terminals without disconnecting the connector The following methods are available Measurement using a test harness Prepare the test harness for the measurement Measurement from the backside of connector Insert a wire from the backside of the connector Measurement on a lead cable Remove the bundling tape from the harness to separate each cable a...

Page 356: ... procedure Disconnect the connector of equipment A and connect the test harness Connect the test probe to connector terminal 1 harness side of equipment A and the test probe to connector terminal 1 equipment side of equipment A and measure the current Note that reversing the connector terminals between the probes and changes the result of the measurement Be sure to connect the probe to the power s...

Page 357: ...of burning or of an odor investigate as described follows 2 3 How to find cause of failure when fuse blown is reproduced Turn the starter switch OFF and remove the connector from the load valve pump Referring to the circuit diagram remove electrical parts that are connected to the circuit such as relays timers and diodes Turn the starter switch ON and see whether the conditions can be reproduced f...

Page 358: ...dentify the location section to which 24 V or 12 V reaches Then replace the harness or take other action 5 Solenoid valve inspection Check ON OFF operation by sound Conduct without running the engine If you run the engine you cannot hear the sound of operation Sound heard The electrical system is normal No sound heard Check with a tester Continuity Turn the starter switch OFF temporarily disconnec...

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Page 360: ...RB 3BY 5WG 8WY R B B AV60 13 14 12 11 5 2 10 9 8 7 6 4 3 1 2Y 5WR B B 3BR WL 8WY 2Y 5BR 3W 3W Y WR 5WR 3W WL YW L g W LgR WG 10 WG 5WG 10 5WG 5WR 5W BrB NO BR COM B B E L B IG S B 3 4 5 6 B BR ACC R2 R1 C 5R 8 5R STOP GY RY RY RB 12V 80AH 95D31R B RW YL FUSE BOX FUSE FUEL PUMP FOOT BRAKE SWITCH F L STARTER MOTOR SOL ENGINE STOP SOLENOID STARTER SWITCH F L BATTERY RELAY ALTERNATOR BATTERY PARKING B...

Page 361: ...arter switch is faulty Replace starter switch 3 Starter Motor 1 When starter switch is ON measure voltage between starter motor terminal B and chassis ground Standard voltage 12 V or more 2 When starter switch is START measure voltage between starter motor terminal S and chassis ground Standard voltage 12 V or more If above items 1 and 2 are OK and starter motor does not run starter motor is fault...

Page 362: ...RB 3BY 5WG 8WY R B B AV60 13 14 12 11 5 2 10 9 8 7 6 4 3 1 2Y 5WR B B 3BR WL 8WY 2Y 5BR 3W 3W Y WR 5WR 3W WL YW L g W LgR WG 10 WG 5WG 10 5WG 5WR 5W BrB NO BR COM B B E L B IG S B 3 4 5 6 B BR ACC R2 R1 C 5R 8 5R STOP GY RY RY RB 12V 80AH 95D31R B RW YL FUSE BOX FUSE FUEL PUMP FOOT BRAKE SWITCH F L STARTER MOTOR SOL ENGINE STOP SOLENOID STARTER SWITCH F L BATTERY RELAY ALTERNATOR BATTERY PARKING B...

Page 363: ...measure voltage between parking interlock relay terminal 3 inlet wire W and chassis ground Standard voltage 12 V or more 3 When starter switch is START measure voltage between parking interlock relay terminal 5 outlet wire BW and chassis ground Standard voltage 12 V or more If above items 1 and 2 are OK and item 3 is NG parking interlock relay is faulty Replace parking interlock relay 7 F R Lever ...

Page 364: ...RB 3BY 5WG 8WY R B B AV60 13 14 12 11 5 2 10 9 8 7 6 4 3 1 2Y 5WR B B 3BR WL 8WY 2Y 5BR 3W 3W Y WR 5WR 3W WL YW L g W LgR WG 10 WG 5WG 10 5WG 5WR 5W BrB NO BR COM B B E L B IG S B 3 4 5 6 B BR ACC R2 R1 C 5R 8 5R STOP GY RY RY RB 12V 80AH 95D31R B RW YL FUSE BOX FUSE FUEL PUMP FOOT BRAKE SWITCH F L STARTER MOTOR SOL ENGINE STOP SOLENOID STARTER SWITCH F L BATTERY RELAY ALTERNATOR BATTERY PARKING B...

Page 365: ...starter motor runs generally trouble is caused by that fuel is not supplied supply amount of fuel is extremely low or selection of fuel is not appropriate Check that fuel is supplied to inlet of fuel pump Reference Fig 2 2 1 Check point Check Cause Action 1 Fuel Pump When starter switch is ON measure voltage between fuel pump terminal inlet wire RB and chassis ground Standard voltage 12 V or more ...

Page 366: ...RB 3BY 5WG 8WY R B B AV60 13 14 12 11 5 2 10 9 8 7 6 4 3 1 2Y 5WR B B 3BR WL 8WY 2Y 5BR 3W 3W Y WR 5WR 3W WL YW L g W LgR WG 10 WG 5WG 10 5WG 5WR 5W BrB NO BR COM B B E L B IG S B 3 4 5 6 B BR ACC R2 R1 C 5R 8 5R STOP GY RY RY RB 12V 80AH 95D31R B RW YL FUSE BOX FUSE FUEL PUMP FOOT BRAKE SWITCH F L STARTER MOTOR SOL ENGINE STOP SOLENOID STARTER SWITCH F L BATTERY RELAY ALTERNATOR BATTERY PARKING B...

Page 367: ...er starting engine measure voltage between alternator terminal B wire WY and chassis ground Standard voltage At least intermediate engine speed 14 V or more If voltage is lower than standard alternator is faulty If voltage is normal and battery is not charged battery is faulty Replace alternator or battery 2 2 5 Glow plugs is not heated Engine starting performance is bad in cold weather Reference ...

Page 368: ...RB 3BY 5WG 8WY R B B AV60 13 14 12 11 5 2 10 9 8 7 6 4 3 1 2Y 5WR B B 3BR WL 8WY 2Y 5BR 3W 3W Y WR 5WR 3W WL YW L g W LgR WG 10 WG 5WG 10 5WG 5WR 5W BrB NO BR COM B B E L B IG S B 3 4 5 6 B BR ACC R2 R1 C 5R 8 5R STOP GY RY RY RB 12V 80AH 95D31R B RW YL FUSE BOX FUSE FUEL PUMP FOOT BRAKE SWITCH F L STARTER MOTOR SOL ENGINE STOP SOLENOID STARTER SWITCH F L BATTERY RELAY ALTERNATOR BATTERY PARKING B...

Page 369: ... Check point Check Cause Action 1 F R Lever Switch When starter switch is OFF and F R lever is F or R check continuity between F R lever switch terminal wire RY and terminal wire LgR There is no continuity in normal condition If there is continuity F R lever switch is faulty Replace F R lever switch ...

Page 370: ... 80AH 95D31R B RW YL FUSE PARKING BRAKE SOLENOID SOL SPEED CHANGE SWITCH SOL SPEED CHANGE SOLENOID F L STARTER SWITCH F L BATTERY RELAY BATTERY PARKING BRAKE SWITCH 65A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 65A TO PARKING INTERLOCK RELAY TO COMBINATION METER TO BRAKE LAMP RELAY ST ON OFF HEAT C BR ACC R2 R1 B STARTER SWITCH B BR R2 R1 ACC C 3 LgR CONNECTION SPEED 1 2 1 3 SPEED CHANGE SWITCH ...

Page 371: ... measure voltage between parking brake switch terminal 1 inlet wire RW and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between parking brake switch terminal 3 outlet wire WB and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG parking brake switch is faulty Replace parking brake switch 3 Foot Brake Switch 1 When starte...

Page 372: ... 80AH 95D31R B RW YL FUSE PARKING BRAKE SOLENOID SOL SPEED CHANGE SWITCH SOL SPEED CHANGE SOLENOID F L STARTER SWITCH F L BATTERY RELAY BATTERY PARKING BRAKE SWITCH 65A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 65A TO PARKING INTERLOCK RELAY TO COMBINATION METER TO BRAKE LAMP RELAY ST ON OFF HEAT C BR ACC R2 R1 B STARTER SWITCH B BR R2 R1 ACC C 3 LgR CONNECTION SPEED 1 2 1 3 SPEED CHANGE SWITCH ...

Page 373: ...r switch is ON measure voltage between speed change switch terminal 1 inlet wire RY and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between speed change switch terminal 2 outlet wire LgW and chassis ground Standard voltage 12 V or more If above item 1 is OK and 2 is NG speed change switch is faulty Replace speed change switch 3 Harness Connecting Betwee...

Page 374: ... 80AH 95D31R B RW YL FUSE PARKING BRAKE SOLENOID SOL SPEED CHANGE SWITCH SOL SPEED CHANGE SOLENOID F L STARTER SWITCH F L BATTERY RELAY BATTERY PARKING BRAKE SWITCH 65A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 65A TO PARKING INTERLOCK RELAY TO COMBINATION METER TO BRAKE LAMP RELAY ST ON OFF HEAT C BR ACC R2 R1 B STARTER SWITCH B BR R2 R1 ACC C 3 LgR CONNECTION SPEED 1 2 1 3 SPEED CHANGE SWITCH ...

Page 375: ... parking brake switch terminal 3 outlet wire WB and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG parking brake switch is faulty Replace parking brake switch 3 Foot Brake Switch 1 When starter switch is ON measure voltage between foot brake switch terminal inlet wire RY and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltag...

Page 376: ... 80AH 95D31R B RW YL FUSE PARKING BRAKE SOLENOID SOL SPEED CHANGE SWITCH SOL SPEED CHANGE SOLENOID F L STARTER SWITCH F L BATTERY RELAY BATTERY PARKING BRAKE SWITCH 65A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 65A TO PARKING INTERLOCK RELAY TO COMBINATION METER TO BRAKE LAMP RELAY ST ON OFF HEAT C BR ACC R2 R1 B STARTER SWITCH B BR R2 R1 ACC C 3 LgR CONNECTION SPEED 1 2 1 3 SPEED CHANGE SWITCH ...

Page 377: ...ng brake switch terminal 3 outlet wire WB and chassis ground There is no electricity in normal condition If there is electricity parking brake switch is faulty Replace parking brake switch 3 Foot Brake Switch When starter switch is ON measure voltage between foot brake switch terminal outlet wire RW and chassis ground There is no electricity in normal condition If there is electricity foot brake s...

Page 378: ...ER SWITCH F L BATTERY RELAY BATTERY SOL SOL 65A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 65A TO INTERLOCK RELAY TO COMBINATION METER B B VIBRATOR SOLENOID SOL 2 2 1 1 LOW HI 2 5 4 6 1 3 47 48 46 BrR RL 23 LgY LgR SOL VIBRATION Lo Hi CHANGE SWITCH VIBRATOR SOLENOID 46 BrR 49 LgB B B B B 46 47 LgR BrR 23 RL VIBRATOR SOLENOID R VIBRATOR SOLENOID F VIBRATORY DRUM SELECT SWITCH SOL SOL R2 R1 ACC C L...

Page 379: ...Standard voltage 12 V or more If above item 1 is OK and item 2 is NG vibration mode select switch is faulty Replace vibration mode select switch 3 Vibratory Drum Select Switch SW354 ROPS 1 When starter switch is ON measure voltage between vibratory drum select switch terminal 1 inlet wire RL terminal 4 inlet wire RL and chassis ground Standard voltage 12 V or more 2 When starter switch is ON and v...

Page 380: ...ER SWITCH F L BATTERY RELAY BATTERY SOL SOL 65A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 65A TO INTERLOCK RELAY TO COMBINATION METER B B VIBRATOR SOLENOID SOL 2 2 1 1 LOW HI 2 5 4 6 1 3 47 48 46 BrR RL 23 LgY LgR SOL VIBRATION Lo Hi CHANGE SWITCH VIBRATOR SOLENOID 46 BrR 49 LgB B B B B 46 47 LgR BrR 23 RL VIBRATOR SOLENOID R VIBRATOR SOLENOID F VIBRATORY DRUM SELECT SWITCH SOL SOL R2 R1 ACC C L...

Page 381: ...er switch 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 inlet wire BrY and chassis ground Standard voltage 12 V or more 3 When starter switch is ON check continuity between vibrator relay terminal B inlet wire BrR and terminal D outlet wire B There ...

Page 382: ...ER SWITCH F L BATTERY RELAY BATTERY SOL SOL 65A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 65A TO INTERLOCK RELAY TO COMBINATION METER B B VIBRATOR SOLENOID SOL 2 2 1 1 LOW HI 2 5 4 6 1 3 47 48 46 BrR RL 23 LgY LgR SOL VIBRATION Lo Hi CHANGE SWITCH VIBRATOR SOLENOID 46 BrR 49 LgB B B B B 46 47 LgR BrR 23 RL VIBRATOR SOLENOID R VIBRATOR SOLENOID F VIBRATORY DRUM SELECT SWITCH SOL SOL R2 R1 ACC C L...

Page 383: ...F R lever vibration switch pressed check continuity between vibrator relay terminal H inlet wire Br and chassis ground There is continuity in normal condition 4 When starter switch is ON and F R lever vibration switch pressed check continuity between vibrator relay terminal B inlet wire BrR and terminal D outlet wire B There is continuity in normal condition If above items 1 2 and 3 are OK and ite...

Page 384: ...ER SWITCH F L BATTERY RELAY BATTERY SOL SOL 65A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 65A TO INTERLOCK RELAY TO COMBINATION METER B B VIBRATOR SOLENOID SOL 2 2 1 1 LOW HI 2 5 4 6 1 3 47 48 46 BrR RL 23 LgY LgR SOL VIBRATION Lo Hi CHANGE SWITCH VIBRATOR SOLENOID 46 BrR 49 LgB B B B B 46 47 LgR BrR 23 RL VIBRATOR SOLENOID R VIBRATOR SOLENOID F VIBRATORY DRUM SELECT SWITCH SOL SOL R2 R1 ACC C L...

Page 385: ...ter switch is ON and vibratory drum select switch is in measure voltage between vibratory drum select switch terminal 6 outlet wire LgR terminal 3 outlet wire LgB and chassis ground There is no electricity in normal condition 4 When starter switch is ON and vibratory drum select switch is in measure voltage between vibratory drum select switch terminal 3 outlet wire LgB and chassis ground Standard...

Page 386: ...ER SWITCH F L BATTERY RELAY BATTERY SOL SOL 65A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 65A TO INTERLOCK RELAY TO COMBINATION METER B B VIBRATOR SOLENOID SOL 2 2 1 1 LOW HI 2 5 4 6 1 3 47 48 46 BrR RL 23 LgY LgR SOL VIBRATION Lo Hi CHANGE SWITCH VIBRATOR SOLENOID 46 BrR 49 LgB B B B B 46 47 LgR BrR 23 RL VIBRATOR SOLENOID R VIBRATOR SOLENOID F VIBRATORY DRUM SELECT SWITCH SOL SOL R2 R1 ACC C L...

Page 387: ...is ground Standard voltage 12 V or more 2 When starter switch is ON and vibration Lo Hi change switch is measure voltage between vibration Lo Hi change switch terminal 3 outlet wire LgR and chassis ground Standard voltage 12 V or more 3 When starter switch is ON and vibration Lo Hi change switch is measure voltage between vibration Lo Hi change switch terminal 2 outlet wire LgY and chassis ground ...

Page 388: ...L BATTERY RELAY BATTERY WATER SPRAY PUMP 65A 45A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 65A TO INTERLOCK RELAY TO COMBINATION METER 3 4 2 1 WATER SPRAY TIMER 70 P 70 P 70 P B 39 LW CONNECTION 1 3 4 5 1 3 4 6 1 2 4 6 VIBRATION CONT AUTO WATER SPRAY MODE SELECT SWITCH ROPS type TW354 504 Except ROPS type ST ON OFF HEAT C BR ACC R2 R1 B STARTER SWITCH g B G e 42 18 39 LW B 3LY 3LB WATER SPRAY RE...

Page 389: ... between water spray relay terminal g inlet wire LW and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between water spray relay terminal B 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 G outlet wire LB and chassis ground Standard voltage 12 V or more If above i...

Page 390: ...L BATTERY RELAY BATTERY WATER SPRAY PUMP 65A 45A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 65A TO INTERLOCK RELAY TO COMBINATION METER 3 4 2 1 WATER SPRAY TIMER 70 P 70 P 70 P B 39 LW CONNECTION 1 3 4 5 1 3 4 6 1 2 4 6 VIBRATION CONT AUTO WATER SPRAY MODE SELECT SWITCH ROPS type TW354 504 Except ROPS type ST ON OFF HEAT C BR ACC R2 R1 B STARTER SWITCH g B G e 42 18 39 LW B 3LY 3LB WATER SPRAY RE...

Page 391: ...tlet wire P If above item 1 is OK and item 2 is NG water spray mode select switch is faulty Replace water spray mode select switch 2 Water Spray Timer ROPS type 1 When starter switch is ON measure voltage between water spray timer terminal 1 and 3 inlet wire P and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between water spray timer terminal 4 outlet wi...

Page 392: ...L BATTERY RELAY BATTERY WATER SPRAY PUMP 65A 45A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 65A TO INTERLOCK RELAY TO COMBINATION METER 3 4 2 1 WATER SPRAY TIMER 70 P 70 P 70 P B 39 LW CONNECTION 1 3 4 5 1 3 4 6 1 2 4 6 VIBRATION CONT AUTO WATER SPRAY MODE SELECT SWITCH ROPS type TW354 504 Except ROPS type ST ON OFF HEAT C BR ACC R2 R1 B STARTER SWITCH g B G e 42 18 39 LW B 3LY 3LB WATER SPRAY RE...

Page 393: ...ulty Replace liquid spray pump 2 Liquid Spray Switch 1 When starter switch is ON measure voltage between liquid spray switch terminal 1 inlet wire BrR and chassis ground Standard voltage 12 V or more 2 When starter switch is ON and liquid spray switch pressed measure voltage between liquid spray switch terminal 2 outlet wire BrW and chassis ground Standard voltage 12 V or more If above item 1 is O...

Page 394: ...USE BRAKE LAMP RELAY TURN SIGNAL LAMP L 21W TAIL LAMP 5W STOP LAMP 21W STOP LAMP 21W TAIL LAMP 5W TURN SIGNAL LAMP R 21W LIGHTING SWITCH F L FLASHER UNIT F L FLOOD LAMP 55W TURN SIGNAL SWITCH BATTERY RELAY BATTERY TURN SIGNAL LAMP L 21W TURN SIGNAL LAMP R 21W HEAD LAMP L 55W HEAD LAMP R 55W 21W 21W 5W 21W 21W 5W 65A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 65A TO COMBINATION METER GB GR 36 GY 3...

Page 395: ...OK and item 2 is NG lighting switch is faulty Replace lighting switch 4 Harness Connecting Between Terminals Measure resistance of harness connecting between terminals Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 2 6 2 Flood lamp does not light Reference Fig 2 6 1 Check point Check Cause Action 1 Each Bulb Check that none of lamp bulbs is b...

Page 396: ...USE BRAKE LAMP RELAY TURN SIGNAL LAMP L 21W TAIL LAMP 5W STOP LAMP 21W STOP LAMP 21W TAIL LAMP 5W TURN SIGNAL LAMP R 21W LIGHTING SWITCH F L FLASHER UNIT F L FLOOD LAMP 55W TURN SIGNAL SWITCH BATTERY RELAY BATTERY TURN SIGNAL LAMP L 21W TURN SIGNAL LAMP R 21W HEAD LAMP L 55W HEAD LAMP R 55W 21W 21W 5W 21W 21W 5W 65A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 65A TO COMBINATION METER GB GR 36 GY 3...

Page 397: ...NG flasher unit is faulty Replace flasher unit 3 Turn Signal Switch 1 When starter switch is ON and turn signal switch lever is moved measure voltage between turn signal switch terminal inlet wire GY and chassis ground Standard voltage 12 V or more with constant intervals 2 When starter switch is ON and turn signal switch lever is moved measure voltage between turn signal switch terminals and chas...

Page 398: ...USE BRAKE LAMP RELAY TURN SIGNAL LAMP L 21W TAIL LAMP 5W STOP LAMP 21W STOP LAMP 21W TAIL LAMP 5W TURN SIGNAL LAMP R 21W LIGHTING SWITCH F L FLASHER UNIT F L FLOOD LAMP 55W TURN SIGNAL SWITCH BATTERY RELAY BATTERY TURN SIGNAL LAMP L 21W TURN SIGNAL LAMP R 21W HEAD LAMP L 55W HEAD LAMP R 55W 21W 21W 5W 21W 21W 5W 65A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 65A TO COMBINATION METER GB GR 36 GY 3...

Page 399: ...r more with constant intervals 2 When starter switch is ON measure voltage between hazard switch terminal 5 outlet wire GR and chassis ground Standard voltage 12 V or more with constant intervals 3 When starter switch is ON measure voltage between hazard switch terminal 2 outlet wire GB and chassis ground Standard voltage 12 V or more with constant intervals If above item 1 is OK and item 2 or 3 i...

Page 400: ...USE BRAKE LAMP RELAY TURN SIGNAL LAMP L 21W TAIL LAMP 5W STOP LAMP 21W STOP LAMP 21W TAIL LAMP 5W TURN SIGNAL LAMP R 21W LIGHTING SWITCH F L FLASHER UNIT F L FLOOD LAMP 55W TURN SIGNAL SWITCH BATTERY RELAY BATTERY TURN SIGNAL LAMP L 21W TURN SIGNAL LAMP R 21W HEAD LAMP L 55W HEAD LAMP R 55W 21W 21W 5W 21W 21W 5W 65A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 65A TO COMBINATION METER GB GR 36 GY 3...

Page 401: ...lty Replace foot brake switch 3 Brake Lamp Relay 1 When starter switch is ON while foot brake is depressed measure voltage between brake lamp relay terminal a inlet wire BrY and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between brake lamp relay terminal c inlet wire RY and chassis ground Standard voltage 12 V or more 3 When starter switch is ON while ...

Page 402: ... NO 0 FUSE LIGHTING SWITCH F L STARTER SWITCH F L BATTERY RELAY ALTERNATOR BATTERY FUEL GAUGE UNIT ENGINE OIL PRESSURE SWITCH THERMO UNIT HYDRAULIC OIL FILTER SWITCH COMBINATION METER TACHO METER SENSOR FUSE 65A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 65A 5A TO STARTER MOTOR TO HEAD LAMP TAIL LAMP TO FLOOD LAMP FUSE BOX BR NO Power excitation circuit 5V power supply Movement Movement Movement ...

Page 403: ...chassis ground Standard voltage 12 V or more If above items 1 and 2 are OK and combination meter does not turn on combination meter is faulty Replace combination meter 2 6 7 Combination meter warning lamp or indicator lamp is abnormal Reference Fig 2 6 2 Check point Check Cause Action 1 Combination Meter Lamp check 1 When starter switch is ON measure voltage between combination meter terminal wire...

Page 404: ... NO 0 FUSE LIGHTING SWITCH F L STARTER SWITCH F L BATTERY RELAY ALTERNATOR BATTERY FUEL GAUGE UNIT ENGINE OIL PRESSURE SWITCH THERMO UNIT HYDRAULIC OIL FILTER SWITCH COMBINATION METER TACHO METER SENSOR FUSE 65A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 65A 5A TO STARTER MOTOR TO HEAD LAMP TAIL LAMP TO FLOOD LAMP FUSE BOX BR NO Power excitation circuit 5V power supply Movement Movement Movement ...

Page 405: ... 1 and 2 are OK and pluse is NG in item 3 tachometer sensor is faulty If above items 1 and 2 are OK and tachometer reading is NG in item 3 combination meter is faulty Replace tachometer sensor or combination meter 2 Harness Connecting Between Terminals Measure resistance of harness connecting between terminals Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or r...

Page 406: ... NO 0 FUSE LIGHTING SWITCH F L STARTER SWITCH F L BATTERY RELAY ALTERNATOR BATTERY FUEL GAUGE UNIT ENGINE OIL PRESSURE SWITCH THERMO UNIT HYDRAULIC OIL FILTER SWITCH COMBINATION METER TACHO METER SENSOR FUSE 65A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 65A 5A TO STARTER MOTOR TO HEAD LAMP TAIL LAMP TO FLOOD LAMP FUSE BOX BR NO Power excitation circuit 5V power supply Movement Movement Movement ...

Page 407: ...g between terminals Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 2 6 11 Fuel meter is abnormal Reference Fig 2 6 2 Check point Check Cause Action 1 Fuel Gauge Unit Disconnect harness and measure resistance of fuel gauge unit Standard resistance 13 5 Ω with float in F 80 0 Ω with float in E If resistance is abnormal fuel gauge unit is faulty...

Page 408: ... NO 0 FUSE LIGHTING SWITCH F L STARTER SWITCH F L BATTERY RELAY ALTERNATOR BATTERY FUEL GAUGE UNIT ENGINE OIL PRESSURE SWITCH THERMO UNIT HYDRAULIC OIL FILTER SWITCH COMBINATION METER TACHO METER SENSOR FUSE 65A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 65A 5A TO STARTER MOTOR TO HEAD LAMP TAIL LAMP TO FLOOD LAMP FUSE BOX BR NO Power excitation circuit 5V power supply Movement Movement Movement ...

Page 409: ... ground terminal wire B Starter switch ACC terminal wire No 11 inlet wire BrB and ground terminal wire B Standard voltage 12 V or more 2 When starter switch is ON measure voltage between combination meter hydraulic oil filter warning terminal outlet wire No 53 wire LR and chassis ground Standard voltage 12 V or more If above items 1 and 2 are OK but hydraulic oil filter warning lamp remains on aft...

Page 410: ... NO 0 FUSE LIGHTING SWITCH F L STARTER SWITCH F L BATTERY RELAY ALTERNATOR BATTERY FUEL GAUGE UNIT ENGINE OIL PRESSURE SWITCH THERMO UNIT HYDRAULIC OIL FILTER SWITCH COMBINATION METER TACHO METER SENSOR FUSE 65A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 65A 5A TO STARTER MOTOR TO HEAD LAMP TAIL LAMP TO FLOOD LAMP FUSE BOX BR NO Power excitation circuit 5V power supply Movement Movement Movement ...

Page 411: ...ontinuity in normal condition If there is continuity engine oil pressure switch is faulty Replace engine oil pressure switch 3 Combination Meter Engine oil pressure warning indicator lamp 1 When starter switch is ON measure voltage between combination meter terminal wires and ground terminal wire Battery 12 V terminal wire No 12 inlet wire Y and ground terminal wire B Starter switch ACC terminal w...

Page 412: ... B STARTER SWITCH TO VIBRATOR SOLENOID TO F R LEVER VIBRATION SWITCH R F R LEVER VIBRATION SWITCH L 51 Br B R B BrW YW G GW YR GR Y W OG GB OW WB RB LgY GY LW Br LB L WR GL LR P YL O 12 2 Y WR COMBINATION METER FUSE 5A 12 Y 11 BrB 11 BrB AV60 FUSE BOX Power excitation circuit 5V power supply Movement Movement Movement LCD CPU EEPROM CAN interface Tachometer Fuel meter Temperature meter Hour meter ...

Page 413: ... lever and vibration mode select switch in below position measure voltage between vibrator lamp relay terminal 5 outlet wire Br and chassis ground F R lever F or R Vibration mode select switch AUTO Standard voltage 12 V or more If above items 1 and 2 are OK and item 3 is NG vibrator lamp relay is faulty Replace vibrator lamp relay 3 Combination Meter Vibration indicator lamp 1 When starter switch ...

Page 414: ...CH g B G e 42 18 39 LW 39 LW B 3LY 3LB WATER SPRAY RELAY STARTER SWITCH R B 2 1 3 9 BrW 9 9 BrW 9 20 2BrR 2BrW LIQUID SPRAY PUMP LIQUID SPRAY SWITCH M ACC 11 BrB B R B BrW YW G GW YR GR Y W OG GB OW WB RB LgY GY LW Br LB L WR GL LR P YL O 12 2 Y WR COMBINATION METER FUSE 5A 12 Y 11 BrB 39 LW BrW Power excitation circuit 5V power supply Movement Movement Movement LCD CPU EEPROM CAN interface Tachom...

Page 415: ... 1 and 2 are OK and water spray indicator lamp does not light combination meter is faulty Replace combination meter 2 6 17 Liquid spray indicator lamp does not light TW354 504 Check that liquid spray pump can be activated Reference Fig 2 6 4 Check point Check Cause Action 1 Harness Measure resistance between liquid spray switch terminal 2 wire BrW and combination meter connector terminal wire No 9...

Page 416: ... METER FUSE 5A 12 Y 11 BrB 11 BrB 38 Or 35 G 36 GR GR 36 YL 15 35 G 38 Or GR 36 35 G 38 Or R1 STARTER SWITCH R2 CONNECTION POSITION 1 3 4 5 1 3 4 6 1 2 4 6 LIGHTING SWITCH 15 YL 15 YL TO HEAD LAMP TAIL LAMP COMBINATION METER Power excitation circuit 5V power supply Movement Movement Movement LCD CPU EEPROM CAN interface Tachometer Fuel meter Temperature meter Hour meter Output interface Output int...

Page 417: ... lamp does not light Reference Fig 2 6 5 Check point Check Cause Action 1 Harness Measure resistance between parking brake switch terminal 5 wire YL and combination meter connector terminal wire No 15 wire YL Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 2 Parking Brake Switch When parking brake switch is applied check continuity between par...

Page 418: ... METER FUSE 5A 12 Y 11 BrB 11 BrB 38 Or 35 G 36 GR GR 36 YL 15 35 G 38 Or GR 36 35 G 38 Or R1 STARTER SWITCH R2 CONNECTION POSITION 1 3 4 5 1 3 4 6 1 2 4 6 LIGHTING SWITCH 15 YL 15 YL TO HEAD LAMP TAIL LAMP COMBINATION METER Power excitation circuit 5V power supply Movement Movement Movement LCD CPU EEPROM CAN interface Tachometer Fuel meter Temperature meter Hour meter Output interface Output int...

Page 419: ...R Between wire No 34 wire GY and wire No 35 wire G There is continuity in normal condition If there is no continuity turn signal switch is faulty Replace turn signal switch 3 Combination Meter Turn signal indicator lamp 1 When starter switch is ON measure voltage between combination meter terminal wires and ground terminal wire Battery 12 V terminal wire No 12 inlet wire Y and ground terminal wire...

Page 420: ... 5 2 10 9 8 7 6 4 3 1 RG 5WR LgW Lg RG 5WR LgR 5WR 5W COM B BR C 5R RG AV60 12V 80AH 95D31R RG FUSE HORN SWITCH BACKUP BUZZER HORN RELAY F L F L BATTERY RELAY BATTERY HORN BACKUP BUZZER SWITCH 65A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 65A ST ON OFF HEAT C BR ACC R2 R1 B STARTER SWITCH FUSE BOX R1 STARTER SWITCH ACC R2 BY Br 308 NC NO COM F R ...

Page 421: ...sure resistance of harness connecting between terminals Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 2 6 22 Backup buzzer does not sound Reference Fig 2 6 6 Check point Check Cause Action 1 Backup Buzzer Disconnect backup buzzer and directly connect battery positive terminal to backup buzzer terminal wire BY side and negative terminal to ba...

Page 422: ...ipes and components in order to prevent foreign substances from entering Never leave the openings exposed or put a shop cloth into them There is the danger of foreign substances entering or of leaking oil causing environmental contamination Do not dispose of waste oil on site Either deliver it to the customer and request disposal or take it back with you and dispose of it 4 Prevent entry of foreig...

Page 423: ... or replace it if necessary Charge pressure decreases due to internal leakage of solenoid valve connecting oil supply circuit with charge circuit Parking brake solenoid valve Speed change solenoid valve When solenoid is energized check if oil flows in return circuit to tank If oil is flowing repair solenoid valve or replace it if necessary 5 Suction Filter for Steering Charge Pump Steering charge ...

Page 424: ...just F R lever linkage or replace it if necessary 2 High 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 condition is accordingly reversed check and adjust high pressure relief valve or replace it if necessary 3 2 3 Slow machine speed or small drive force...

Page 425: ...it pressure is not held in propulsion pump case Measure propulsion pump case pressure If case pressure is not within allowable pressure repair propulsion pump or replace it if necessary 3 2 4 Machine speed cannot be switched Check point Cause Check Action 1 Charge Circuit Pressure Insufficient steering charge pump discharge Repair steering charge pump or replace it if necessary Charge pressure dec...

Page 426: ... oil in circuit to rise Measure propulsion circuit pressure If low increase relief setting pressure If load is excessively heavy relief valve opens causing temperature of hydraulic oil in circuit to rise Measure propulsion circuit pressure If high decrease propulsion load 5 Suction Filter for Steering Charge Pump Load of steering charge pump increases due to clogged filter causing temperature of h...

Page 427: ...in neutral position Repair or replace vibrator solenoid valve if valve does not shift Decrease in circuit pressure due to faulty setting of relief valve or internal leakage Measure vibrator circuit pressure If low check and clean relief valve or replace it if necessary 6 Vibrator Motor Vibrator circuit pressure is not held in vibrator motor case Measure vibrator motor case pressure If case pressur...

Page 428: ...nsufficient discharge rate from vibrator pump due to reduced efficiency of vibrator pump Measure discharge flow 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 drive shaft spline Replace vibrator pump 3 3 3 Vibratory drum does not changeover vibrating ...

Page 429: ...or replace it if necessary 3 3 7 Abnormal noise from vibrator system Check point Cause Check Action 1 Oil Level of Hydraulic Oil Tank Pump suction pressure is high because oil level of hydraulic oil tank is low causing cavitation in vibrator circuit Fill tank until correct oil level is obtained 2 Vibrator Circuit Cavitation is caused by air in circuit Bleed circuit 3 Vibrator Bearings Vibrator bea...

Page 430: ... cylinder Repair steering cylinder or replace it if necessary 5 Suction Filter for Steering Charge Pump Steering charge pump discharge rate decreases due to clogged filter Clean suction filter or replace it if necessary 6 Steering Charge Pump Discharging pressure is insufficient due to efficiency degradation of steering charge pump Measure steering circuit pressure If low replace steering charge p...

Page 431: ... is excessively heavy relief valve is open causing temperature of hydraulic oil in circuit to rise Measure steering circuit pressure If high decrease steering load 4 Suction Filter for Steering Charge Pump Load of steering charge pump increases due to clogged filter causing temperature of hydraulic oil in circuit to rise Clean suction filter or replace it if necessary 3 4 5 Abnormal noise from ste...

Page 432: ...ow rate of vibrator pump with flow meter If discharge flow rate is not within specified range repair vibrator pump or replace it if necessary 5 Cooling Fan Drive Motor Internal leakage or internal failure of cooling fan drive motor Repair or replace cooling fan drive motor Output torque is not transmitted due to worn spline of cooling fan drive motor output shaft Replace cooling fan drive motor 3 ...

Page 433: ...o different ways using the electronic service tool or a method of displaying it on a display monitor in a combination meter To check the fault code occurring in the electronic fuel system protection system of the engine on the display monitor 1 Set the start switch to ON 2 Set and hold the diagnostic switch to DIAG SW504 10011 DIAG OFF Diagnostic switch VIEW A No fault code Self diagnosis in progr...

Page 434: ...circuit short to ground 110 0 Engine overheat Overheat of engine coolant temperature Insufficient output Overheat 3 Coolant temperature sensor High Open circuit or B short circuit of sensor harness Amount of white smoke increases at low temperatures Insufficient output Worsening exhaust gas performance 4 Coolant temperature sensor Low Ground short circuit of sensor harness 132 1 Intake air volume ...

Page 435: ...mance 636 2 NE sensor Crankshaft position sensor pulse number error Open circuit or short circuit of sensor harness Failure of sensor Running only with G signal Faulty starting Vibration is slightly large Insufficient output 7 NE G phase shift Large phase shift between NE crankshaft position sensor pulse and G camshaft position sensor pulse Invalid G signal Engine hesitates at start up 8 No input ...

Page 436: ...tected when excess fuel consumption is found Insufficient output Worsening exhaust gas performance Engine stops in some case 1347 3 B short circuit of SCV MPROP B short circuit of SCV Insufficient output Worsening exhaust gas performance 4 SCV MPROP drive system error Open circuit or ground short circuit of SCV 5 Open circuit of SCV MPROP Open circuit of SCV 7 SCV MPROP stuck SCV stuck at open pos...

Page 437: ...n level4 4765 0 Emergency Exhaust gas temperature sensor 0 High DOC inlet temperature T0 high Engine stops Inhibit cranking until down to 300 C 572 F 3 Exhaust gas temperature sensor 0 High Open circuit or B short circuit of sensor harness None 4 Exhaust gas temperature sensor 0 Low Ground short circuit of sensor harness 523523 3 1 4 cylinder injector short to B or all cylinder injector short to B...

Page 438: ...l short 523575 7 EGR actuator valve stuck EGR actuator valve stuck 523576 2 EGR DC motor overheat EGR DC motor overheat 523577 2 EGR DC motor temperature sensor failure EGR DC motor temperature sensor failure 523578 2 No communication with EGR No communication with EGR 523580 2 Intake throttle feedback error Intake throttle feedback error None 523582 3 Intake throttle lift sensor High Intake throt...

Page 439: ...nd time to the start time of the regeneration Worsening exhaust gas performance NOx 523603 15 Over heat pre caution Coolant temperature 523604 2 CAN1 Bus off CAN1 B GND short circuit or high traffic error Insufficient output Transmitted data is invalid 523605 6 Short circuit in injector driver IC Open circuit of air glow relay Insufficient output Large vibration Worsening exhaust gas performance E...

Page 440: ...30 86 e B G 9 GLOW PLUGS DIODE 2 1 8WR 2 5WR 8W F L 75A 2 5 3 1 25A ECU MAIN RELAY 2 3WR 312 10 5BY 5WG 90 89 GW G GLOW RELAY 98 LR 99 LY 27 GY f e c b a B NEUTRAL RELAY 85 LY 26 5BR 86 L 25 3W I_S_TRO_N SW 217 V_V_5VAPP1 5V 201 I_A_APP1 SIG 229 G_R_GND1 GND 240 POWER GND 252 POWER GND 254 G_R_GND2 GND 227 I_A_APP2 SIG 214 V_V_5VAPP2 5V 202 POWER GND 251 V_V_BAT3 BP 253 G_R_GND1 GND 209 V_V_BAT2 B...

Page 441: ...and chassis ground Standard voltage 12 V or more If above items 1 and 2 are OK and starter motor does not run starter motor is faulty Replace starter motor 4 Starter Relay 1 When starter switch is START measure voltage between starter relay terminal 86 inlet wire LY and chassis ground Standard voltage 12 V or more 2 When starter switch is START measure voltage between starter relay terminal 87 inl...

Page 442: ...30 86 e B G 9 GLOW PLUGS DIODE 2 1 8WR 2 5WR 8W F L 75A 2 5 3 1 25A ECU MAIN RELAY 2 3WR 312 10 5BY 5WG 90 89 GW G GLOW RELAY 98 LR 99 LY 27 GY f e c b a B NEUTRAL RELAY 85 LY 26 5BR 86 L 25 3W I_S_TRO_N SW 217 V_V_5VAPP1 5V 201 I_A_APP1 SIG 229 G_R_GND1 GND 240 POWER GND 252 POWER GND 254 G_R_GND2 GND 227 I_A_APP2 SIG 214 V_V_5VAPP2 5V 202 POWER GND 251 V_V_BAT3 BP 253 G_R_GND1 GND 209 V_V_BAT2 B...

Page 443: ...When starter switch is ON measure voltage between parking brake switch terminal 1 inlet wire RW and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between parking brake switch terminal 2 outlet wire Y and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG parking brake switch is faulty Replace parking brake switch 9 Interlo...

Page 444: ...30 86 e B G 9 GLOW PLUGS DIODE 2 1 8WR 2 5WR 8W F L 75A 2 5 3 1 25A ECU MAIN RELAY 2 3WR 312 10 5BY 5WG 90 89 GW G GLOW RELAY 98 LR 99 LY 27 GY f e c b a B NEUTRAL RELAY 85 LY 26 5BR 86 L 25 3W I_S_TRO_N SW 217 V_V_5VAPP1 5V 201 I_A_APP1 SIG 229 G_R_GND1 GND 240 POWER GND 252 POWER GND 254 G_R_GND2 GND 227 I_A_APP2 SIG 214 V_V_5VAPP2 5V 202 POWER GND 251 V_V_BAT3 BP 253 G_R_GND1 GND 209 V_V_BAT2 B...

Page 445: ...ll not start while starter motor runs generally trouble is caused by that fuel is not supplied supply amount of fuel is extremely low or selection of fuel is not appropriate Check that fuel is supplied to inlet of fuel pump Reference Fig 4 2 1 Check point Check Cause Action 1 Fuel Pump When starter switch is ON measure voltage between fuel pump terminal inlet wire WL and chassis ground Standard vo...

Page 446: ...30 86 e B G 9 GLOW PLUGS DIODE 2 1 8WR 2 5WR 8W F L 75A 2 5 3 1 25A ECU MAIN RELAY 2 3WR 312 10 5BY 5WG 90 89 GW G GLOW RELAY 98 LR 99 LY 27 GY f e c b a B NEUTRAL RELAY 85 LY 26 5BR 86 L 25 3W I_S_TRO_N SW 217 V_V_5VAPP1 5V 201 I_A_APP1 SIG 229 G_R_GND1 GND 240 POWER GND 252 POWER GND 254 G_R_GND2 GND 227 I_A_APP2 SIG 214 V_V_5VAPP2 5V 202 POWER GND 251 V_V_BAT3 BP 253 G_R_GND1 GND 209 V_V_BAT2 B...

Page 447: ...d chassis ground There is electricity in normal condition 2 Measure voltage between glow relay terminal B inlet wire BY and chassis ground Standard voltage 12 V or more 3 When starter switch is ON measure voltage between glow relay terminal G outlet wire WG and chassis ground Standard voltage 12 V or more If above items 1 and 2 are OK and item 3 is NG glow relay is faulty Replace glow relay 3 Harn...

Page 448: ...30 86 e B G 9 GLOW PLUGS DIODE 2 1 8WR 2 5WR 8W F L 75A 2 5 3 1 25A ECU MAIN RELAY 2 3WR 312 10 5BY 5WG 90 89 GW G GLOW RELAY 98 LR 99 LY 27 GY f e c b a B NEUTRAL RELAY 85 LY 26 5BR 86 L 25 3W I_S_TRO_N SW 217 V_V_5VAPP1 5V 201 I_A_APP1 SIG 229 G_R_GND1 GND 240 POWER GND 252 POWER GND 254 G_R_GND2 GND 227 I_A_APP2 SIG 214 V_V_5VAPP2 5V 202 POWER GND 251 V_V_BAT3 BP 253 G_R_GND1 GND 209 V_V_BAT2 B...

Page 449: ...rd voltage 5 0 5 V 3 When starter switch is ON measure voltage between potentiometer terminal OUT1 wire Y and potentiometer terminal GND1 wire Br When throttle lever is at IDLE position Standard voltage 0 5 to 1 0 V When throttle lever is at FULL position Standard voltage 4 0 to 4 5 V 4 When starter switch is ON measure voltage between potentiometer terminal OUT2 wire G and potentiometer terminal ...

Page 450: ......

Page 451: ...10 101 TROUBLESHOOTING SW504 4 3 Propulsion Refer to P 10 022 ...

Page 452: ...W 63 BrB R2 R1 ACC C LgR AV60 FUSE BOX NC NO COM F R LEVER SWITCH F R BR NO DIODE 2 5WR 12V CONNECTION 1 3 4 5 1 3 4 6 1 2 4 6 POSITION AUTO VIBRATION MODE SELECT SWITCH TO COMBINATION METER C BR ACC R2 R1 B STARTER SWITCH ON ST OFF HEAT CONNECTION 1 3 4 5 1 3 4 6 1 2 4 6 POSITION VIBRATORY DRUM SELECT SWITCH VIBRATORY DRUM SELECT SWITCH VIBRATOR SOLENOID R CONNECTION 1 2 4 5 1 3 4 6 VIBRATION Lo ...

Page 453: ...is ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG vibration mode select switch is faulty Replace vibration mode select switch 3 Vibratory Drum Select Switch ROPS 1 When starter switch is ON measure voltage between vibratory drum select switch terminal 1 4 inlet wire RL and chassis ground Standard voltage 12 V or more 2 When starter switch is ON and vibratory drum selec...

Page 454: ...W 63 BrB R2 R1 ACC C LgR AV60 FUSE BOX NC NO COM F R LEVER SWITCH F R BR NO DIODE 2 5WR 12V CONNECTION 1 3 4 5 1 3 4 6 1 2 4 6 POSITION AUTO VIBRATION MODE SELECT SWITCH TO COMBINATION METER C BR ACC R2 R1 B STARTER SWITCH ON ST OFF HEAT CONNECTION 1 3 4 5 1 3 4 6 1 2 4 6 POSITION VIBRATORY DRUM SELECT SWITCH VIBRATORY DRUM SELECT SWITCH VIBRATOR SOLENOID R CONNECTION 1 2 4 5 1 3 4 6 VIBRATION Lo ...

Page 455: ...Change Switch except ROPS 1 When starter switch is ON measure voltage between vibration Lo Hi change switch terminal 1 4 inlet wire RL and chassis ground Standard voltage 12 V or more 2 When starter switch is ON and vibration Lo Hi change switch is measure voltage between vibration Lo Hi change switch terminal 3 outlet wire LgR terminal 6 outlet wire LgB and chassis ground Standard voltage 12 V or...

Page 456: ...W 63 BrB R2 R1 ACC C LgR AV60 FUSE BOX NC NO COM F R LEVER SWITCH F R BR NO DIODE 2 5WR 12V CONNECTION 1 3 4 5 1 3 4 6 1 2 4 6 POSITION AUTO VIBRATION MODE SELECT SWITCH TO COMBINATION METER C BR ACC R2 R1 B STARTER SWITCH ON ST OFF HEAT CONNECTION 1 3 4 5 1 3 4 6 1 2 4 6 POSITION VIBRATORY DRUM SELECT SWITCH VIBRATORY DRUM SELECT SWITCH VIBRATOR SOLENOID R CONNECTION 1 2 4 5 1 3 4 6 VIBRATION Lo ...

Page 457: ... 12 V or more 2 When starter switch is ON measure voltage between F R lever switch terminal outlet wire GY and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG F R lever switch is faulty Replace F R lever switch 8 Harness Connecting Between Terminals Measure resistance of harness connecting between terminals Standard resistance 10 Ω or less If resistance is abnor...

Page 458: ...W 63 BrB R2 R1 ACC C LgR AV60 FUSE BOX NC NO COM F R LEVER SWITCH F R BR NO DIODE 2 5WR 12V CONNECTION 1 3 4 5 1 3 4 6 1 2 4 6 POSITION AUTO VIBRATION MODE SELECT SWITCH TO COMBINATION METER C BR ACC R2 R1 B STARTER SWITCH ON ST OFF HEAT CONNECTION 1 3 4 5 1 3 4 6 1 2 4 6 POSITION VIBRATORY DRUM SELECT SWITCH VIBRATORY DRUM SELECT SWITCH VIBRATOR SOLENOID R CONNECTION 1 2 4 5 1 3 4 6 VIBRATION Lo ...

Page 459: ...switch is ON and vibratory drum select switch is in measure voltage between vibratory drum select switch terminal 6 outlet wire LgR terminal 3 outlet wire LgB and chassis ground Standard voltage 12 V or more 4 When starter switch is ON and vibratory drum select switch is in measure voltage between vibratory drum select switch terminal 3 outlet wire LgB and chassis ground Standard voltage 12 V or m...

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Page 461: ...10 110 TROUBLESHOOTING SW504 4 5 Water Spray Refer to P 10 040 Refer to ROPS type for water spray timer ...

Page 462: ...5WR 8WY 2Y 5WR LgR 8WR 8W BrB 12 Y 2 WR COM E L B IG B BR ACC R2 R1 C 5R AV60 FUSE LIGHTING SWITCH F L STARTER SWITCH F L BATTERY RELAY ALTERNATOR BATTERY FUEL GAUGE UNIT HYDRAULIC OIL FILTER SWITCH 65A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 75A 5A TO STARTER MOTOR TO HEAD LAMP TAIL LAMP TO FLOOD LAMP FUSE BOX 2 5WR BR DIODE 9 8 13 4 5 23 26 22 21 20 27 28 24 25 30 18 19 16 17 15 14 1 2 3 10 ...

Page 463: ...nector terminal wire No 37 wire GB Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 2 Combination Meter Combination meter illumination 1 When starter switch is ON measure voltage between combination meter terminal wires and ground terminal wire Battery 12 V terminal wire No 12 inlet wire Y and ground terminal wire B Starter switch ACC terminal ...

Page 464: ...5WR 8WY 2Y 5WR LgR 8WR 8W BrB 12 Y 2 WR COM E L B IG B BR ACC R2 R1 C 5R AV60 FUSE LIGHTING SWITCH F L STARTER SWITCH F L BATTERY RELAY ALTERNATOR BATTERY FUEL GAUGE UNIT HYDRAULIC OIL FILTER SWITCH 65A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 75A 5A TO STARTER MOTOR TO HEAD LAMP TAIL LAMP TO FLOOD LAMP FUSE BOX 2 5WR BR DIODE 9 8 13 4 5 23 26 22 21 20 27 28 24 25 30 18 19 16 17 15 14 1 2 3 10 ...

Page 465: ...t start unless parking brake switch is applied parking brake indicator lamp does not go out even after starting engine Replace combination meter 4 6 3 Tachometer reading is abnormal Reference Fig 4 6 1 Check point Check Cause Action 1 Combination Meter Tachometer 1 When starter switch is ON measure voltage between combination meter terminal wires and ground terminal wire Battery 12 V terminal wire...

Page 466: ...5WR 8WY 2Y 5WR LgR 8WR 8W BrB 12 Y 2 WR COM E L B IG B BR ACC R2 R1 C 5R AV60 FUSE LIGHTING SWITCH F L STARTER SWITCH F L BATTERY RELAY ALTERNATOR BATTERY FUEL GAUGE UNIT HYDRAULIC OIL FILTER SWITCH 65A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 75A 5A TO STARTER MOTOR TO HEAD LAMP TAIL LAMP TO FLOOD LAMP FUSE BOX 2 5WR BR DIODE 9 8 13 4 5 23 26 22 21 20 27 28 24 25 30 18 19 16 17 15 14 1 2 3 10 ...

Page 467: ...it Disconnect harness and measure resistance of fuel gauge unit Standard resistance 13 5 Ω with float in F 80 0 Ω with float in E If resistance is abnormal fuel gauge unit is faulty Replace fuel gauge unit 2 Combination Meter Fuel meter When starter switch is ON measure voltage between combination meter terminal wires and ground terminal wire Battery 12 V terminal wire No 12 inlet wire Y and groun...

Page 468: ...5WR 8WY 2Y 5WR LgR 8WR 8W BrB 12 Y 2 WR COM E L B IG B BR ACC R2 R1 C 5R AV60 FUSE LIGHTING SWITCH F L STARTER SWITCH F L BATTERY RELAY ALTERNATOR BATTERY FUEL GAUGE UNIT HYDRAULIC OIL FILTER SWITCH 65A 20A 15A 15A 15A 20A 20A 15A 15A 20A 20A 15A 75A 5A TO STARTER MOTOR TO HEAD LAMP TAIL LAMP TO FLOOD LAMP FUSE BOX 2 5WR BR DIODE 9 8 13 4 5 23 26 22 21 20 27 28 24 25 30 18 19 16 17 15 14 1 2 3 10 ...

Page 469: ...and ground terminal wire B Starter switch ACC terminal wire No 314 inlet wire BY and ground terminal wire B Standard voltage 12 V or more 2 When starter switch is ON measure voltage between combination meter hydraulic oil filter warning terminal inlet wire No 53 wire LR and chassis ground Standard voltage 12 V or more If above items 1 and 2 are OK but hydraulic oil filter warning lamp remains on a...

Page 470: ...Fuel meter REV ratio SEL 2 REV ratio SEL 4 DTC display Hour meter Turn signal L Preheating 13 14 15 16 17 18 19 20 21 22 23 24 Water splay Flood lamp Vibrator Liquid spray High beam COMBI meter ILLUMI Exhaust system high temperature DEF low level Manual regeneration LYS pin ECO mode 25 26 27 28 29 30 31 32 33 34 35 15 16 27 30 18 21 22 12 11 10 3 4 5 9 8 2 1 COMBINATION METER BAT BAT CAN Fuel mete...

Page 471: ... lever and vibration mode select switch in below position measure voltage between vibrator lamp relay terminal 5 outlet wire Br and chassis ground F R lever F or R Vibration mode select switch AUTO Standard voltage 12 V or more If above items 1 and 2 are OK and item 3 is NG vibrator lamp relay is faulty Replace vibrator lamp relay 3 Combination Meter Vibration indicator lamp 1 When starter switch ...

Page 472: ...play Hour meter Turn signal L Preheating 13 14 15 16 17 18 19 20 21 22 23 24 Water splay Flood lamp Vibrator Liquid spray High beam COMBI meter ILLUMI Exhaust system high temperature DEF low level Manual regeneration LYS pin ECO mode 25 26 27 28 29 30 31 32 33 34 35 15 16 27 30 18 21 22 12 11 10 3 4 5 9 8 2 1 COMBINATION METER BAT BAT CAN Fuel meter REV ratio SEL 1 REV ratio SEL 2 REV ratio SEL 3 ...

Page 473: ... spray indicator lamp 1 When starter switch is ON measure voltage between combination meter terminal wires and ground terminal wire Battery 12 V terminal wire No 12 inlet wire Y and ground terminal wire B Starter switch ACC terminal wire No 314 inlet wire BY and ground terminal wire B Standard voltage 12 V or more 2 When starter switch is ON water spray mode select switch is CONT measure voltage b...

Page 474: ...nual regeneration Engine warning Engine stop HYD oil filter warning Parking brake Exhaust system high temperature Head lamp ECO mode COMBI meter ILLUMI Hour meter DEF low level Pull up Resistor 3 6KΩ x3 Pull up Resistor 3 6KΩ x9 Pull down Resistor 4 7KΩ x5 Pull up Resistor 31KΩ x4 CAN DC DC Converter CAN Transceiver 5V LDO CPU MOTOR driver LCD driver Illumination LED Engine oil pressure indicator ...

Page 475: ...tor lamp does not light Reference Fig 4 6 4 Check point Check Cause Action 1 Harness Measure resistance between parking brake switch terminal 5 wire YL and combination meter connector terminal wire No 15 wire YL Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 2 Parking Brake Switch When parking brake switch is applied check continuity between ...

Page 476: ...nual regeneration Engine warning Engine stop HYD oil filter warning Parking brake Exhaust system high temperature Head lamp ECO mode COMBI meter ILLUMI Hour meter DEF low level Pull up Resistor 3 6KΩ x3 Pull up Resistor 3 6KΩ x9 Pull down Resistor 4 7KΩ x5 Pull up Resistor 31KΩ x4 CAN DC DC Converter CAN Transceiver 5V LDO CPU MOTOR driver LCD driver Illumination LED Engine oil pressure indicator ...

Page 477: ...o 35 wire G There is continuity in normal condition If there is no continuity turn signal switch is faulty Replace turn signal switch 3 Combination Meter Turn signal indicator lamp 1 When starter switch is ON measure voltage between combination meter terminal wires and ground terminal wire Battery 12 V terminal wire No 12 inlet wire Y and ground terminal wire B Starter switch ACC terminal wire No ...

Page 478: ...10 127 TROUBLESHOOTING SW504 5 HYDRAULIC SYSTEM TROUBLESHOOTING SW504 Refer to P 10 073 ...

Page 479: ......

Page 480: ...46 99019 0 30912 D 0449 99017 0 30245 C Printed in Japan 2019 07 10 1 K P 0448 99031 0 30663 0 SW TW354 SW TW504 SHOP MANUAL SAKAI HEAVY INDUSTRIES LTD Head office Seiwa Bldg 4 8 Shibadaimon 1 chome Minato ku Tokyo Japan Telephone 81 3 3434 3401 Global Service Division 2500 Takayanagi Kuki shi Saitama Japan Telephone 81 480 52 1111 ...

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