Sakai SW800-II Shop Manual Download Page 44

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4-001

HYDRAULIC SYSTEMS

1. SYSTEM CIRCUIT DIAGRAM

1-1. Graphic Symbols for Hydraulic Circuits

Basic Symbols

DESCRIPTION

SYMBOL

Lines:

Main working
Pilot control
Drain or bleed

Lines, joining

Not connected

Component outline

Arrow indicates direction

of flow.
Line with fixed restriction

(orifice).

Test port, pressure

measurement.
Temperature measure-

ment gauge

Pressure measurement

gauge

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

Bidirectional

Variable displace

ment pressure com-

pensated

Unidirectional

Hydraulic Motor:

Unidirectional

Bidirectional

Double acting hydraulic

cylinder

Differential cylinder

Electric motor

Summary of Contents for SW800-II

Page 1: ...SW800 850 SHOP MANUAL 3498 65547 0...

Page 2: ......

Page 3: ...e 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 m...

Page 4: ......

Page 5: ...Stopping 1 004 1 10 Maintenance 1 005 1 11 Transporting the Machine 1 007 2 SPECIFICATIONS 1 SPECIFICATION DATA 1 1 SW800 2 001 1 2 SW850 2 003 2 TABLE OF STANDARD VALUES 2 1 Engine 2 005 2 2 Propulsi...

Page 6: ...007 2 2 2 Propulsion hydraulic motor front SW800 4 009 2 2 3 Propulsion hydraulic motor front SW850 4 011 2 2 4 Propulsion hydraulic motor rear SW800 4 013 2 2 5 Propulsion hydraulic motor rear SW850...

Page 7: ...Vibratory Drum Assembly SW800 6 007 3 1 1 Vibratory drum exploded diagram 6 008 3 2 Vibratory Drum Assembly SW850 6 009 3 2 1 Vibratory drum exploded diagram 6 010 4 DISASSEMBLY AND REASSEMBLY OF VIB...

Page 8: ...1 Measurement 9 007 5 MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE 5 1 Measurement 9 008 6 MEASUREMENT AND ADJUSTMENT OF VIBRATOR CIRCUIT PRESSURE 6 1 Measurement 9 009 6 1 1 Measurement of main rel...

Page 9: ...10 029 2 4 3 Brake does not operate 10 031 2 5 Vibrator 10 033 2 5 1 No vibration occurs 10 033 2 5 2 Amplitude does not change Remains either Low or High 10 035 2 5 3 Vibration frequency does not cha...

Page 10: ...0 075 3 2 1 Vehicle moves neither forward nor backward 2 2 10 076 3 2 2 Vehicle moves in one direction only forward or backward 10 076 3 2 3 Slow vehicle speed or small drive force 10 076 3 2 4 Vehicl...

Page 11: ...SAFETY...

Page 12: ......

Page 13: ...machine if you fail to observe or important point to maintain of quality in maintenance works Indicates standard value to judge whether measured value is good or not Items that indicate the weight of...

Page 14: ...guidance of a skilled electrician and according to electrical engineering rules and regulations Work on the frame brakes hydraulic and steering systems must be performed by skilled personnel with spec...

Page 15: ...eadable 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 t...

Page 16: ...nging banks or on grades that could cause the compactor to slide or roll over Avoid any areas that may be a risk to machine stability Avoid side hill travel Always operate up and down the slope Always...

Page 17: ...t until the machine has cooled down Use care when attaching and securing lifting tackle to individual parts and large assemblies being removed or repositioned for repair purposes to avoid the risk of...

Page 18: ...or perform grinding on the machine unless expressly authorized as there may be a risk of fire or explosion Disconnect the battery when welding on the machine Clean the machine and its surrounding fro...

Page 19: ...dth Block the drums or tires front and rear of the hauling vehicle when loading and unloading the compactor Ensure that the haul vehicle is on level ground and approach the loading ramps squarely to m...

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Page 21: ...SPECIFICATIONS...

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Page 24: ...00 mm 67 in Minimum height above ground 280 mm 11 in Curb clearance 500 mm 20 in Drive speed Forward reverse 1st 0 to 7 5 km h 0 to 4 7 mph 2nd 0 to 12 5 km h 0 to 7 8 mph Vibration performance Freque...

Page 25: ...type Hydraulic transmission Reverser Switching the direction of flow delivered from the variable pump Final drive Planetary gear Vibrating system Transmission Hydraulic transmission Vibrator Eccentric...

Page 26: ...Minimum height above ground 330 mm 13 in Curb clearance 550 mm 21 5 in Drive speed Forward reverse 1st 0 to 7 0 km h 0 to 4 3 mph 2nd 0 to 11 0 km h 0 to 6 8 mph Vibration performance Frequency Low am...

Page 27: ...type Hydraulic transmission Reverser Switching the direction of flow delivered from the variable pump Final drive Planetary gear Vibrating system Transmission Hydraulic transmission Vibrator Eccentric...

Page 28: ...or engine details 2 2 Propulsion Classi fication Item Standard value Remarks SW800 SW850 Propulsion Speed forward and reverse 1st 0 to 7 5 km h 0 to 4 7 mph 0 to 7 0 km h 0 to 4 3 mph 2nd 0 to 12 5 km...

Page 29: ...disc assembly 7 discs 18 5 to 19 1 mm 0 73 to 0 75 in Note 3 See dimensions Allowable when thickness is within this range Replace all 7 discs when thickness becomes 18 5 or less SW880 02002 Note 3 2 6...

Page 30: ...110 ISO 3448 Grease Lithium type extreme pressure NLGI 2 Fuel Diesel oil ASTM D975 2D 3 2 Recommended Lubricants Lubricant Oil company Engine oil API CH 4 Gear oil API GL 4 Hydraulic oil VG 46 Grease...

Page 31: ...3 253 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 1...

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Page 33: ...ENGINE AND CONTROLS...

Page 34: ......

Page 35: ...3 001 ENGINE AND CONTROLS 1 ENGINE 1 1 Engine Mount 1 6 2 A B 5 4 3 DETAIL A VIEW B 0554 01803 0 11053 B 1 Engine 4 Damper 2 Bolt M12 130 5 Base 3 Washer 6 Nut M12 6 Nut M12 108 N m 80 lbf ft...

Page 36: ...ylinder head cover 4 Fan 17 Control block FCU Fuel Control Unit 5 Alternator 18 Exhaust manifold line 6 Coolant pump 19 Turbocharger 7 Tension pulley 20 Lubricating oil return line from exhaust turboc...

Page 37: ...TAIL B 23 22 21 A B C 24 25 0554 12805 0 10876 B D 1 Forward reverse lever 10 Nut M16 18 Nut M6 Left hand thread 2 Nut M6 11 Nut M10 19 Clevis M6 Left hand thread 3 Nut M6 12 Bolt M10 40 20 Clevis M6...

Page 38: ...lt M10 40 2 Bolt M16 50 6 S bolt M16 10 Bolt M10 35 3 Spring pin 7 Bolt M20 45 11 Housing 4 Hub 8 Pump 2 Bolt M16 50 210 to 230 N m 155 to 170 lbf ft 5 Set screw M16 22 100 to 120 N m 74 to 89 lbf ft...

Page 39: ...m 74 to 89 lbf ft Install housing 11 to pump 8 and fix with six bolts 7 and washers 7 Bolt M20 45 539 N m 398 lbf ft Install rubber body of coupling 1 to hub 4 by locating with spring pins 3 Tighten f...

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Page 41: ...HYDRAULIC SYSTEMS...

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Page 44: ...eservoir 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 indicate...

Page 45: ...s 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 tio...

Page 46: ......

Page 47: ...brator Front vibrator Rear drum Front drum Vibration HI Vibration LO Vibration HI Vibration LO Vibrator solenoid valve front Vibrator solenoid valve rear Power cylinder right Power cylinder left Brake...

Page 48: ......

Page 49: ...PT2 BB Fa PMB B PA2 PA3 PR2 FMB FM5 FMA RM5 RMB RMA PS2 A PMA VFT VFA VFB FVA FVB FVP FVT T P VCO VCS P T O R L VP VT VA VRB VRT RVT RVP RVA RVB Vibration HI Vibration LO Vibration HI Vibration LO st...

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Page 51: ...A G3 4 PT2 G3 4 B G3 4 Ps G3 8 E C Propulsion pump Hose Hydraulic oil tank drain Hose PMA BA Hose PT2 Filter Hose B JMA Coupling R1 4 Hose VA JM5 Hose LO2 VP Hose A JMB Hose PMB BB Hose VT Hydraulic...

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Page 53: ...B G3 4 C TM1 G1 2 TM3 G1 2 TEE Hydraulic oil tank SECTION A A SECTION B B DETAIL C JMA G3 4 JMB G3 4 JM5 G1 4 JM1 G1 2 Bracket Hose TM3 JM1 Hose FM1 TM1 Hose FM5 JM5 Hose RM5 VA Hose B RMB Hose A RMA...

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Page 56: ...tions 2 2 1 Hydraulic pump assembly propulsion vibrator 1 1 1 1 2 1 7 1 3 1 4 1 5 back of 1 6 2 1 8 2 3 2 4 2 5 2 6 1 9 2 2 1 12 1 13 1 14 1 10 1 11 2 1 SW800 04001 1 14 1 8 1 4 1 10 1 12 2 5 2 6 2 2...

Page 57: ...ort A PMA G1 4 1 13 High pressure relief valve For Port A 1 14 Drain port PT2 G3 4 Specifications Displacement 90 cm3 rev 5 49 cu in rev High pressure relief valve pressure setting 40 2 0 8 MPa 5 829...

Page 58: ...8UNF 9 Filler cap 7 8 14UNF 4 Drain port FM1 7 8 14UNF 5 High pressure gauge port For Port B FM4 9 16 18UNF 6 High pressure gauge port For Port A FM3 9 16 18UNF 1 5 3 2 6 4 Pump circuit diagram SW800...

Page 59: ...r 8 Reduction gear 7 1 Cylinder block kit 8 1 Floating seal kit 7 2 Roller bearing 8 2 Angular bearing 7 3 Shaft 8 3 Carrier B 7 4 Oil seal 8 4 Planetary gear B 7 5 Swash plate assembly 8 5 Needle rol...

Page 60: ...8UNF 9 Filler cap 7 8 14UNF 4 Drain port FM1 7 8 14UNF 5 High pressure gauge port For Port B FM4 9 16 18UNF 6 High pressure gauge port For Port A FM3 9 16 18UNF 1 5 3 2 6 4 Pump circuit diagram SW800...

Page 61: ...004 7 Motor 8 Reduction gear 7 1 Cylinder block kit 8 1 Floating seal kit 7 2 Bearing 8 2 Angular bearing 7 3 Oil seal 8 3 Planetary gear 2nd 7 4 Shaft 8 4 Needle roller 7 5 Swash plate assembly 8 5 C...

Page 62: ...port RM1 7 8 14UNF 10 Shuttle valve housing 5 High pressure gauge port For Port B RM4 9 16 18UNF 11 Charge pressure gauge port RM8 7 16 20UNF 6 High pressure gauge port For Port A RM3 9 16 18UNF 2 6...

Page 63: ...or 8 Reduction gear 7 1 Cylinder block kit 8 1 Floating seal kit 7 2 Roller bearing 8 2 Angular bearing 7 3 Shaft 8 3 Carrier B 7 4 Oil seal 8 4 Planetary gear B 7 5 Swash plate assembly 8 5 Needle ro...

Page 64: ...port RM1 7 8 14UNF 10 Shuttle valve housing 5 High pressure gauge port For Port B RM4 9 16 18UNF 11 Charge pressure gauge port RM8 7 16 20UNF 6 High pressure gauge port For Port A RM3 9 16 18UNF 2 6...

Page 65: ...4006 7 Motor 8 Reduction gear 7 1 Cylinder block kit 8 1 Floating seal kit 7 2 Bearing 8 2 Angular bearing 7 3 Oil seal 8 3 Planetary gear 2nd 7 4 Shaft 8 4 Needle roller 7 5 Swash plate assembly 8 5...

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Page 67: ...16 18UNF Hydraulic oil tank CO 1 1 16 12UN CS 1 1 16 12UN Vibrator pump PA2 G3 4 PA3 G3 4 PR2 G1 2 Vibrator solenoid valve Front Vibrator solenoid valve Rear The letters and figures such as PA2 and FV...

Page 68: ......

Page 69: ...A G1 2 JVB G1 2 JVA G1 2 Vibrator solenoid valve Front Vibrator solenoid valve Rear Hose VFA JVA Hose VFT TM2 Hose VFB JVB Hose VRA RVA Hose VRB RVB Hose VRT Hydraulic oil tank Hose JVB FVB Hose JVA F...

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Page 71: ...Clockwise rotation 3 4 Counterclockwise rotation Hydraulic circuit diagram A VIEW A Flow of oil 1 Drain port T1 VFT VRT G1 2 2 Drain port T2 M12 1 5 3 Port B VFB VRB 1 1 16 12UN 2B 4 Port A VFA VRA 1...

Page 72: ...PR1 7 High pressure relief valve PR2 3 Port A FVA RVA G1 2 8 Inlet cover 4 Port T FVT RVT G3 4 9 Port P FVP RVP G1 2 5 Outlet cover 10 High pressure relief valve R1 Specifications Rated pressure 25 0...

Page 73: ...G1 2 R1 G1 2 Hydraulic oil tank The letters and figures such as LO2 and Fa show each port and the arrow show the hose connection and the direction of the flow of the oil symbols Hose T LS2 Hose LO2 Fa...

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Page 75: ...Orbitrol SW800 04018 Hydraulic circuit diagram 1 2 3 4 1 2 3 4 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 Specifications Displacement 369 cm3 rev 22 5 cu in r...

Page 76: ...SYSTEMS 4 2 2 Steering pump SW800 04019 3 2 1 A VIEW A 1 Pump 2 Outlet port VCO G1 2 3 Inlet port VCS G1 Specifications Displacement 23 3 cm3 rev 1 42 cu in rev Rated pressure 20 6 MPa 2 987 psi Weigh...

Page 77: ...3 4 1 Bolt M16 60 7 Bolt M16 45 2 Bolt M16 80 8 Cover 3 Nut M20 9 Roller bearing 4 Bolt M20 90 10 Bracket upper 5 Swing bearing 11 Bracket lower 6 Yoke 12 O ring 1 Bolt M16 60 265 N m 195 lbf ft 2 Bol...

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Page 79: ...ELECTRICAL SYSTEM...

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Page 81: ...2 ON WATER SPRAY PUMP 2 ON 4 3 5 2 4 5 f e c a b b FUEL SENSOR 64 FUEL SENSOR 63 FUEL SENSOR 10 5WR 93 5WL 92 5WB 24 YG 28 GB 71 G X B X B X B 44 BrB 37 YR 35 LgY 33 GL 32 LR 3 5 1 2 FUSE 100A DIAGNOS...

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Page 83: ...ck relay DC contactor Engine controller EMR3 Air differential pressure switch Battery Alternator Vibrator solenoid valve R Vibrator solenoid valve F Hydraulic oil filter switch Glow plug Thermo unit C...

Page 84: ......

Page 85: ...itch 12 Vibration relay 2 23 Horn relay 2 Vibration frequency selector switch 13 Fuse box 24 Foot brake relay 3 Diagnostic switch 14 Lamp check relay 25 Delay relay 4 Engine check lamp 15 Starter moto...

Page 86: ...t level sensor WL Horn relay Backup buzzer switch WG F R lever switch GW Lamp switch Flood lamp switch WR Water spray selector switch WB Water spray relay F Water spray relay R Battery relay WR Batter...

Page 87: ...73 94 1 3 5 Internal circuit Harness side 100 10 3BW Wire number Terminal number Wire color AVS wire size 109 P DIANOSTIC 55 LAMP 116 LgR 117 LgY 71 OIL PRES 51 OIL PRES EMR 3 D2 2 k 111 LgB COOLANT L...

Page 88: ...rR BrR 97 97 SWP 4M SWP 4M SWP 4F SWP 4F SWP 4M SWP 4F 2 3 4 100 BW Wire color and number Refer to 1 4 Wire Color Code and number of TROUBLESHOOTING Wire number Harness side Harness side Wire color Th...

Page 89: ...erface Input interface TA pulse pickup TA pulse square wave Fuel sensor Temperature sensor Engine speed 1 Engine speed 2 Engine speed 3 Engine speed 4 Position lamp Backlight Turn signal right Turn si...

Page 90: ...Cover 2 Connector COMP Specifications Maximum peak inverse withstand voltage 100 V Maximum mean rectified current 1 A Maximum surge current 50 A Insulation resistance At least 3 M with a 500 VM insul...

Page 91: ...VIBRATORY DRUM...

Page 92: ......

Page 93: ...ubstances 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 n...

Page 94: ...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 reinsta...

Page 95: ...lock bar 3 WARNING When lifting the vehicle 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 secu...

Page 96: ...t for the hydraulic oil to cool down before starting the work 8 Disconnection of piping Propulsion motor piping Remove the hydraulic hose clamp 5 Disconnect the four hydraulic hoses 6 7 8 and 9 connec...

Page 97: ...m frame Drum 15 SW800 2 280 kg 5 026 lbs SW850 3 080 kg 6 790 lbs 11 Put chocks or the like under the removed drum 15 to prevent it from moving SW800 06007 14 15 Support stand Support stand SW800 0600...

Page 98: ...g the vibratory drum pay particular attention to the following precaution CAUTION If the engine is run at high speed or the cylinder is operated to full stroke when the engine is started for the first...

Page 99: ...Vibrator bearing 36 Bolt M12 40 11 Eccentric shaft 37 Roller bearing 12 Vibrator bearing 38 Oil seal 13 Axle shaft 39 Plug 14 Bolt M16 50 40 O ring 15 Housing 41 O ring 16 Bracket 42 Sleeve 17 Bolt M1...

Page 100: ......

Page 101: ...e numbers shown in the illustration are consistent with the part numbers of the vibratory drum shown on page 6 007 2 Housing 11 Eccentric shaft 13 Axle shaft 15 Housing 16 Bracket 22 Bracket 27 Vibrat...

Page 102: ......

Page 103: ...36 Bolt M12 40 7 Spring pin 37 Roller bearing 8 Housing 38 Oil seal 9 Bolt M16 50 39 Plug 10 Vibrator bearing 40 O ring 11 Eccentric shaft 41 O ring 12 Vibrator bearing 42 Sleeve 13 Axle shaft 43 Spr...

Page 104: ......

Page 105: ...ine numbers shown in the illustration are consistent with the part numbers of the vibratory drum shown on page 6 009 2 Housing 11 Eccentric shaft 13 Axle shaft 15 Housing 16 Bracket 22 Bracket 27 Vibr...

Page 106: ......

Page 107: ...WARNING When standing the drum use wooden blocks of sufficient strength to securely support the drum 2 Lift the vibratory drum with a crane and stand it with its vibrator motor side facing up as show...

Page 108: ...em NOTICE Since the parts cannot be lifted in a level position in the illustrated state lift them using a support or the like until the spigot joint of the housing is disengaged Total weight of parts...

Page 109: ...9 Slowly lift the axle shaft subassembly with a crane to remove it NOTICE In order not to lift the eccentric shaft together with the axle shaft subassembly tap on the eccentric shaft end with a woode...

Page 110: ...c shaft 11 70 kg 154 lbs For machines with SW800 skip steps 11 to 15 11 SW850 Attach a lifting bolt M8 to the end of the eccentric shaft Lift the eccentric shaft 11 to remove it Eccentric shaft 11 45...

Page 111: ...50 14 Install lifting bolts M16 on the housing 8 15 Lift the housing subassembly with a crane to remove it Total weight of parts to be lifted 8 and 4 70 kg 154 lbs SW800 06024 8 Pulling bolt SW800 06...

Page 112: ...s SW850 2 650 kg 5 842 lbs 17 Install lifting bolts and nuts M22 as shown on the right 18 Remove the sixteen bolts 54 Lift the brackets 48 and 56 damper 59 and plate 55 together with a crane to remove...

Page 113: ...20 Install lifting bolts M20 on the propulsion motor 53 21 Lift the propulsion motor 53 with a crane to remove it Propulsion motor 53 SW800 185 kg 408 lbs SW850 210 kg 463 lbs SW800 06030 50 SW800 06...

Page 114: ...Using two pulling bolts lift the housing 2 Pulling bolt SW800 M16 50 SW850 M20 60 24 Install lifting bolts on the housing 2 Lifting bolt SW800 M16 SW850 M20 SW800 06035 2 Lifting bolt SW800 06035 2 L...

Page 115: ...kg 132 lbs SW850 75 kg 165 lbs 26 Shown on the right is the axle shaft subassembly removed from the vibratory drum Remove the six bolts 36 Remove the cover 35 27 Remove the eight bolts 28 Remove the c...

Page 116: ...rate the housing 15 together with the roller bearing from the axle shaft 13 29 Install lifting bolts M12 on the housing 13 30 Lift the housing 15 with a crane to separate it from the axle shaft 13 Hou...

Page 117: ...2 0 M16 2 0 C 2 C 2 C 2 C 3 4 C 2 4 18 16 50 157 110 110 270 50 162 75 6 Plate Puller Two shafts Two tabs SW800 06001 33 Turn the nuts of the bearing puller counterclockwise to remove the vibrator bea...

Page 118: ...16 and lift the housing 8 with a crane Housing 8 60 kg 132 lbs 36 Put the housing 8 and eccentric shaft 4 lifted with a crane on wooden blocks SW800 06046 Lift with crane Lifting bolt 8 SW800 06047 8...

Page 119: ...he retaining ring 45 38 Lift the housing 8 with a crane to separate it from the eccentric shaft 4 Housing 8 30 kg 66 lbs 39 Put the housing 8 on wooden blocks SW800 06049 8 4 Lift with crane SW800 060...

Page 120: ...6 024 VIBRATORY DRUM 40 Tap on the bearing 5 with a hammer via a wooden bar or the like to remove it from the housing 8 NOTICE Be careful not to damage the bearing SW800 06051 8 5 Wooden bar Hammer...

Page 121: ...TICE Take care not to damage the bearing when installing it Apply a thin coat of grease to the O ring 47 Install the O ring 47 in the O ring fitting groove in the housing 2 WARNING When attaching the...

Page 122: ...ly with a crane and install it in the vibratory drum NOTICE When installing the housing subassembly take care not to allow the O ring to protrude from the fitting groove Housing subassembly SW800 60 k...

Page 123: ...L1 L2 60 120 0 0 2 H 9 D2 D 1 d d Bearing inner race fixture SW800 SW850 L1 375 420 L2 425 470 d 18 22 H 49 84 D1 60 65 D2 78 82 6 Shown on the right is a sectional view of the housing subassembly to...

Page 124: ...SW800 1 580 kg 3 483 lbs SW850 2 200 kg 4 850 lbs For machines with SW800 skip steps 8 and 11 8 Eccentric shaft subassembly Apply a thin coat of gear oil to the surface to which the vibrator bearing 5...

Page 125: ...using subassembly with a crane and install it on the eccentric shaft 4 NOTICE Install the housing subassembly taking care not to tilt the vibrator bearing inner race Housing subassembly 30 kg 66 lbs I...

Page 126: ...ousing 8 NOTICE Take care not to damage the bearing when installing it Install a lifting bolt M8 on the shaft end of the eccentric shaft 11 Apply a thin coat of gear oil to the inner surface of the vi...

Page 127: ...Nut Bracket L75 75 9 4 18 24 80 300 240 710 22 30 Eyebolt Lifting jig Two shafts SW800 06002 10 Apply gear oil to the bearing mounting surface of the eccentric shaft Slowly lift the eccentric shaft su...

Page 128: ...d install it in the drum 46 Eccentric shaft subassembly 70 kg 154 lbs 13 Axle shaft subassembly 13 1 Apply a thin coat of gear oil to the surface of the outer race of the roller bearing 37 to be press...

Page 129: ...crane and reverse it Apply a thin coat of gear oil to the surface of the inner race of the roller bearing 37 to be press fitted Install the inner race of the roller bearing 37 Axle shaft subassembly...

Page 130: ...aring Install a shim 26 of about 1 mm 0 08 in on the axle shaft and install the cover 29 The shim provides a clearance between the end face of the axle shaft and the inner surface of the cover 29 Tigh...

Page 131: ...bolts 28 Remove the cover 29 and shim 26 Without inserting shim install the cover 29 Install washers to the four bolts 28 and tighten Using a thickness gauge measure the gap at dimension A Preload ad...

Page 132: ...e eight bolts 28 with washers Bolts 28 M14 40 167 N m 123 lbf ft Install the oil seal 25 on the cover 35 Apply a thin coat of grease to the lip surface of the oil seal 25 Apply liquid packing to the m...

Page 133: ...upporting the eccentric shaft 11 with a pipe or the like align the center of the vibrator bearing inner race to that of the shaft NOTICE Install the axle shaft taking care not to tilt the vibrator bea...

Page 134: ...und bar on the drum and the plugs 39 1 and 39 2 17 Secure the axle shaft subassembly to the drum with the sixteen bolts 14 Bolts 14 M16 50 265 N m 195 lbf ft 18 Install a lifting bolt M8 on the shaft...

Page 135: ...08 in 20 Install lifting bolts and nuts M22 on a subassembly of the brackets 16 22 and 32 and dampers 18 as shown on the right 21 Lift the bracket subassembly with a crane Bracket subassembly SW800 17...

Page 136: ...in the housing 23 Secure the bracket subassembly to the housing with the sixteen bolts 23 and washers Bolts 23 M20 60 540 N m 400 lbf ft Wind seal tape around the threaded portion of the breather 24 I...

Page 137: ...to protrude from the fitting groove Bolts 30 M10 30 60 N m 44 lbf ft WARNING Be careful because reversing the vibratory drum is dangerous work Confirm that the surrounding area is safe and work in a n...

Page 138: ...fting bolt M10 on the shaft end of the eccentric shaft 30 Slowly lift the eccentric shaft with a crane and check that there is an axial play of 1 to 2 mm 0 04 to 0 08 in SW800 06102 Eccentric shaft Li...

Page 139: ...53 Lifting bolt SW800 M16 SW850 M20 33 Slowly lift the propulsion motor 53 with a crane and install it in the drum NOTICE When installing the propulsion motor take care not to allow the O ring to prot...

Page 140: ...540 N m 398 lbf ft 35 Install lifting bolts and nuts M22 on a subassembly of the brackets 48 and 56 plate 55 and dampers 59 as shown on the right 36 Lift the bracket subassembly with a crane Bracket s...

Page 141: ...sembly to the propulsion motor 53 with the sixteen bolts 54 and washers Bolts 54 SW800 M16 50 265 N m 196 lbf ft SW850 M20 60 540 N m 398 lbf ft 39 Lift the assembled drum assembly with a crane and la...

Page 142: ...1 and 39 2 Supply gear oil from the oil supply port and check that the oil drips from the gauge port Gear oil SW800 19 L 5 0 gal SW850 22 L 5 8 gal Reinstall the plugs 39 1 and 39 2 SW800 06113 39 2...

Page 143: ...BRAKE...

Page 144: ......

Page 145: ...6 A B DETAIL A DETAIL B 2 7 1 Brake pedal 9 Bolt M10 45 2 Foot brake switch 10 Nut M10 3 Bolt M8 50 11 Rod end M10 4 Nut M8 12 Nut M10 5 Nut M10 P 1 25 13 Nut M10 6 Stopper bolt M10 50 P 1 25 14 Bolt...

Page 146: ...il flow Propulsion pump When brake pedal is depressed Propulsion pump swash plate in neutral position Servo valve forcibly neutralizing mechanism Servo valve Brake piston Brake disc assembly Brake Bra...

Page 147: ...rcuit diagram 4 8 7 6 30 to 37 N m 22 1 to 27 3 lbf ft 4 9 N m 3 6 lbf ft 1 Solenoid valve 2 O ring 1B P14 3 Spool 4 Port A VA G1 4 5 Spring 6 Body 7 Port P VP G1 4 8 Port T VT G1 4 Specifications Rat...

Page 148: ......

Page 149: ...WATER SPRAY SYSTEM...

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Page 151: ...ank Pipe 1 Pipe 2 Filter Water spray pump 2 Strainer Filter IN Water spray pump 1 Pump 1 IN Pump 1 OUT Pump 2 OUT Gauge Hose Pump 1 OUT Pipe 1 Hose Pump 2 OUT Pipe 2 Rubber A A Pipe 1 Pipe 2 Pump 2 Va...

Page 152: ......

Page 153: ...R SPRAY SYSTEM 2 WATER SPRAY COMPONENT SPECIFICATION 2 1 Water Spray Pump 1 2 SW800 08001 1 IN 2 OUT Specifications Discharge rate 3 0 L min 0 79 gal min Discharge pressure 0 26 MPa 38 psi Weight 1 8...

Page 154: ......

Page 155: ...INSPECTION AND ADJUSTMENT...

Page 156: ......

Page 157: ...n 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...

Page 158: ...auge port 2 Reverse side gauge port 1 Pressure gauge 0 to 50 MPa 0 to 7 250 psi Start the engine and set the throttle switch to the Full position Establish a condition in which the vehicle propulsion...

Page 159: ...e Adjustment screw turned counterclockwise Pressure drop Pressure change rate 10 MPa turn 1 450 psi turn If there is no evidence of the locknut having loosened remove the cut off valve 1 3 Check the r...

Page 160: ...urn If there is no evidence of the locknut having loosened remove the high pressure relief valve 1 9 or 1 13 Check the removed high pressure relief valve for trapped dirt and scratches on its seat If...

Page 161: ...41 F Remove the plug from the coupling 1 Attach the pressure gauge through the hose and the adapter Coupling R1 4 M16 Adapter for hose M16 P 2 0 Pressure gauge connector M16 G3 8 Pressure gauge 0 to...

Page 162: ...ge rate 0 4 MPa turn 58 psi turn If there is no evidence of the locknut having loosened remove the charge relief valve 1 11 Check the removed charge relief valve for trapped dirt and scratches on its...

Page 163: ...et the throttle switch to the Full position Operate forward reverse lever and perform pressure setting When forward reverse lever is in Neutral position pressure reading at 1 2 and 1 7 should be the s...

Page 164: ...e 1 from propulsion motor Attach the pressure gauge through the adapter Adapter G1 4 Pressure gauge 0 to 5 MPa 0 to 725 psi Confirm that the forward reverse lever is in the Neutral position Apply the...

Page 165: ...the vibration mode continuous automatic selector switch to the Continuous position Set the vibrator switches to the LOW position and the vibration frequency selector to the 3 000 vpm position respecti...

Page 166: ...the vibration frequency selector to the 3 000 vpm position Start the engine and set the throttle switch to the Full position Set the vibrator switches to the HIGH or LOW position respectively Press th...

Page 167: ...tment screw 7 Adjustment screw turned clockwise Pressure rise Adjustment screw turned counterclockwise Pressure drop Pressure change rate 12 9 MPa turn 1 870 psi turn If there is no evidence of the lo...

Page 168: ...ed clockwise Pressure rise Adjustment screw turned counterclockwise Pressure drop Pressure change rate 12 9 MPa turn 1 870 psi turn If there is no evidence of the locknut having loosened remove the po...

Page 169: ...connect the hose 1 or 2 from the power cylinder Attach the pressure gauge through the adapter Adapter G3 8 Pressure gauge 0 to 25 MPa 0 to 3 625 psi Confirm that the forward reverse lever is in the ne...

Page 170: ...emoved relief valve for trapped dirt scratches on its seat and other abnormalities If trapped dirt is present disassemble and clean the relief valve If a scratch or any other abnormality is found on t...

Page 171: ...ed dimension of rod 3 a 290 mm 11 4 in Specified dimensions of control cable 5 ends b 238 mm 9 37 in c 209 mm 8 23 in Confirm the stroke of the control lever 6 on the propulsion pump side Specified di...

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Page 173: ...TROUBLESHOOTING...

Page 174: ......

Page 175: ...y 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 inspectin...

Page 176: ...4 Wire Color Code and Number B Black BrY Brown Yellow stripe L Blue LgY Light green Yellow stripe W White YL Yellow Blue stripe BR Black Red stripe G Green LR Blue Red stripe R Red WB White Black stri...

Page 177: ...internally Since connectors are not numbered be sure to affix alignment marks so that you can restore them to their original condition Before making a diagnosis check related connectors for faulty con...

Page 178: ...equipment A measuring resistance between terminals 1 and 3 1 2 3 3 4 2 5 1 2 3 1 2 3 1 GW750 2 10004 Equipment A Connector Harness Equipment A Ohmmeter tester Equipment B Main power source of equipmen...

Page 179: ...probes and does not make any difference in the measurement Criteria for harness defects When there is no abnormality in the harness Less than 10 measured value If there is any abnormality in the harne...

Page 180: ...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 th...

Page 181: ...SHOOTING GW750 2 10002 Measurement from the backside of connector Measurement on a lead cable Connector Wire Test probe Needle Lead cable Measurement using a test harness Equipment B Test harness Equi...

Page 182: ...n 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 e...

Page 183: ...f burning or of an odor investigate as described follows 2 3 How to find cause of failure when fuse blown is reproduced Turn the starter switch OFF and remove the connector from the load valve pump Re...

Page 184: ...entify 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 I...

Page 185: ...g the DIAGNOSTIC switch displayed as a blink code Analyse the blink code as per the table on the engine manual After the fault blink code has been displayed the ENGINE CHECK lamp goes out for five sec...

Page 186: ...cable break or short circuit 1 2 6 Hand throttle cable break short circuit or signal implausible compared to signal of idle sensor 1 2 8 Charge air temperature sensor cable break or short circuit 1 3...

Page 187: ...cuit injector 6 1 6 4 Single injector cable break or short circuit injector 7 1 6 5 Single injector cable break or short circuit injector 8 2 1 2 Engine speed sensor engine running with cam shaft spee...

Page 188: ...2 8 1 ECU internal error EEPROM memory access 2 8 2 ECU internal error wrong voltage of internal 5 V reference source 1 to 3 2 9 2 ECU internal error ambient pressure sensor defective 3 1 4 Sensor 2 c...

Page 189: ...period outside target range or missing cylinder 5 5 3 6 Begin of injection period outside target range or missing cylinder 6 5 3 7 Begin of injection period outside target range or missing cylinder 7...

Page 190: ...3 D2 2 k RESISTOR UNIT AV60 B AV60 B 77 AIR DIFFERENTIAL 97 BrR 46 8R 86 8RW 55 15R DIODE DIODE 54 15R THROTTLE SWITCH 6 5 3 2 4 1 85 8WY F L 75A SWITCH RELAY EMR CONTROL GLOW PLUGS 52 BR 52 BR 64 FU...

Page 191: ...ity between connection If there is no continuity starter switch is faulty Replace starter switch 3 Starter Motor 1 When starter switch is START measure voltage between starter motor terminal 30 and ch...

Page 192: ...3 D2 2 k RESISTOR UNIT AV60 B AV60 B 77 AIR DIFFERENTIAL 97 BrR 46 8R 86 8RW 55 15R DIODE DIODE 54 15R THROTTLE SWITCH 6 5 3 2 4 1 85 8WY F L 75A SWITCH RELAY EMR CONTROL GLOW PLUGS 52 BR 52 BR 64 FU...

Page 193: ...art check relay terminal 1 inlet wire BR and chassis ground Standard voltage 12 V or more 2 When starter switch is START measure voltage between start check relay terminal 3 inlet wire BY and chassis...

Page 194: ...pressure area mounted on device side 3 Line to fuel supply pump 4 Fuel supply pump 5 Line to spin on fuel filter 6 Exchangeable fuel filter 7 Fuel line to control block 8 Control block FCU Fuel Contro...

Page 195: ...fail Replace fuel in tank with an appropriate one 2 Fuel Prefilter with sedimenter Fuel Filter Check that water in sedimenter is not above upper limit If amount of water exceeds limit engine does not...

Page 196: ...3 D2 2 k RESISTOR UNIT AV60 B AV60 B 77 AIR DIFFERENTIAL 97 BrR 46 8R 86 8RW 55 15R DIODE DIODE 54 15R THROTTLE SWITCH 6 5 3 2 4 1 85 8WY F L 75A SWITCH RELAY EMR CONTROL GLOW PLUGS 52 BR 52 BR 64 FU...

Page 197: ...and between 4 and 6 There is continuity in normal condition 2 When throttle switch is in MID position check continuity between throttle switch terminal 1 and 3 and between 4 and 6 There is continuity...

Page 198: ...3 D2 2 k RESISTOR UNIT AV60 B AV60 B 77 AIR DIFFERENTIAL 97 BrR 46 8R 86 8RW 55 15R DIODE DIODE 54 15R THROTTLE SWITCH 6 5 3 2 4 1 85 8WY F L 75A SWITCH RELAY EMR CONTROL GLOW PLUGS 52 BR 52 BR 64 FU...

Page 199: ...chassis ground Standard voltage 12 V or more 2 When starter switch is START measure voltage between switch relay terminal 5 wire and chassis ground Standard voltage 12 V or more If above item 1 is OK...

Page 200: ...20 A 20 A 15 A 15 A 20 A 20 A 18 L 14 WY SOL B BRAKE SOL VALVE 15 LgR 17 Y 15 LgR 14 WY 14 WY 17 Y 1 3 4 5 X B 1 3 4 5 5 3 2 1 16 BrW FOOT BRAKE RELAY X B FUSE BOX TO COMBINATION METER Not depressed...

Page 201: ...ground Standard voltage 12 V or more If above items 1 and 2 are OK and item 3 is NG foot brake relay is faulty Replace foot brake relay 3 Foot Brake Switch 1 When starter switch is ON measure voltage...

Page 202: ...20 A 20 A 15 A 15 A 20 A 20 A 18 L 14 WY SOL B BRAKE SOL VALVE 15 LgR 17 Y 15 LgR 14 WY 14 WY 17 Y 1 3 4 5 X B 1 3 4 5 5 3 2 1 16 BrW FOOT BRAKE RELAY X B FUSE BOX TO COMBINATION METER Not depressed...

Page 203: ...OK and item 3 is NG foot brake relay is faulty Replace foot brake relay 3 Foot Brake Switch 1 When starter switch is ON measure voltage between foot brake switch inlet wire WY and chassis ground Stand...

Page 204: ...20 A 20 A 15 A 15 A 20 A 20 A 18 L 14 WY SOL B BRAKE SOL VALVE 15 LgR 17 Y 15 LgR 14 WY 14 WY 17 Y 1 3 4 5 X B 1 3 4 5 5 3 2 1 16 BrW FOOT BRAKE RELAY X B FUSE BOX TO COMBINATION METER Not depressed...

Page 205: ...icity flows foot brake relay is faulty Replace foot brake relay 3 Foot Brake Switch When starter switch is ON measure voltage between foot brake switch outlet wire LgR and chassis ground There is no e...

Page 206: ...5Br F R LEVER VIBRATOR SWITCH VIBRATION MODE SELECTOR SWITCH 72 1 25Br 72 1 25Br 72 1 25Br 72 1 25Br 39 GY 36 BrR 38 WB 36 BrR 40 WL 40 WL X B 39 GY 37 YR VIBRATION FREQENCY SELECTOR SWITCH VIBRATOR S...

Page 207: ...em 1 is OK and item 2 is NG vibrator switch is faulty Replace vibrator switch F or R 3 F R Lever Vibrator Switch 1 When starter switch is ON measure voltage between F R lever vibrator switch terminal...

Page 208: ...5Br F R LEVER VIBRATOR SWITCH VIBRATION MODE SELECTOR SWITCH 72 1 25Br 72 1 25Br 72 1 25Br 72 1 25Br 39 GY 36 BrR 38 WB 36 BrR 40 WL 40 WL X B 39 GY 37 YR VIBRATION FREQENCY SELECTOR SWITCH VIBRATOR S...

Page 209: ...e between vibrator switches terminal 1 or 4 inlet wire Br and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between vibrator switches terminal 2 or 5 outlet...

Page 210: ...5Br F R LEVER VIBRATOR SWITCH VIBRATION MODE SELECTOR SWITCH 72 1 25Br 72 1 25Br 72 1 25Br 72 1 25Br 39 GY 36 BrR 38 WB 36 BrR 40 WL 40 WL X B 39 GY 37 YR VIBRATION FREQENCY SELECTOR SWITCH VIBRATOR S...

Page 211: ...ion frequency selector switch is faulty Replace vibration frequency selector switch 3 Vibration Relay 1 Vibration frequency selector switch is in 3000 and vibrator switches are in High or Low 1 When s...

Page 212: ...5Br F R LEVER VIBRATOR SWITCH VIBRATION MODE SELECTOR SWITCH 72 1 25Br 72 1 25Br 72 1 25Br 72 1 25Br 39 GY 36 BrR 38 WB 36 BrR 40 WL 40 WL X B 39 GY 37 YR VIBRATION FREQENCY SELECTOR SWITCH VIBRATOR S...

Page 213: ...normal condition with vibrator switch F is either High or Low and vibrator switch R is High Standard voltage 12 V or more with vibrator switch F is either High or Low and vibrator switch R is Low 3 W...

Page 214: ...5Br F R LEVER VIBRATOR SWITCH VIBRATION MODE SELECTOR SWITCH 72 1 25Br 72 1 25Br 72 1 25Br 72 1 25Br 39 GY 36 BrR 38 WB 36 BrR 40 WL 40 WL X B 39 GY 37 YR VIBRATION FREQENCY SELECTOR SWITCH VIBRATOR S...

Page 215: ...1 inlet wire GL and chassis ground There is no electricity in normal condition with vibrator switch F is Low and vibrator switch R is either High or Low Standard voltage 12 V or more with vibrator sw...

Page 216: ...5Br F R LEVER VIBRATOR SWITCH VIBRATION MODE SELECTOR SWITCH 72 1 25Br 72 1 25Br 72 1 25Br 72 1 25Br 39 GY 36 BrR 38 WB 36 BrR 40 WL 40 WL X B 39 GY 37 YR VIBRATION FREQENCY SELECTOR SWITCH VIBRATOR S...

Page 217: ...is either High or Low and vibrator switch R is Low Standard voltage 12 V or more when vibrator switch F is either High or Low and vibrator switch R is High 3 When starter switch is ON measure voltage...

Page 218: ...5Br F R LEVER VIBRATOR SWITCH VIBRATION MODE SELECTOR SWITCH 72 1 25Br 72 1 25Br 72 1 25Br 72 1 25Br 39 GY 36 BrR 38 WB 36 BrR 40 WL 40 WL X B 39 GY 37 YR VIBRATION FREQENCY SELECTOR SWITCH VIBRATOR S...

Page 219: ...n mode selector switch terminal 3 outlet wire G and chassis ground Standard voltage 12 V or more 3 When vibration mode selector switch is AUTO and starter switch is ON measure voltage between vibratio...

Page 220: ...5Br F R LEVER VIBRATOR SWITCH VIBRATION MODE SELECTOR SWITCH 72 1 25Br 72 1 25Br 72 1 25Br 72 1 25Br 39 GY 36 BrR 38 WB 36 BrR 40 WL 40 WL X B 39 GY 37 YR VIBRATION FREQENCY SELECTOR SWITCH VIBRATOR S...

Page 221: ...ore 3 When starter switch is ON measure voltage between vibration relay 4 terminal 5 outlet wire Br and chassis ground Standard voltage 12 V or more If above items 1 and 2 are OK and item 3 is NG vibr...

Page 222: ...5Br F R LEVER VIBRATOR SWITCH VIBRATION MODE SELECTOR SWITCH 72 1 25Br 72 1 25Br 72 1 25Br 72 1 25Br 39 GY 36 BrR 38 WB 36 BrR 40 WL 40 WL X B 39 GY 37 YR VIBRATION FREQENCY SELECTOR SWITCH VIBRATOR S...

Page 223: ...nal f inlet wire O and chassis ground Standard voltage 12 V or more If above items 1 and 2 are OK and item 3 is NG starter motor relay is faulty Replace starter motor relay 4 F R Lever Switch 1 When F...

Page 224: ...PRAY PUMP 2 R X 2B WATER SPRAY PUMP 1 R P WATER SPRAY PUMP 2 F X 2B P 83 2L 84 2LW WATER SPRAY PUMP SWITCH R 42 2Y 28 GB 28 GB 29 3WB X B 91 2YR 20A FUSE WATER SPRAY RELAY R P WATER SPRAY PUMP 1 F X 2...

Page 225: ...rminal 2 or 5 inlet wire and chassis ground Water spray pump switch F inlet wire W Water spray pump switch R inlet wire Y Standard voltage 12 V or more 2 When starter switch is ON measure voltage betw...

Page 226: ...PRAY PUMP 2 R X 2B WATER SPRAY PUMP 1 R P WATER SPRAY PUMP 2 F X 2B P 83 2L 84 2LW WATER SPRAY PUMP SWITCH R 42 2Y 28 GB 28 GB 29 3WB X B 91 2YR 20A FUSE WATER SPRAY RELAY R P WATER SPRAY PUMP 1 F X 2...

Page 227: ...ctor switch terminal 1 inlet wire WB and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between water spray selector switch terminal 2 outlet wire GB and chas...

Page 228: ...PRAY PUMP 2 R X 2B WATER SPRAY PUMP 1 R P WATER SPRAY PUMP 2 F X 2B P 83 2L 84 2LW WATER SPRAY PUMP SWITCH R 42 2Y 28 GB 28 GB 29 3WB X B 91 2YR 20A FUSE WATER SPRAY RELAY R P WATER SPRAY PUMP 1 F X 2...

Page 229: ...s NG with no abnormality found in grounding of water spray timer unit water spray timer is faulty Replace water spray timer 2 Water Spray Selector Switch 1 When starter switch is ON measure voltage be...

Page 230: ...5WR 5 2 6 4 3 1 43 LgB 1 2RB LAMP SWITCH 1 2RB 1 2RB HEADLAMP L 55W HEADLAMP R 55W FLOODLAMP L 55W FLOODLAMP R 55W 4 2O FUSE BOX X B 49 5L 49 5L Power excitation circuit 5V power supply Movement Movem...

Page 231: ...wire RB Terminal 4 outlet wire LgB Standard voltage 12 V or more If above item 1 is OK and item 2 is NG lamp switch is faulty Replace lamp switch 3 Flood Lamp Switch 1 When starter switch is ON measur...

Page 232: ...5WR 5 2 6 4 3 1 43 LgB 1 2RB LAMP SWITCH 1 2RB 1 2RB HEADLAMP L 55W HEADLAMP R 55W FLOODLAMP L 55W FLOODLAMP R 55W 4 2O FUSE BOX X B 49 5L 49 5L Power excitation circuit 5V power supply Movement Movem...

Page 233: ...voltage between combination meter terminal wire WR backlight terminal and chassis ground Standard voltage 12 V or more If above items 1 and 2 are OK and combination meter lamp does not turn on combina...

Page 234: ...5WR 5 2 6 4 3 1 43 LgB 1 2RB LAMP SWITCH 1 2RB 1 2RB HEADLAMP L 55W HEADLAMP R 55W FLOODLAMP L 55W FLOODLAMP R 55W 4 2O FUSE BOX X B 49 5L 49 5L Power excitation circuit 5V power supply Movement Movem...

Page 235: ...nal Standard voltage 12 V or more 2 Check that combination meter terminal RB GB and OG wires Engine speed 1 to 3 are grounded 3 Start engine and measure pulse between combination meter terminal O wire...

Page 236: ...5WR 5 2 6 4 3 1 43 LgB 1 2RB LAMP SWITCH 1 2RB 1 2RB HEADLAMP L 55W HEADLAMP R 55W FLOODLAMP L 55W FLOODLAMP R 55W 4 2O FUSE BOX X B 49 5L 49 5L Power excitation circuit 5V power supply Movement Movem...

Page 237: ...t unit temperature of 103 C 217 F If resistance is abnormal thermo unit is faulty Replace thermo unit 2 Resistor Unit Measure resistance between resistor unit R4 wire G and wire Sb Standard resistance...

Page 238: ...P COOLANT LEVEL 79 POWER INPUT 3 POWER INPUT 5 E G START SW 43 POWER INPUT 1 E G SPEED OUT 14 E G SPEED IN 15 GRAUND FOR MAIN RELAY 72 71 OIL PRES 51 OIL PRES EMR 3 D2 2 k 77 AIR DIFFERENTIAL 64 FUEL...

Page 239: ...and terminal wire B ground terminal Standard voltage 12 V or more If above item is OK and no abnormality is found in fuel unit combination meter is faulty Replace combination meter 3 Harness Connectin...

Page 240: ...P COOLANT LEVEL 79 POWER INPUT 3 POWER INPUT 5 E G START SW 43 POWER INPUT 1 E G SPEED OUT 14 E G SPEED IN 15 GRAUND FOR MAIN RELAY 72 71 OIL PRES 51 OIL PRES EMR 3 D2 2 k 77 AIR DIFFERENTIAL 64 FUEL...

Page 241: ...2 Check point Check Cause Action 1 Diode Unit 1 When starter switch is ON measure voltage between diode unit terminals and chassis ground Vibrator switch F is High Terminal E inlet wire GL Low Termina...

Page 242: ...P COOLANT LEVEL 79 POWER INPUT 3 POWER INPUT 5 E G START SW 43 POWER INPUT 1 E G SPEED OUT 14 E G SPEED IN 15 GRAUND FOR MAIN RELAY 72 71 OIL PRES 51 OIL PRES EMR 3 D2 2 k 77 AIR DIFFERENTIAL 64 FUEL...

Page 243: ...ke indicator lamp does not light even though parking brake switch is applied release parking brake switch is faulty Replace parking brake switch 2 Combination Meter 1 When starter switch is ON measure...

Page 244: ...4 REV RATIO SEL 3 REV RATIO SEL 2 OW WB W LgY OG GB 12V KEY SW ACC REV PULSE INPUT 1 R P O FUSE BOX B X 29 3WB 29 5WB 29 5WB 29 5WB BR NO COM E B BATTERY RELAY BACKLIGHT Power excitation circuit 5V p...

Page 245: ...d chassis ground Standard voltage 12 V or more If above items 1 and 2 are OK combination meter is faulty Replace combination meter 2 7 13 Flood lamp indicator lamp does not light Check that flood lamp...

Page 246: ...4 REV RATIO SEL 3 REV RATIO SEL 2 OW WB W LgY OG GB 12V KEY SW ACC REV PULSE INPUT 1 R P O FUSE BOX B X 29 3WB 29 5WB 29 5WB 29 5WB BR NO COM E B BATTERY RELAY BACKLIGHT Power excitation circuit 5V p...

Page 247: ...resistance of harness connecting between terminals Standard resistance 10 or less If resistance is abnormal harness is faulty Repair or replace harness 2 7 15 Backup buzzer does not sound Reference Fi...

Page 248: ...pes 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...

Page 249: ...l leakage of solenoid valve connecting oil supply circuit with charge circuit Brake release solenoid valve When solenoid is energized check if oil flows in return circuit to tank If so carry out follo...

Page 250: ...ure Stroke of propulsion pump swash plate is small because charge pressure is low decreasing discharge rate of propulsion pump Measure charge pressure If low check and adjust charge relief valve or re...

Page 251: ...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 dec...

Page 252: ...ibrator circuit pressure If normal clean or replace vibrator solenoid valve Vibrator pressure is bypassed because vibrator solenoid valve spool does not switch If vibrator solenoid valve spool does no...

Page 253: ...tor motor If drain quantity is larger than standard value repair vibrator motor or replace it if necessary 5 Vibrator Pump Decrease in discharge rate from vibrator pump due to reduced vibrator pump ef...

Page 254: ...r circuit pressure If high decrease vibration load 4 Suction Filter for Vibrator Pump Load of vibrator pump increases due to clogged filter causing temperature of hydraulic oil in circuit to rise Clea...

Page 255: ...al leakage of steering cylinder Repair steering cylinder or replace it if necessary 5 Suction Filter for Steering Pump Steering pump discharge rate decreases due to clogged filter Clean suction filter...

Page 256: ...valve If load is excessively heavy relief valve is open causing temperature of hydraulic oil in circuit to rise Measure steering circuit pressure If high decrease steering load 4 Suction Filter for S...

Page 257: ......

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