Sakai SW800 Series Shop Manual Download Page 94

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4-005

How to Use this Chapter, "TROUBLESHOOTING" and How to Follow the Troubleshooting Flow

Has filament of
bulb burnt?

YES

• 20~28V
• Switch on job lamp
switch.

Is stated voltage
fed to job lamp (in-
operative) terminal
that carries wire RL
(O)?

Possible cause

Remedy

Repair or renew
wire.

Renew.

High beam: Wire RL from job
lamp to job lamp switch termi-
nal 5 (from branch point) not
connected or incorrectly con-
nected.
Low beam: Wire O from job
lamp to relay terminal 5 (from
branch point) not connected or
incorrectly connected.

Repair or renew
wire.

Bulb filament has burnt.

Job lamp earth wire not con-
nected or incorrectly connect-
ed.

①

E-07 Head lamps do not operate

②

★

Measure the voltage with the starter switch ON.

★

Before diagnosis, check to see if the fuse has burnt.

③

b) Either right or left lamp does not light
* Wire color codes in parentheses ( ): SW800

➡

To Machine No.10122

SW850

➡

To Machine No.10126

Codes with no parentheses

➡

Common to both models

④

Summary of Contents for SW800 Series

Page 1: ...CONFIDENTIAL SHOP MANUAL Series ...

Page 2: ......

Page 3: ... SAKAI SW800 850 Series Vibrating Rollers This manual is designed to serve as a guide for the operator and maintenance personnel to acquire correct information and repair procedure on these machines in order to give a correct decision on problems which the machines will confront thus leading to quality repair Fully understand the contents of the manual and make the best of it We will make utmost e...

Page 4: ......

Page 5: ...CONTENTS SPECIFICATIONS 1 001 STRUCTURE OPERATION 2 001 INSPECTION ADJUSTMENT 3 001 TROUBLE SHOOTING 4 001 ...

Page 6: ......

Page 7: ...SPECIFICATIONS ...

Page 8: ......

Page 9: ...1 001 SPECIFICATIONS 1 External Views and Specifications 1 1 SW800 1 002 1 2 SW850 1 003 ...

Page 10: ...erall height 3 080 mm 121 Frequency 50 Hz 3 000 vpm Wheelbase 3 300 mm 130 Wheel Front Roll dia x width 1 300 x 1 700 mm 51 x 67 Rear Roll dia x width 1 300 x 1 700 mm 51 x 67 Performance Travel speed forward reverse Rated output 82 kW 111 PS 2 300 min 1 rpm 109 HP 2 300 rpm Low 0 7 5 km h 0 4 6 mile h Max torque 333 N m 1 600 min 1 rpm 246 ft lb 1 600 rpm High 0 12 5 km h 0 7 7 mile h Engine Vibr...

Page 11: ...verall width 2 205 mm 87 High amplitude Overall height 3 130 mm 123 Frequency 50 Hz 3 000 vpm Wheelbase 3 400 mm 134 42 Hz 2 500 vpm 42 Hz 2 500 vpm Wheel Vibrating power 100 kN 22 490 lbs Front Roll dia x width 1 400 x 2 000 mm 55 x 79 50 Hz 3 000 vpm Rear Roll dia x width 1 400 x 2 000 mm 55 x 79 Fuel tank Performance 250 liters 66 gal Gradability Travel speed forward reverse 31 17 2 Rated outpu...

Page 12: ...MEMO ...

Page 13: ...STRUCTURE OPERATION ...

Page 14: ......

Page 15: ...motor ass y 2 016 2 2 Coupling and hydraulic circuit 2 2 1 Coupling 2 017 2 2 2 Hydraulic circuit SW800 2 019 2 2 3 Hydraulic circuit SW850 2 020 2 3 Propulsion system 2 3 1 Propulsion controls 2 021 2 3 2 Hydraulic piping Ⅰ 2 022 2 3 3 Hydraulic piping Ⅱ 2 023 2 3 4 Propulsion circuit 2 024 2 3 5 Description and operation of propulsion system 2 025 2 4 Vibrating system 2 4 1 Amplitude select valv...

Page 16: ...nt panel and relays Ⅰ SW800 From Machine No 10122 SW850 From Machine No 10126 2 046 5 2 Locations of instrument panel and relays Ⅱ SW800 From Machine No 10123 SW850 From Machine No 10127 2 047 5 3 Locations of electric components Ⅰ SW800 From Machine No 10122 SW850 From Machine No 10126 2 048 5 4 Locations of electric components Ⅱ SW800 From Machine No 10123 SW850 From Machine No 10127 2 049 5 5 F...

Page 17: ...Engine related Units 2 003 1 Engine related Units 1 1 Engine mount SW800 SW8002001 1 1 1 2 2 2 1 Engine mount front 2 Engine mount rear ...

Page 18: ...2 004 1 2 Engine mount SW850 SW8502001 1 1 1 2 2 2 1 Engine mount front 2 Engine mount rear Engine related Units ...

Page 19: ...2 005 Engine related Units 1 3 Intake system SW800 1 Air cleaner 2 Intake hose 3 Air feed pipe 4 Turbo charger SW8002002 1 2 4 1 2 4 3 3 ...

Page 20: ...2 006 1 4 Intake system SW850 1 Air cleaner 2 Intake hose SW8502002 2 1 1 2 Engine related Units ...

Page 21: ...Engine related Units 1 5 Exhaust system SW800 C E E E E SECTION C C SECTION E E SECTION B B SECTION A A B A A C SECTION F F F F SW8002003 B 4 3 2 1 2 3 1 Exhaust pipe 2 Muffler 3 Exhaust pipe 4 Turbo charger ...

Page 22: ...2 008 1 6 Exhaust system SW850 E E SECTION A A SECTION B B SECTION E E SECTION C C B B A A E E C C SECTION F F F F SW8502003 3 2 1 2 3 1 Exhaust pipe 2 Muffler 3 Exhaust pipe Engine related Units ...

Page 23: ...2 009 Engine related Units 1 7 Cooling piping radiator SW8002004 1 5 3 1 2 4 1 Radiator 2 Sub tank 3 Radiator inlet hose 4 Radiator outlet hose 5 Oil cooler ...

Page 24: ... VIEW B VIEW A B A SW8002005 7 3 9 4 7 4 7 2 2 4 1 4 3 8 6 5 1 Fuel tank 2 Sedimenter 3 Hose fuel tank to sedimenter 4 Hose sedimenter to feed pump 5 Pipe feed pump to filter 6 Pipe filter to injection pump 7 Hose engine to fuel tank 8 Filter 9 Fuel unit ...

Page 25: ...011 Engine related Units 1 9 Fuel controls SW800 A DETAIL A SECTION B B B B SW8002006 5 3 1 2 3 4 1 Throttle lever 2 Throttle cable 3 Engine stopper 4 Engine stopper cable 5 Throttle lever adjusting screw ...

Page 26: ...12 1 10 Fuel controls SW850 A SECTION B B DETAIL A B B SW8502004 3 5 1 2 4 3 1 Throttle lever 2 Throttle cable 3 Engine stopper 4 Engine stopper cable 5 Throttle lever adjusting screw Engine related Units ...

Page 27: ...lve 8 Charge circuit pressure gauge port 9 Control valve 10 Servo piston 11 Cut off valve Vibrator pump 12 Port A2 front circuit 13 Port A3 rear circuit 14 Circuit pressure gauge port port A2 15 Circuit pressure gauge port port A3 16 Suction port 17 Frequency delivery select valve Specifications propulsion pump Model A4VG90HW Max displacement 90cm3 rev cc rev Relief valve setting 40 2MPa 410kgf cm...

Page 28: ...tion of Hydraulic System SW8002008 1 2 2 1 2 Steering pump 1 Port A 2 port B 3 Drain port Specifications Model A2FM16 Displacement 16cm3 rev cc rev Circuit pressure setting 22 5MPa 230kgf cm2 3270psi Set by amplitude select valve ...

Page 29: ...ain circuit port Brake 11 Disc 12 Plate 13 Brake piston Motor 14 Piston 15 Cylinder block 16 Swashplate Specifications SW800 Model MF55 5111 front MF55 506 rear Displacement 55 1cm3 rev cc rev Flushing relief setting 2 4MPa 24kgf cm2 340psi Circuit pressure setting 40 2MPa 410kgf cm2 5830psi To be set on propulsion pump side Specifications SW850 Model MF75E front MF75D rear Displacement 75cm3 rev ...

Page 30: ... Hydraulic System 2 1 4 Vibrator motor ass y SW8002010 2 2 1 3 1 Suction port 2 Delivery port Specifications Model SGP123R517 Displacement 23 3cm3 rev cc rev Circuit pressure setting 15 2MPa 155kgf cm2 2200psi To be set on Orbitrol side ...

Page 31: ...2 017 Description and Operation of Hydraulic System 2 2 Coupling and hydraulic circuit 2 2 1 Coupling SW8002011 1 2 3 6 5 4 7 1 Flywheel 2 Bolt 3 Coupling 4 Bolt 5 Set screw 6 Spring pin 7 Boss ...

Page 32: ...2 018 ...

Page 33: ...ropulsion pump 2 5MPa 25kgf cm2 350psi 37 2MPa 380kgf cm2 5400psi Frequency selector valve Suction filter Vibrator pump Line filter charge circuit 23 3cm3 cc rev 15 2MPa 155kgf cm2 2200psi 461cm3 cc rev Orbitrol Steering pump Suction filter Steering cylinder φ70Xφ35 380ST mm φ2 8Xφ1 4 15ST in Steering cylinder φ70Xφ35 380ST mm φ2 8Xφ1 4 15ST in Brake release solenoid valve 22 5MPa 230kgf cm2 3270p...

Page 34: ...Pa 25kgf cm2 350psi 37 2MPa 380kgf cm2 5400psi Frequency selector valve Suction filter Vibrator pump Line filter charge circuit 23 3cm3 cc rev 15 2MPa 155kgf cm2 2200psi 461cm3 cc rev Orbitrol Steering pump Suction filter Steering cylinder φ70Xφ35 380ST mm φ2 8Xφ1 4 15ST in Steering cylinder φ70Xφ35 380ST mm φ2 8Xφ1 4 15ST in Brake release solenoid valve 22 5MPa 230kgf cm2 3270psi 24 0MPa 245kgf c...

Page 35: ...m 2 3 Propulsion system 2 3 1 Propulsion controls SECTION B B DETAIL C C B B SW8002013 6 5 2 5 4 3 1 1 Forward reverse F R lever 2 Vibrator switch 3 Forward reverse F R lever switch 4 Reverse alarm switch 5 Control cable 6 Control lever propulsion pump ...

Page 36: ...nloader valve 5 Hose unloader 6 High pressure hose forward travel of front motor 7 High pressure hose reverse travel of rear motor 8 Brake release hose filter to brake release valve 9 Brake release hose brake relief valve to front propulsion motor 10 Return hose front propulsion motor to hydraulic tank 11 Return hose propulsion pump to hydraulic tank 12 Hydraulic tank drain hose Hose 10 meets with...

Page 37: ... Brake release valve to front propulsion motor 10 Return hose front propulsion motor to hydraulic tank 14 Propulsion pump 15 Front propulsion motor 16 Rear propulsion motor 17 High pressure hose forward travel of front motor 18 High pressure hose reverse travel of rear motor 19 Brake release hose brake release valve to rear propulsion motor 20 Return hose rear propulsion motor to hydraulic tank 21...

Page 38: ... ass y a Control valve b Servo cylinder c High pressure relief valve d Charge relief valve e Cut off valve 4 Return filter 5 Unloader valve 6 Vibrator pump ass y 7 Rear propulsion motor ass y f Shuttle valve g Flushing valve h Negative brake i Gear reducer 8 Front propulsion motor h Negative brake valve i Gear reducer 9 Front drum 10 Rear drum 11 Brake release valve 12 Suction filter 13 Steering p...

Page 39: ...7 and rear drum 9 Brake release solenoid valve 11 is mount ed on the chassis Basic function of propulsion pump and propulsion motor Propulsion pump A piston pump is used which selects forward travel neutral and backing by varying the swashplate inclination and thus varying the piston stroke The travel speed is infinitely variable by the operation of the F R forward reverse lever Propulsion motor A...

Page 40: ...ports of the motors drives the motors flowing out from the opposite side ports Two flows of oil from the motors meet with each other and get into port A of pump 3 At the same time part of oil in the rear motor is dumped into the tank through shuttle valve f and flushing valve g both of which are built in motor 7 and also through the motor casings Power from the motors is delivered to drums 9 and 1...

Page 41: ...on circuit is of a closed circuit which needs feeding of oil into it for making up for deficiency and for other purposes In the charge circuit oil from steering pump 13 flows into Orbitrol 14 then the whole amount of oil goes to propulsion pump 3 via filter 15 irrespective of the steering wheel operation The pressure adjustment is achieved by charge relief valve d built in the propulsion pump when...

Page 42: ...Port A1 connected to port B in front motor and to port A in rear motor Port B1 connected to port A in front motor and to port B in rear motor 1 Main relief valve 2 Port relief valve 3 Port relief valve 4 Check valve 5 Solenoid 6 Solenoid 7 Spool Specifications Model 1D04T1S00432 0 Main relief valve setting 22 5MPa 230kgf cm2 3270psi Port relief valve setting 24 0MPa 245kgf cm2 ...

Page 43: ...ct in the same direction HIGHT Amp LOW Amp Fixed and movable weights direct in the opposite direction with each other 1 Vibrator shaft 2 Roller bearing 3 Sleeve 4 Spring pin 5 Housing 6 Vibrator shaft 7 Axle shaft 8 Plug fill drain 9 Oil seal 10 Roller bearing 11 Damper 12 Oil seal 13 Cover 14 Vibrator motor 15 Shim 16 Breather 17 Disc 18 Sleeve 19 Spring pin 20 Drum 21 Housing 22 Propulsion motor...

Page 44: ...lect valve front 4 Delivery hose pump to amplitude select valve 5 Return hose amplitude select valve to hydraulic tank front 6 Return hose amplitude select valve to hydraulic tank rear 7 Oil cooler 8 Return hose oil cooler to hydraulic tank 9 Drain hose vibrator pump to hydraulic tank 10 Suction filter vibrator pump 11 Frequency select valve 12 Pilot pressure hose for frequency select valve ...

Page 45: ...nt 15 High pressure hose hose A 16 High pressure hose hose B 17 Drain hose vibrator motor to hydraulic tank 18 Vibrator motor rear 19 Amplitude select valve rear 20 High pressure hose hose B 21 High pressure hose hose A 22 Drain hose vibrator motor to hydraulic tank 23 Hydraulic tank Hose 17 meets with vibrator motor hose 22 and leads to tank P 2 032 ...

Page 46: ...pump ass y 4 Vibrator pump ass y a Solenoid valve frequency select b Control piston frequency select c Spring delivery control 5 Amplitude select valve d Solenoid a Low e Solenoid b High f Spool g Main relief valve h Port relief valve 6 Amplitude select valve rear d solenoid a High amp e Solenoid b Low amp f Spool g Main relief valve h Port relief valve i Check valve 7 Front vibrator motor 8 Rear ...

Page 47: ... A bent axis type fixed displacement piston motor is used The displacement per rotation of motor shaft is not variable Operation The vibrator pump delivers an amount of oil set by the frequency selector switch which is drained to the tank via frequency select valves 5 6 and oil cooler 11 Only the rear propulsion circuit includes an oil cooler The frequency select solenoid valves provide Maximum de...

Page 48: ...d line line which feeds oil to motor of the motor because ports A1 and B1 are blocked Then the one way valve mounted in port relief valve h on the low pressure side opens to feed part of oil in the return line to the motor In addition because the outlet port of the motor stays closed oil displaced from the enertia rotating motor flows into the return line by opening the port relief valve in the ou...

Page 49: ...lector switch F Fuse 15A Vibrator relay 1 Vibrator relay 3 Vibrator relay 2 Amplitude select valve F Amplitude select valve R Frequency select valve SW8002026 a b To combination meter Amplitude selector switch R Frequency selector switch 3 Operation of amplitude selector switches and solenoids 1 Amplitude selector switch set to Low amplitude Terminal 1 connects to terminal 2 Solenoid b of the fron...

Page 50: ...om the frequency selector switch energizes solenoid b of the frequency select valve This gives the same frequency Medium frequency as in item 4 2 above 4 Frequency selector switch in High frequency position Terminals 1 and 4 connect with terminals 3 and 5 respectively with amplitude selector switch in Low amplitude position terminal 1 connects with terminal 2 Current flow from terminal 3 of the fr...

Page 51: ...t needle 8 Retaining ring 9 Oil seal 10 Dust seal 11 Seal gland bush 12 Filter sub ass y 13 Lock nut 14 Spool 15 Valve seat 16 Ball 17 Ball guide 18 Inner valve spring 19 Spacer 20 End cap Specifications Valve system Open center non load reaction Displacement 461 cm3 rev cc rev Relief valve setting 15 2 MPa 155 kgf cm2 2200 psi ...

Page 52: ... ass y SW8002027 16 14 15 2 6 13 5 12 4 9 10 1 14 15 11 7 3 8 1 Cylinder 2 Piston rod 3 End cap 4 Bush 5 Piston 6 Nut 7 Washer 8 Dust seal 9 U packing 10 O ring 11 O ring 12 Slipper seal 13 Wear ring 14 Spherical bearing 15 Ring 16 Grease fitting ...

Page 53: ...pump 2 Pump outlet hose 3 Suction hose 4 Steering valve Orbitrol 5 Steering cylinders 6 High pressure hose left turn 7 High pressure hose right turn 8 Charge line hose Orbitrol to filter 9 Line filter charge line A VIEW A 5 2 4 8 9 5 1 7 6 3 4 9 8 SW8002028 ...

Page 54: ...rcuit T OUT IN P D S PTO R L SW8002029 C 6 6 5 4 7 a b 1 2 3 To propulsion pump 1 Engine 2 PTO engine side 3 Suction filter 4 Steering pump 5 Orbitrol a Relief valve b Check valve 6 Steering cylinder c Piston rod 7 Line filter charge circuit ...

Page 55: ... handled varies with the direction in which the steer ing wheel is rotated and with the speed at which the steering wheel is turned The fluid fed into both steering cylinders 6 moves the piston rods c to achieve steer ing The oil displaced from the opposite side of the pistons flows through Orbitrol 5 and line filter 7 to the propulsion charge cir cuit Refer to Charge circuit Relief valve a built ...

Page 56: ...e System 3 1 Brake pedal and linkage SW8002031 1 2 6 5 5 6 2 4 1 3 7 1 Brake pedal 2 Rod 3 Adjusting bolt pedal height adjustment 4 Stopper 5 Lever F R lever neutral position 6 Lever F R lever neutral position 7 Foot brake switch ...

Page 57: ...rent to flow through terminals 1 and 3 to terminal 3 of the brake relay If at this time the brake pedal is not depressed foot brake switch 7 remains ON energizing the brake relay This connects terminal 3 with terminal 5 of the brake relay The solenoid of the brake release valve is energized to disengage the parking brakes negative brakes 11 Parking brake switch set to position PARK ING Pushing dow...

Page 58: ...C B D A SW8002033 3 2 4 5 6 7 1 12 8 7 11 9 10 5 6 1 Sprinkler pump front 2 Sprinkler tank ass y front 3 Sprinkler filter front 4 Sprinkler pipe front 5 Hose tank to filter 6 Hose filter to pump 7 Hose pump to pipe 8 Sprinkler pump rear 9 Sprinkler tank ass y rear 10 Sprinkler filter rear 11 Sprinkler pipe rear 12 Hose front pump to rear pump ...

Page 59: ...0123 SW850 From Machine No 10127 SW8002043 SECTION A A VIEW B B 7 6 7 8 6 B B A A 3 1 2 1 5 3 5 4 1 Sprinkler pump 2 Sprinkler tank 3 Sprinkler filter 4 Sprinkler pipe 5 Hose tank to filter 6 Hose filter to pump 7 Hose filter to pump 8 Hose pump to sprinkler pipe ...

Page 60: ...F HEAT OFF START ON FRONT REAR FREQUENCY OFF OFF FRONT REAR SW8002034 1 2 5 6 7 4 3 8 15 14 13 12 11 10 9 17 16 1 Combination meter panel 2 Vibrator relay 1 3 Vibrator relay 3 4 Vibrator relay 2 5 Horn relay 6 Lamp check relay 7 Foot brake relay 8 Fuse box 9 Diode 10 Engine stop relay 11 Delay relay 12 Glow timer 13 Job lamp relay 14 Diode unit 15 Lamp relay 16 Sprinkler relay 17 Sprinkler relay ...

Page 61: ... A D C B 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 2 1 Combination panel 2 Sprinkler relay rear 3 Sprinkler relay front 4 Fuse box 5 Horn relay 6 Foot brake relay 7 Vibrator relay 4 8 Diode 9 Vibrator relay 1 10 Vibrator relay 3 11 Starter motor relay 12 Lamp check relay 13 Diode 14 Engine stop relay 15 Delay relay 16 Vibrator relay 17 Glow timer ...

Page 62: ... direction select 8 Thermo unit 9 Job lamp 10 Glow plug 11 Engine oil pressure switch 12 Engine stopper 13 Sprinkler pump rear 14 Reverse alarm 15 Tachometer sensor 16 Starter 17 F R lever switch 18 Reverse alarm switch 19 Amplitude selector switch front vibrator motor rotating direction select 20 Frequency select valve vibrator pump delivery select 21 Brake release solenoid valve 22 Vibrator swit...

Page 63: ...otor 8 Thermo unit 9 Job lamp 10 Glow plug 11 Engine oil pressure switch 12 Engine stopper 13 Sprinkler pump rear 14 Reverse alarm 15 Tachometer sensor 16 Starter 17 F R lever switch 18 Reverse alarm switch 19 Amplitude select valve front selects rotating direction of vibrator drive motor 20 Frequency select valve selects vibrator drive pump delivery 21 Brake release solenoid valve 22 Vibrator swi...

Page 64: ...top relay terminal 3 connects with terminal 5 The current flows as follows Battery Battery relay Terminal A of engine stop per Terminal B of engine stopper Terminal 5 of engine stop relay Terminal 3 of engine stop relay Plus terminal of motor in engine stopper The motor is driven The control cable is extended Terminal D rotates with the motor When insulated part of terminal D reaches terminal B th...

Page 65: ...rminal C of engine stopper Terminal 6 of engine stop relay Terminal 3 of engine stop relay Plus terminal of motor in engine stopper The motor runs The control cable is retracted Terminal D rotates with the motor When the insulated portion of terminal D reaches terminal C the circuit between terminal A and terminal B is open to cut off current from the battery The motor continues running by inertia...

Page 66: ... 2Y HEADLAMP 62W LOW HIGH F R LEVER SWITCH VIBRATOR ON OFF a b SOL a SOL FREQUENCY SELECTOR SWITCH SOLENOID VALVE F SOLENOID VALVE b b SOL SOLENOID VALVE R a LR WY YR BrY GY GY WL LW B WB BrR YR LgY LR WY 4 5 1 2 2 B WATER SPRAY WATER SPRAY SWITCH RELAY F WL BrR VIBRATOR RELAY 1 B B VIBRATOR RELAY 3 GL LgY YR L H H L H L LIGHTING SWITCH LIGHTING RELAY 1 5 B 2RY FLOOD LAMP SWITCH O L G GB G GW 5WR ...

Page 67: ... B WB BrR YR LgY YW BY 4 5 1 2 4 5 1 2 2 B WATER SPRAY RELAY F WL BrR B VIBRATOR RELAY 1 B B VIBRATOR RELAY 3 GL LgY YR L H L H H L H L LIGHTING SWITCH 6 B 4 WR RL FLOOD LAMP SWITCH WR O BrB RB GB LgB WB 5WR F L 65A 5WR 5W WB 2BY B WATER SPRAY RELAY R GB STARTER MOTOR RELAY BrR B RELAY 2 GL BrB GL LR Br G Br 4 5 1 2 B VIBRATION RELAY 4 3 6 LR YL YR LgY GL P WATER SPRAY PUMP FRONT 2B P WATER SPRAY ...

Page 68: ...INSPECTION ADJUSTMENT ...

Page 69: ......

Page 70: ... the machine leaves the factory They should be used for estimation of wear after extended operation and for guidance when the machine is repaired 2 Values in the chart are ones based on various test results etc They should be used for a guide for fault finding practice in due consideration of the past repair frequency and operating record of the machine 3 Values in the chart should not be used for...

Page 71: ... 1 0 2 0 440 0 20 6260 280 39 2 400 5690 2 9 0 3 30 3 0 420 42 2 0 20 280 Vibrator circuit 17 2 1 0 175 10 2490 140 20 6 210 2130 22 5 1 0 230 10 3270 140 20 6 210 2980 Steering relief pressure 18 1 1 0 185 10 2630 140 16 7 170 2410 Parking brake release pressure 2 9 0 3 30 3 0 420 42 2 0 20 280 Engine at full throttle Coolant temp Green zone on gauge Hydraulic oil working temperature 50 5 C 122 4...

Page 72: ... pressure 1st Reverse 2300 Travel speed Forward 2nd km h mph 0 7 0 1 5 0 4 35 0 93 Port relief pressure Oil pressure Hydraulic oil working temperature 50 5 C 122 41 F For adjustment see relevant items in this chapter INSPECTION AND ADJUSTMENT 0 11 0 1 5 0 6 21 0 93 2nd MPa kgf cm2 psi 0 7 0 1 5 0 4 35 0 93 0 11 0 1 5 0 6 21 0 93 Propulsion circuit 37 2 0 2 0 380 0 20 5400 280 34 3 350 4970 43 1 0 ...

Page 73: ...3 101 ...

Page 74: ...ward travel Port 2 for reverse travel Pressure gauge 0 60 MPa 0 600 kgf cm2 0 9000 psi 2 Apply the parking brake by operating the parking brake switch 3 Start the engine and set the throttle to high idle 4 Move the F R lever so that the pressure in the port to be measured may build up Take the pressure reading quickly Immediately when the measurement has been taken bring the lever to the neutral p...

Page 75: ...ures as described in steps 1 1 1 to 1 1 4 above 2 Adjustment If the measured value falls outside the permissible range adjust as follows 2 1 Cut off valve 1 If locknut 4 of cut off valve 3 has no signs of looseness dismount and disas semble the cut off valve to clean Do not loosen locknut 4 to keep the set ting unchanged Renew parts having signs of damages Tightening torque Item 3 22 N m 224 kgf c...

Page 76: ...or reverse travel has no signs of looseness dismount and disas semble the high pressure relief valve Do not loosen locknut 4 to keep the setting unchanged Renew parts having signs of damage Tightening torque Items 7 8 150 N m 1 530 kgf cm 110 lbf ft Item 9 100 N m 1 020 kgf cm 73 8 lbf ft Item 10 50 N m 510 kgf cm 36 9 lbf ft Item 11 20 N m 204 kgf cm 14 8 lbf ft Carefully perform disassembly and ...

Page 77: ... if correctly adjusted 6 When the adjustment is complete bring the cut off valve to the correct setting by screwing out adjust screw 5 of the cut off valve one full turn and tightening locknut 4 7 Recheck the setting of the cut off valve by using the procedures in steps 1 1 1 to 1 1 4 above 8 If the valve is beyond adjustment take necessary measures referring to relevant items in TROUBLE SHOOTING ...

Page 78: ...ulsion to vibrator pump and fit a pressure gauge with adapter Gauge port G3 8 Pressure gauge 0 5 MPa 0 50 kgf cm2 0 700 psi 2 Start the engine and set the throttle to high idle 3 The charge pressure will vary Take the maximum pressure reading 2 Adjustment 1 If locknut 15 of charge relief valve 14 has no signs of looseness dismount disassemble and clean the charge relief valve Do not loosen locknut...

Page 79: ...e or decrease in pressure per 1 4 turns of adjust screw 0 38 MPa 3 9 kgf cm2 55 psi 3 For the pressure measurement during the adjustment use procedures as described in steps 1 1 to 1 3 above 4 When the adjustment is complete tighten locknut 14 and recheck to see if correctly adjusted 5 If the valve is beyond adjustment take necessary measures referring to relevant items in TROUBLE SHOOTING ...

Page 80: ... Measurement Hydraulic oil temperature 50 5 C 122 41 F 1 Disconnect brake release hoses 1 from the propulsion motor and fit a pressure gauge with adapter Plug the open port of the motor Pressure gauge 0 5 MPa 0 50 kgf cm2 0 700 psi 2 Start the engine and set the throttle to high idle 3 Make sure that the F R lever stays in the neutral position 4 Press down the parking brake switch to free the brak...

Page 81: ...ock the line Plug the open port of the motor 3 Operate the frequency selector switch and amplitude selector switch to select MEDI UM FREQUENCY and LOW AMPLITUDE respectively For the machines falling into the following machine numbers select CONT mode by means of CONT AUTO selector switch SW800 From Machine No 10123 SW850 From Machine No 10127 4 Start the engine and set the throttle to high idle 5 ...

Page 82: ...he vibrator by pressing the vibrator switch on top of the F R lever Measure the port relief pressure in the HIGH AMPLITUDE port Take the reading and shut down the vibrator as quickly as practicable 6 Select LOW AMPLITUDE by operating the amplitude selector switch Operate the vibrator by pressing the switch on top of the F R lever Measure the port relief pres sure in LOW AMPLITUDE port Take the rea...

Page 83: ...rm disassembly and reassembly taking necessary means to avoid ingress of foreign matter 2 To adjust the setting loosen locknut 5 and rotate adjusting screw 6 Adjusting screw Clockwise turn increases pressure Counterclockwise turn decreases pres sure Increase or decrease in pressure per 1 4 turns of adjust screw 3 38 MPa 34 5 kgf cm2 490 psi 3 Use the procedures in item 1 1 Main relief valve for pr...

Page 84: ...cknut 10 and rotate adjusting screw 11 Adjusting screw Clockwise turn increases pressure Counterclockwise turn decreases pres sure Increase or decrease in pressure per 1 4 turns of adjust screw 5 5 MPa 56 kgf cm2 796 psi 4 Use the procedures in item 1 2 Port relief valve for pressure measurement during the setting adjustment 5 When the adjustment is complete tighten the locknut and recheck the set...

Page 85: ...auge 0 25 MPa 0 250 kfg cm2 0 3 500 psi 2 Start the engine Ensuring that the F R lever is in the neutral position set the throt tle lever to high idle 3 Rotate the steering wheel clockwise to full lock and take the reading of the pressure gauge Do not allow the relief valve to stay open longer than 3 seconds 2 Adjustment If the measured value is not within the permissible range disassemble and cle...

Page 86: ...0 950 25 min 1 rpm SW850 800 25 min 1 rpm 4 With throttle lever 1 set to full throttle loosen locknut 7 and adjust stop bolt 8 so that governor lever 3 makes contact with stopper 6 on the full throttle side 5 Start the engine Check that the high idle rpm is to specification High idle 2 580 50 min 1 rpm If high idle is lower than specified with governor lever 3 in contact with the stopper on the fu...

Page 87: ...as shown Length Rod 2 290 mm 11 41 in Cable 3 401 mm 9 37 in Make sure that the F R lever moves smoothly 2 Set pump control lever 4 to the neutral position Connect the cable to the pump control lever with length a adjusted by nuts 5 3 Move the F R lever to notch positions for ward and backward to see if lever 4 cer tainly follows the F R lever movement 4 To adjust the neutral position rotate nuts ...

Page 88: ...TROUBLESHOOTING ...

Page 89: ......

Page 90: ...ow to perform troubleshooting practice 4 003 3 How to use this chapter TROUBLESHOOTING and how to follow the flow chart 4 004 4 Precautions for troubleshooting of electric system 4 006 5 Troubleshooting for electric system Mode E 4 201 6 Troubleshooting Mode H 4 401 ...

Page 91: ...urs spare parts or expendables like oil or grease To make matters worse such a careless prac tice will invite operator s customer s dis trust For these reasons sufficient advance investigations and diagnosis in accordance with troubleshooting procedures specified are essential for efficient fault finding prac tices 2 Questions to be addressed to the opera tor customer 1 Are there any trouble other...

Page 92: ...alogue Procedure 4 Going to site where the faulty machine stays idle Procedure 7 Troubleshooting Determination of remedy 1 Before troubleshooting find out and rectify simple failure Daily inspections Other inspections required 2 With reference to TROUBLESHOOTING in this manual make a diagnosis by following proper diagnosis flows best applicable to rectify the trouble Procedure 5 Getting detailed i...

Page 93: ... diagnosis Each box contains diagnosis procedure Depending upon these results of inspection or measurement proceed to YES or NO line Normally if the result is YES then proceed to upper line If NO then go to the lower line NOTE The number above each box is a reference number It does not mean a sequence in which diagnoses proceed As a result of a diagnosis if YES line or NO line directly goes to the...

Page 94: ...nch point not connected or incorrectly con nected Low beam Wire O from job lamp to relay terminal 5 from branch point not connected or incorrectly connected Repair or renew wire Bulb filament has burnt Job lamp earth wire not con nected or incorrectly connect ed E 07 Head lamps do not operate Measure the voltage with the starter switch ON Before diagnosis check to see if the fuse has burnt b Eithe...

Page 95: ...for the controller circuit If the power source is switched on with the connector disconnected this can cause an incorrect measurement 4 When making a diagnosis of circuits measurement of voltage resistance current test for conti nuity etc check to see if tester readings vary by shaking connectors or harnesses If readings vary a possible cause is a poor connection of the circuit 5 For voltage measu...

Page 96: ...n Black stripe RW Red White stripe Y Yellow Sb Sky blue Wire color code E 01 Engine does not start 4 202 E 02 Engine does not stop 4 207 E 03 Glow plugs do not become red hot Engine is hard to start 4 208 E 04 No charging charge lamp stays bright 4 210 E 05 Reverse alarm does not sound 4 211 E 06 Horn does not sound 4 212 E 07 Headlamps do not operate 4 214 E 08 Job lamps do not come on 4 220 E 09...

Page 97: ...s set to ON and OFF 3 YES Is stated voltage present at starter terminal B that car ries wire B 20 28V Turn starter switch to START NO 13 Is stated voltage present at battery relay terminal BR that carries wire RB BrY YES 4 YES Is stated voltage present at starter ter minal C NO Is stated voltage present at safety relay terminal C 5 YES NO NO Is stated voltage present at battery relay terminal B 20...

Page 98: ... renew wire Alternator faulty including regulator Renew Wire B from battery relay to starter not connected or incor rectly connected Repair or renew wire Battery relay contact faulty Renew Renew Battery relay coil faulty Wire BR or RB BrY from start er switch terminal BR to bat tery relay terminal BR not con nected or incorrectly connect ed including diode Repair or renew wire Starter switch fault...

Page 99: ...onnected in cluding fuse Renew fuse Repair or renew wire F R lever switch faulty Renew to B on this page 20 28V Turn starter switch to START Wire BW LB from starter switch terminal C to F R lever switch not connected or incorrectly con nected Repair or renew wire Starter switch faulty between B and C Renew Electric wiring diagram for mode E 01 a Wire color codes in parentheses SW800 From Machine N...

Page 100: ...tage present at engine stopper that carries wire L G Is specified voltage present at engine stop relay terminal 1 that carries wire BR YES NO 20 28V 20 28V Possible cause Remedy Wire BY L from engine stop per to battery relay to branch point not connected or incor rectly connected Repair or renew wires To A on this page Wire LW from engine stopper to engine stop relay terminal 5 not connected or i...

Page 101: ...Y B P1 P2 AR E LW L G G B RB A B C D M Engine stopper Engine stop relay Starter switch SW8004002 Fusible link BrY From delay relay terminal 5 Electric wiring diagram for mode E 01 b and E 02 Wire color codes in parentheses SW800 From Machine No 10123 SW850 From Machine No 10127 Codes with no parentheses Common to both models ...

Page 102: ... that carries wire BR YES NO Is stated voltage fed to engine stop relay terminal 6 that carries wire LY 4 YES NO 5 Disconnect cable from fuel cut off lever Possible cause Remedy Engine stopper cable faulty Adjust Renew if necessary 20 28V To A on this page Engine stopper faulty Renew Wire BY L from engine stop per to battery relay terminal B to branch point not connect ed or incorrectly connected ...

Page 103: ...r ter minal that carries wire RG Does stated vol tage appear at glow plug that car ries wire G W YES NO 4 20 28V Turn starter switch ON 1 b Indicator becomes bright but engine does not start smoothly 20 28V Turn starter switch to HEAT 20 28V Turn starter switch ON 20 28V Turn starter switch to HEAT Possible cause Remedy Glow plug timer faulty Renew Wire G W from starter switch terminal R2 to glow ...

Page 104: ...r Fuse 15A SW8004003 W W W WL Number of glow plugs 4 pieces for SW800 and 6 pieces for SW850 From battery relay Glow plug timer Combination meter Electric wiring diagram for mode E 03 Wire color codes in parentheses SW800 From Machine No 10123 SW850 From Machine No 10127 Codes with no parentheses Common to both models ...

Page 105: ... carries wire R Possible cause Remedy Lamp check relay faulty Renew Alternator faulty Renew Alternator earth wire not con nected or incorrectly connect ed Repair or renew wire Wire R or Y from battery to alternator terminal B not con nected or incorrectly connect ed Repair or renew wire Battery relay B Y Diode BR RB WG L BY LgB BY L Delay relay B BR ACC LgW LgW LgB B BY 1 2 5 3 3 5 2 1 3 Fuse 15A ...

Page 106: ... 4 YES NO 20 28V Does specified vol tage appear at reverse alarm switch terminal that carries wire RW WG 20 28V Move F R lever to Backward Possible cause Remedy Reverse alarm faulty Renew Reverse alarm earth wire not connected or incorrectly con nected Repair or renew wire Wire RY from reverse alarm switch to reverse alarm not connected or incorrectly con nected Repair or renew wire Reverse alarm ...

Page 107: ...horn switch terminals normal YES NO 5 YES NO 6 7 8 YES NO Is stated voltage present at horn relay terminal 1 that carries wire GR Is resistance of horn switch earth wire as specified YES NO Possible cause Remedy Horn faulty Renew Horn earth wire not connected or incorrectly connected Repair or renew wire 20 28V Switch ON horn switch Wire Lg from horn to horn relay terminal not connected or incorre...

Page 108: ...m Horn Horn switch Lg GR Horn relay 1 2 5 3 Fuse 15A RW WG SW8004015 Electric wiring diagram for mode E 06 Wire color codes in parentheses SW800 From Machine No 10123 SW850 From Machine No 10127 Codes with no parentheses Common to both models ...

Page 109: ...with job lamp relay 20 28V Set lamp switch to LOW beam NO 4 Is stated voltage fed to relay termi nal 3 that carries wire G Is stated voltage fed to relay termi nal 1 that carries wire BrY 5 YES NO NO Is stated voltage fed to lamp switch terminals 1 and 4 that carry wire RY 20 28V 2 YES NO YES 20 28V Is stated voltage fed to lamp switch terminal 1 that car ries wire RY 20 28V 8 YES NO Is stated vol...

Page 110: ... not connected or incorrectly connected Repair or renew wire Wire BrY from lamp switch ter minal 6 to relay terminal 1 not connected or incorrectly con nected Repair or renew wire Lamp switch defective Renew Renew Lamp switch defective Wire RY from lamp switch ter minal 1 to fuse from branch point not connected or incor rectly connected Repair or renew wire Renew Wire RW from lamp switch ter minal...

Page 111: ...beam Wire RW from lamp to lamp switch terminal 5 from branch point not con nected or incorrectly connect ed Low beam Wire RB from lamp to relay terminal 5 from branch point not connected or incorrectly connected Repair or renew wire Filament has burnt Lamp earth wire not connect ed or incorrectly connected Troubleshooting for Electric System RY RW RB RW RY RW RB RW Fuse 30A SW8004006 B B B 5 3 2 1...

Page 112: ...Wire RW from lighting switch terminal 6 to lamp not con nected or incorrectly connect ed Repair or renew wire Lighting switch faulty Renew 20 28V Repair or renew wire Low beam only Wires RB from lighting switch terminal 1 to lamp not connect ed or incorrectly connected Is bulb filament blown 1 2 YES NO YES NO 20 28V Lighting switch Set to Lo and Hi Is stated voltage fed to inoperative lamp termina...

Page 113: ...ic System Electric wiring diagram for mode E 07 c d SW800 From Machine No 10123 SW850 From Machine No 10127 RY RW RB RW RY RW RB RW Fuse 20A SW8004016 B B 3 1 RB LgB LgB RW 4 6 2 5 WR WR Lighting switch To panel lamp Headlamp Headlamp ...

Page 114: ...4 219 Troubleshooting for Electric System ...

Page 115: ...ed voltage fed to job lamp relay terminal 3 that carries wire LY Is stated voltage fed to job lamp relay terminal 1 that carries wire YB 5 YES NO NO Is stated voltage fed to job lamp switch terminals 1 and 4 that carry wires RY 20 28V 2 YES NO YES Set job lamp switch to Low Is stated voltage fed to job lamp switch terminal 1 that carries wire RY 8 YES NO Is stated voltage fed to job lamp switch te...

Page 116: ...inal 5 to job lamps to branch point not connected or incorrectly connected Repair or renew wire Wire YB from job lamp switch terminal 6 to job lamp relay ter minal 1 not connected or incor rectly connected Repair or renew wire Job lamp switch defective Renew Renew Job lamp switch defective Wire RY from job lamp switch terminal 1 to fuse from branch point not connected or incorrectly connected Repa...

Page 117: ...air or renew wire Renew High beam Wire RL from job lamp to job lamp switch termi nal 5 from branch point not connected or incorrectly con nected Low beam Wire O from job lamp to relay terminal 5 from branch point not connected or incorrectly connected Repair or renew wire Bulb filament has burnt Job lamp earth wire not con nected or incorrectly connect ed RY RW O RL RY RW O RL Fuse 30A SW8004007 B...

Page 118: ...inal 6 to job lamps not connected or incorrectly con nected Repair or renew wire Job lamp switch is faulty Renew 20 28V Repair or renew wire Low beam only Wire O from job lamp switch terminal 1 to job lamps not connected or incorrectly con nected including fuse Has bulb filament burnt 1 2 YES NO YES NO 20 28V Job lamp switch Set to Low and High beams Is stated voltage present at job lamp terminal ...

Page 119: ...for Electric System Electric wiring diagram for mode E 08 c d SW800 From Machine No 10123 SW850 From Machine No 10127 RY RW O RL RY RW O RL Fuse 20A SW8004017 B B 1 3 O LY LY RL 4 6 2 5 WR WR To panel lamp Job lamp Job lamp ...

Page 120: ...new wire Vibrator switch defective Wire Br from vibrator switch to amplitude selector switch to branch point not connected or incorrectly connected 20 28V Switch on vibrator switch 1 SW800 To Machine No 10122 SW850 To Machine No 10126 2 SW850 From Machine No 10123 SW850 From Machine No 10127 Fuse 15A SW8004008 4 5 1 LR LR 3 a b WB GL LgY YR WY BY B B SOL a b b a 4 5 1 Br Br 2 YR LgY 2 GY BrR WY BY...

Page 121: ...m solenoid 20 28V Possible cause Remedy Solenoid valve defective See H 03 Amplitude select valve solenoid defective Renew Solenoid earth wire not con nected or incorrectly connect ed Repair or renew wire Renew Repair or renew wire Wire 3 from vibrator switch to amplitude selector switch ter minal 1 not connected or incorrectly connected Amplitude selector switch on inoperative side defective Wire ...

Page 122: ...select valve solenoid defective Renew Solenoid earth wire not con nected or incorrectly connect ed Repair or renew wire Renew Repair or renew wire Wire 3 from vibrator switch to amplitude selector switch ter minal 4 to branch point not connected or incorrectly con nected Amplitude selector switch on inoperative side defective Wire 2 from solenoid to ampli tude selector switch terminal 5 not connec...

Page 123: ...s Is stated voltage fed to frequency selec tor switch terminal 2 that carries wire WY BY 5 YES NO Is stated voltage fed to frequency selec tor switch terminal 1 that carries wire LR 3 YES NO Is solenoid earth wire resistance as specified Lower than 1 Ω Disconnect wire from solenoid 20 28V Possible cause Remedy Solenoid valve defective See H 03 Frequency select valve solenoid defective Renew Soleno...

Page 124: ...tor relay 1 terminal 5 that carries wire WL 3 YES NO Is solenoid earth wire resistance as specified Lower than 1 Ω Disconnect wire from solenoid Possible cause Remedy Solenoid valve defective See H 05 Frequency select valve solenoid defective Renew Solenoid earth wire not con nected or incorrectly connect ed Repair or renew wire To A on this page Repair or renew wire To B on this page Lower than 1...

Page 125: ...at carries wire YW YES NO 20 28V CONT AUTO selector switch CONT 20 28V CONT AUTO selector switch defective Renew Wire YW from fuse to vibrator switch not connected or incor rectly connected including fuse Renew Vibrator switch defective 20 28V Switch on vibrator switch Select CONT and AUTO modes WireGfromCONT AUTOselec tor switch to vibrator switch to branch point not connected or incorrectly conn...

Page 126: ...ude selector switch R Amplitude selector switch F Frequency select valve delivery select Vibrator relay 2 Vibrator relay 3 Vibrator relay 1 3 3 5 2 1 4 3 5 2 1 4 BrR GY YR B WL 3 5 2 1 4 GY LB LB B O BrR WL B BrB BrB BrB GL B 1 5 2 3 P Br O B 1 5 2 Frequency selector switch F R Lever switch NC NO COM YW GW GW BW To safety relay terminal S Amplitude select valve SOL Diode From starter switch termin...

Page 127: ...t at battery relay terminal BR that carries wire RB BrY YES YES NO Is resistance of vibration relay 4 earth wire resist ance as specified Lower than 1 Ω Disconnect relay from wire 4 YES NO Is stated voltage present at starter motor terminal 2 that carries wire O Is stated voltage present at starter motor terminal 3 that carries wire Gy 5 YES NO YES NO YES 20 28V CONT AUTO selector switch AUTO NO 2...

Page 128: ...epair or renew wire Starter motor relay contact sticking Renew Diode included in wire LB from starter switch terminal C to F R lever switch defective Repair or renew wire Renew F R lever switch defective Wire GW from fuse to F R lev er switch not connected or incorrectly connected Repair or renew wire Renew CONT AUTO selector switch defective Repair or renew wire Wire P from CONT AUTO selector swi...

Page 129: ... brake switch termi nal 1 that carries wire RG WY YES YES NO Is solenoid earth wire resistance as specified Lower than 1 Ω Disconnect relay from wire 3 YES NO Is stated voltage present at brake relay terminal 2 that carries wire LgR Is brake relay earth wire resistance as specified 6 YES NO YES NO YES NO 7 NO Is specified voltage present at foot brake switch that carries wire LgR YES 8 20 28V Do n...

Page 130: ...ew Foot brake switch defective Wire RG WY from fuse to foot brake switch not connect ed or incorrectly connected Repair or renew wire Renew Repair or renew wire Wire Y from parking brake switch terminal 3 to brake relay terminal 3 not connected or incorrectly connected Wire Br from brake release valve solenoid to brake relay terminal 5 not connected or incorrectly connected Repair or renew wire Wi...

Page 131: ...odes in parentheses SW800 From Machine No 10123 SW850 From Machine No 10127 Codes with no parentheses Common to both models Fuse SW8004010 LgR BrW 5 3 2 1 3 Y B B 5 1 RG RG WY WY LgR 4 Foot brake switch Parking brake switch Brake relay Brake release solenoid valve SOL L From combination meter ...

Page 132: ...d voltage present at sprinkler switch terminal 2 that carries wire G R 8 YES NO 20 28V Is specified voltage present at sprinkler switch terminal 1 that carries wire LW LW A 20 28V Possible cause Remedy Sprinkler pump faulty Renew Sprinkler pump earth wire not connected or incorrectly con nected Repair or renew wire Wire Y W from sprinkler pump to sprinkler relay terminal 5 not connected or incorre...

Page 133: ...e No 10126 Troubleshooting for Electric System SW8004009 Fuse 15A 4 5 1 LW LW 2 GB Sprinkler relay R 3 1 5 2 LW G G B Y B Sprinkler switch Rear P Sprinkler pump Rear 4 5 1 LW LW LW 2 R GB Sprinkler relay F 3 1 5 2 LW B W B Sprinkler switch Front P Sprinkler pump Front To combination meter ...

Page 134: ...4 239 Troubleshooting for Electric System ...

Page 135: ...ltage present at sprinkler switch terminal 2 that carries wire GB NO 8 Is specified voltage fed to sprinkler relay terminal 3 that carries wire BY BY YES NO Is specified voltage present at sprinkler switch terminal 3 that carries wire BY 20 28V 3 YES NO Is specified voltage present at sprinkler switch terminal 1 that carries wire BY Lower than 1 Ω Disconnect wire from pump 4 YES NO Is resistance o...

Page 136: ...rinkler pump defective Renew Sprinkler pump earth wire not connected or incorrectly con nected Repair or renew wire Renew Sprinkler relay defective Sprinkler relay earth wire not connected or incorrectly con nected Repair or renew wire Wire BY BY from sprinkler relay terminal 3 to fuse to branch point not connected or incorrectly connected Repair or renew wire Wire GB GB from fuse to sprinkler rel...

Page 137: ...2 to branch point not connected or incorrectly con nected Sprinkler timer defective Renew Wire G from sprinkler switch terminal 5 to sprinkler timer connectors 1 and 3 not con nected or incorrectly connect ed Repair or renew wire Sprinkler switch defective Renew Wire BY from fuse to sprinkler switch terminal 4 not connect ed or incorrectly connected in cluding fuse Repair or renew wire 20 28V Spri...

Page 138: ...h relat ed parts disconnect ed from fuel unit Possible cause Remedy Fuel unit earth wire is incor rectly connected or fuel unit malfunctions Fuel unit is faulty Renew Fuel gauge faulty Renew 1 7V Disconnect wire from fuel unit Wire YB from fuel gauge to fuel unit not connected or incorrectly connected Repair or renew wire Fuel gauge faulty Renew Fuel unit wire YB Gauge reading Disconnected Empty G...

Page 139: ... Remedy Thermo unit earth wire incor rectly connected or thermo unit malfunctioning Thermo unit faulty Renew Coolant temperature gauge faulty Renew 3 8V Disconncect wire from thermo unit Wire Sb from Coolant temper ature gauge to thermo unit not connected or incorrectly connected Repair or renew wire Coolant temperature gauge faulty Renew Thermo unit termi nal wire Sb Gauge reading Disconnected Lo...

Page 140: ...tate its shaft by hand Possible cause Remedy Tachometer unit incorrectly fitted Fit correctly Wire YG from tachometer unit to tachometer not connected or incorrectly connected Repair or renew wire To A on this page Power feed wire inside combi nation meter defective Renew Lower tnan 1 Ω Disconnect wire YG from tachometer 4 YES NO Is specified voltage fed to tachometer positive terminal that carrie...

Page 141: ...of lamps or all lamps inop erative 1 20 28V 20 28V Part of lamps All lamps 20 28V Troubleshooting for Electric System E 15 Charge warning lamp engine oil pressure warning lamp hydraulic oil filter warning lamp and parking brake indicator lamp do not come on with starter switch ON Wire color codes in parentheses SW800 From Machine No 10123 SW850 From Machine No 10127 Codes with no parentheses Commo...

Page 142: ...faulty Renew combination meter Wire BY YG from check relay terminal 3 to combina tion meter not connected or incorrectly connected Repair or renew wire Check relay faulty Renew Check relay earth wire not con nected or incorrectly connect ed Repair or renew wire Wire YW WL from fuse to com bination meter not connected or incorrectly connected Repair or renew wire Fuse has burnt Renew Wire LgB from ...

Page 143: ...o starter Fuse 15A Fusible link 65A YW R Combination meter Charge lamp Engine oil pressure lamp Hydraulic oil filter lamp Parking brake lamp SW8004014 Lamp check relay WR W YG WR WL Electric wiring diagram for mode E 15 Wire color codes in parentheses SW800 From Machine No 10123 SW850 From Machine No 10127 Codes with no parentheses Common to both models ...

Page 144: ...speed not gained or low traction 4 408 H 03 Vibrator does not work 4 412 H 04 Weak vibratory force 4 413 H 05 Frequency is not selected 4 413 H 06 Steering not performed 4 414 H 07 Heavy or slow steering 4 414 H 08 Parking brake not applied sufficiently 4 415 H 09 Parking brake not released 4 415 H 10 No sprinking 4 415 6 Fault Finding for Hydraulic and Mechanical Systems Mode H ...

Page 145: ...ont drive Inside of Motor Reduction gear Parking brake Rear drive Inside of motor Reduction gear Parking brake Flushing valve Brake release solenoid valve Front Inside of motor Amplitude select valve Main pressure relief valve Port relief valve Vibrator Rear Motor unit Amplitude select valve Main pressure relief valve Port relief valve Vibrator Steering Steering pump Orbitrol including pressure re...

Page 146: ...ms Vibrator Steering Parking brake Inoperative Frequency not selected Either front or rear Either front or rear Not performed Heavy or slow H 03a H 03b H 04 H 05 H 06 H 07 H 08 Front and rear Low intensity H 09 H 10 No sprinkling Poor braking Not released ...

Page 147: ...cedures Start with checking the oil level in the hydraulic tank a Not propelled in both directions forward and backward 1 2 Does steering sys tem work correct ly 1 2 NO Does unload valve stay closed 3 YES Does parking brake work correct ly NO 5 Do pump servo valve and servo linkage work cor rectly YES NO YES 4 Is F R lever move ment normal NO YES YES NO ...

Page 148: ...akage at sliding portions such as piston of front wheel motor Internal leakage of brake cylinder Steering pump faulty Renew Leakage at sliding portions pistons of propulsion pump or vibrator pump etc Repair or renew wire Pump servo valve or servo linkage defective See Standard Value Chart Clean and adjust Renew if necessary Repair Renew if necessary Repair Renew if necessary Oil leakage at sliding...

Page 149: ...motor damaged Is fault rectified if high pressure relief valve is disassem bled and cleaned Cut off valve faulty Clean and adjust Renew if necessary High pressure relief valve faulty To B on this page Leakage at sliding portions such as piston of front motor Leakage at sliding portions such as piston of rear motor NO Repair Renew as necessary Repair Renew as necessary Repair Renew as necessary Rep...

Page 150: ...B motor side and pump side are blocked 1 2 YES NO YES NO Is F R lever move ment normal Does charge pres sure vary with F R lever moved for ward and back ward YES YES NO NO 7 NO YES Are pump servo valve and servo linkage normal YES NO 6 A B Possible cause Remedy To A on this page Pump servo valve and servo linkage defective Repair Renew if necessary F R lever linkage defective Unloader valve lever ...

Page 151: ...ed in both travel directions 1 2 Does unloader valve stay closed 1 2 NO Is F R lever move ment normal 3 YES Are pump servo valve and servo linkage normal NO 5 Is charge pressure higher than permissi ble minimum with F R lever operated forward and backward YES NO YES 13 Does charge pres sure return to nor mal if charge relief valve is disassem bled and cleaned NO YES YES NO NO 4 Is propulsion charg...

Page 152: ...loader valve opened Clean and adjust Renew if necessary Repair Renew if necessary Leakage at sliding portions such as piston of front motor Repair Renew if necessary Pump servo valve or servo linkage faulty F R lever linkage faulty Set lever correctly Unloader valve lever position incorrect 1 Recheck the item enclosed by a dotted line 2 Due to difficulty in deciding checking sequence a NO line on ...

Page 153: ...tor ports A and B blocked un loader valve opened Propulsion pump perfor mance lowered Propulsion motor performance lowered Cut off valve faulty High pressure relief valve faulty Leakage at sliding portions such as piston of front motor NO Repair Renew as necessary Repair Renew as necessary Repair Renew as necessary Repair Renew as necessary Repair Renew as necessary Due to difficulty in deciding c...

Page 154: ...ump side blocked 1 2 YES NO YES NO Does F R lever move correctly Is there any dif ference in charge reassure between forward travel and backing YES YES NO NO 7 NO YES Are pump servo valve and servo linkage normal YES NO 6 A B Possible cause Remedy To A on this page Pump servo valve or servo linkage defective Repair Renew if necessary F R lever linkage faulty Unloader valve lever position incorrect...

Page 155: ... NO A Does machine trav el Either in LOW or HIGH amplitude In both LOW and HIGH amplitudes Possible cause Remedy Vibrator pump or pump coupling faulty Repair Renew if necessary Engine coupling faulty Amplitude select valve faulty Clean and adjust Renew if necessary Amplitude select solenoid valve faulty To A on this page Vibrator faulty Vibrator drive motor faulty Main pressure relief valve faulty...

Page 156: ...amplitude In both LOW and HIGH amplitudes Possible cause Remedy Port relief valve faulty For eign matter is present or valve is faulty Clean or renew Amplitude select valve faulty Repair or renew Amplitude select valve malfunctions Vibrator pump performance lowered Repair or renew To A on this page Main relief valve faulty Valve is faulty or Foreign matter is present Clean or renew Repair or renew...

Page 157: ... seal is faulty Fully extend the steering piston rod disconnect hose from piston rod side Exert pressure from cylinder head side Steering cylinder faulty Fault Finding for Hydraulic and Mechanical Systems H 06 Steering not performed Start with checking the oil level in the hydraulic tank Is relief pressure in steering system as specified 1 2 YES NO YES NO Is fault rectified if relief valve is clea...

Page 158: ...arking brake not released Diagnose electric systems first If they are normal use procedures described as below 1 YES NO Is brake release valve output pres sure as specified Possible cause Remedy Parking brake piston seized Renew motor Brake release valve faulty Clean and adjust Renew if necessary See Standard Value Chart H 10 No sprinkling Diagnose electric systems first If they are normal then us...

Page 159: ...Printed in Japan 2000 3 100 0 C D Head office 1 4 8 Shiba Daimon Minato ku Tokyo Japan Telephone Tokyo 03 3431 9971 Facsimile 03 3431 6212 ...

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Sakai SW800 Series, Shop Manual

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