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Sakai SW880-1, Shop Manual

The Sakai SW880-1 Operator's Manual is an essential resource for anyone using this powerful machine. Designed for easy understanding, this comprehensive manual covers all aspects of operation and maintenance. Download your free manual from manualshive.com and unlock the full potential of the Sakai SW880-1.

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11-202

TROUBLESHOOTING

Fig.: 2-9-1

SW880-1-11007

AV60,R

STARTER

SWITCH

Y

17

L

18

LgR

15

B

X

BrY

74

2RW

2

2RW

2

2W

70

2WR

3

LgB

47

B

X

LgW

64

YG

24

B

X

B

X

GB

23

GB

23

LgW

64

1.25BR

52

5L

49

5R

46

5Y

45

5R

86

5Y

85

5R

203

5Y

202

3BY

172

5L

49

5WG

51

R

155

RG

156

5WR

10

2WR

25

5W

11

2WL

160

LgW

64

178 G

181 GW

182 LW

176 BR

180 RB

184 RY

179 RW

175 B

175 B

175 B

175 B

171 BW

171 BW

171 BW

171 BW

172

3B

Y

171

3B

W

Lg

LW

182

22

GW

181

B

X

GB

B

X

166

1.25BR

52

LgR

15

5B
215

3B

175

LgB

47

2RL

5

B

X

1.25BR

52

FLOOD LAMP (L)

55W

FLOOD LAMP (R)

55W

2RL

5

2RL

5

2B
X2

2B
X2

2B
X2

2B
X2

B

X

28

GB

GB

28

G
152

GL
151

O

78

GW

77

G
11

5

B

X

B

X

B

X

GW

20

5W

R

10

2W
70

WL
13

2W

R

3

B

X

GW

181

G

178

WL

13

R

200

YB

21

TO 

PARKING

INTERLOCK

RELAY

B

X

YG

24

Lg

22

GB

23

L

18

YG

24

G

115

YB

21

B

X

YL

148

GB

28

2RL

5

RW

2

GW

20

LgW

64

R

155

14_16M
15_16M
16_16M

13_16M

2_16M
3_16M
4_16M
5_16M
6_16M
7_16M
8_16M
9_16M

12_16M

11_16M

10_16M

1_16M

12_12P

11_12P

10_12P

9_12P

8_12P

7_12P

6_12P

5_12P

4_12P

3_12P

2_12P

1_12P

COMBINATION

METER

TO

WATER SPRAY

PUMP RELAY (F,2),  (R,2)

F.L.65A

F.L.65A

F.L.65A

F.L.65A

F.L.65A

HYDRAURIC OIL

FILTER SWITCH1

HYDRAURIC OIL

FILTER SWITCH2

THERMO

UNIT

FUEL

UNIT

TACHOMETER

SENSOR

FUSE BOX

LAMP CHECK

RELAY

TO

FORWARD

SWITCH

HEAD LAMP (L)

55W

HEAD LAMP (R)

55W

LIGHTING

SWITCH

TO

PROPULSION PUMP

NEUTRAL RELAY (1)

TO

PROPULSION PUMP

NEUTRAL RELAY (2)

PARKING

BRAKE

SWITCH

TO 

PARKING

BRAKE

SOLENOID

WATER SPRAY

MODE SELECT

SWITCH

WATER SPRAY MODE

SELECT SWITCH

WATER 

SPRAY TIMER

SWITCH

WATER SPRAY

TIMER

TO

WATER SPRAY PUMP

RELAY (PUMP 1)
TO 

WATER SPRAY PUMP

RELAY (PUMP 2)

0.5GW

77

0.5YL

148

0.5WB

25

0.5B

X

0.5WB

25

0.5WB

25

0.5Gr

162

0.5Gr

162

0.5B

X

0.5WB

25

0.5B

X

12

4

7

5

11

6

8

9

10

1
2

6

5

10

4

11

3

12

2

7

1

46

40

39

47
48

50

38

30

26

3

5

4

9

6

8

7

22

13

21
25
31

1

32

2

33

14

34

23

35

17

36

18

37

19
20

24

WAIT TO START

LAMP

WARNING LAMP

ENGINE STOP LAMP

ENGINE

STUD

BOLT

BATTERY

RELAY

AV60,B

AV60,R

STARTER SWITCH

RELAY

ENGINE OIL

PRESSURE SWITCH

RELAY

EGT WARNING

LAMP RELAY

EGT

WARNING

LAMP

+

-

S

F

L

P

ALTERNATOR

(130A)

-

+

12V

BA

TTE

R

Y

-

+

12V

BA

TTE

R

Y

2

1

5

3

E

COM

BR

NO

5

52

44

4

43

19

14

59

13

32

15

31

39

22

38

21

26

18

3

17

12

16

11

8

2

ENGINE ECM

(CM2250)

J3 (60PIN)

6

1

1.0kΩ

1.0kΩ

1.0kΩ

2

1

5

3

20

A

20

A

20

A

20

A

15

A

15

A

15

A

15

A

20

A

2

1

5

3

BR

B

R1

ACC

R2

C

5

4

1

2

3

3
2

1

4

6
5

4

3

2

1

3

4

2

1

FUSE 30A

FUSE

5A

FUSE

15A

FUSE

BOX-10

5A

1
3

2

5

4
6

1

4

3

2
6

5

1

3

5

2

LIGHTING SWITCH

CONNECTION

SWITCH

POSITION

1-3,4-5

1-3,4-6

1-2,4-6

B A

CC

B

R

C

OFF

ON

ST

STARTER SWITCH

CONNECTION

POSITION

2-3,5-6

2-1,5-4

WATER SPRAY TIMER SWITCH

CONNECTION

WATER SPRAY

MODE

1-3,4-5

1-3,4-6

1-2,4-6

AUTO

WORKING

CONTROLLER

(C2)

WORKING

CONTROLLER

(C1)

TRAVELING

CONTROLLER

1

R

2

R

3

P

4

O

5

WR

6

GL

7

LR

8

YL

9 FLOOD LAMP

LW

10 WATER SPRAY

Br

11

LB

12

L

COMBINATION METER (SWP-12M)

REV. PULSE INPUT  1

STARTER SWITCH(ACC)

BATTERY 24V(+)

BATTERY 12V(+)

COMBINATION METER ILLUMINATION
TURN SIGNAL(R)
TURN SIGNAL(L)
SIDE MARKER LAMP

LIQUID SPRAY
VIBRATOR

GB

12

RB

11

GY

10

W

9

G

8

GW

7

GR

PARKING BRAKE

6

BrW

LAMP CHECK

5

YW

4

YR

FUEL METER

3

Y

2

B

1

OG

13

LgY

14

WB

15

OW

16

GND
GND
GND
OPEN
OPEN
OPEN

COMBINATION METER (SWP-16F)

REV. RATIO SEL.2
REV. RATIO SEL.3
REV. RATIO SEL.4
COOLANT TEMP. SEL.1
COOLANT TEMP. SEL.2

GNROUND
REV. PULSE INPUT  2

TEMPERATURE METER

HYDRAULIC OIL FILTER WARNING

CHARGE WARNING
PREHEATING
REV. RATIO SEL.1

ENGINE OIL PRESSURE WARNING

Summary of Contents for SW880-1

Page 1: ...SW880 1 990 1 SHOP MANUAL 3498 6568A 0 ...

Page 2: ......

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

Page 4: ......

Page 5: ...Instructions 1 003 1 7 Starting 1 004 1 8 Operating 1 004 1 9 Stopping 1 004 1 10 Maintenance 1 005 1 11 Transporting the Machine 1 007 2 SPECIFICATIONS 1 SPECIFICATION DATA 1 1 SW880 1 2 001 1 2 SW990 1 2 004 2 TABLE OF STANDARD VALUES 2 1 Engine 2 007 2 2 Propulsion 2 007 2 3 Hydraulic System 2 007 2 4 Steering 2 008 2 5 Brakes 2 008 2 6 Capacities 2 008 3 FUEL AND LUBRICANTS SPECIFICATION 3 1 R...

Page 6: ...005 2 2 Hydraulic Component Specifications 4 006 2 2 1 Hydraulic pump assembly propulsion vibrator 4 006 2 2 2 Propulsion hydraulic motor front 4 008 2 2 3 Propulsion hydraulic motor rear 4 010 2 2 4 Valve block 4 012 3 VIBRATOR HYDRAULIC SYSTEM 3 1 Vibrator Hydraulic Piping 4 013 3 1 1 Vibrator hydraulic piping 1 4 013 3 1 2 Vibrator hydraulic piping 2 4 014 3 1 3 Vibrator hydraulic piping 3 4 01...

Page 7: ...ut 2 5 006 3 4 Wiring Harness Layout 3 5 007 4 WIRING HARNESSES 4 1 Main Harness 1 5 008 4 1 Main Harness 2 5 010 4 2 Fuse Relay Harness 5 012 4 3 Engine Harness 5 014 4 4 Battery Harness 5 016 4 5 Front Frame Harness 5 018 4 6 F R Lever Harness 5 020 4 7 Panel Harness L 5 022 4 8 Panel Harness R 5 024 4 9 Floor Bord Harness 5 026 4 10 Starter Relay Harness 5 028 4 11 Torque Control Box Harness 5 ...

Page 8: ...djustment of Swivel Lock Release Pedal 8 002 9 WATER SPRAY SYSTEM 1 WATER SPRAY PIPING 9 001 10 INSPECTION AND ADJUSTMENT 1 INSPECTION AND ADJUSTMENT 1 1 Safety Precautions for Inspection and Adjustment 10 001 1 2 Preparation for Inspection and Adjustment 10 001 1 3 Precautions for Inspection and Adjustment 10 001 1 4 Warm up 10 001 1 5 Inspection and Adjustment of Engine Related Items 10 001 2 ME...

Page 9: ... Inspection 10 013 8 MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE 8 1 Measurement 10 014 8 2 Inspection 10 015 9 MEASUREMENT OF HYDRAULIC PUMP CASE PRESSURE 9 1 Measurement of Propulsion Pump Case Pressure 10 016 9 2 Measurement of Vibrator Pump Case Pressure 10 017 10 MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE 10 1 Measurement 10 018 11 MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE 11...

Page 10: ...11 027 2 4 1 Engine will not start Starter motor does not run 3 17 11 029 2 4 1 Engine will not start Starter motor does not run 4 17 11 031 2 4 1 Engine will not start Starter motor does not run 5 17 11 033 2 4 1 Engine will not start Starter motor does not run 6 17 11 035 2 4 1 Engine will not start Starter motor does not run 7 17 11 037 2 4 1 Engine will not start Starter motor does not run 8 1...

Page 11: ...stops in automatic speed mode 1 2 11 087 2 5 2 Machine and engine suddenly stops in automatic speed mode 2 2 11 089 2 5 3 Machine moves neither forward nor backward 1 6 11 091 2 5 3 Machine moves neither forward nor backward 2 6 11 093 2 5 3 Machine moves neither forward nor backward 3 6 11 095 2 5 3 Machine moves neither forward nor backward 4 6 11 097 2 5 3 Machine moves neither forward nor back...

Page 12: ...does not illuminate while driving 6 9 11 157 2 7 1 Exact meter indicator lamp does not illuminate while driving 7 9 11 159 2 7 1 Exact meter indicator lamp does not illuminate while driving 8 9 11 161 2 7 1 Exact meter indicator lamp does not illuminate while driving 9 9 11 163 2 7 2 No vehicle speed indication on display 1 3 11 165 2 7 2 No vehicle speed indication on display 2 3 11 167 2 7 2 No ...

Page 13: ...es in one direction only forward or backward 11 208 3 2 3 Slow machine speed or small drive force 1 2 11 208 3 2 3 Slow machine speed or small drive force 2 2 11 209 3 2 4 Machine does not stop completely with F R lever in N 11 209 3 2 5 Propulsion system is overheating 11 210 3 2 6 Abnormal noise from propulsion system 11 210 3 3 Vibrator System 11 211 3 3 1 No vibration 11 211 3 3 2 Only front o...

Page 14: ......

Page 15: ...SAFETY ...

Page 16: ......

Page 17: ...machine if you fail to observe or important point to maintain of quality in maintenance works Indicates standard value to judge whether measured value is good or not Items that indicate the weight of a part or equipment and require attention in wire selection and operating posture for slinging operation N m In the assembly operation tightening torque in locations that require particular attention ...

Page 18: ... guidance of a skilled electrician and according to electrical engineering rules and regulations Work on the frame brakes hydraulic and steering systems must be performed by skilled personnel with special knowledge and training for such work 1 4 Safety Practices and Policies Keep the manuals in the container provided on the machine Manuals must always be available at the site where the machine is ...

Page 19: ...readable Never fill the fuel tank with the engine running or while near an open flame or while smoking Always clean up any spilled fuel Check for any warning tags placed on the machine do not operate the machine until all repairs have been made and warning tags have been removed by authorized personnel Check the seat belt for wear or damage inspect the belt hardware and fabric Replace if hardware ...

Page 20: ...to slide or roll over Avoid any areas that may be a risk to machine stability Avoid side hill travel Always operate up and down the slope Always keep the propulsion travel control lever in low speed range when climbing or descending hills or steep grades Make sure there is sufficient clearance when crossing underpasses bridges and tunnels or when passing under overhead power lines Never allow anyo...

Page 21: ... to avoid the risk of accident Use lifting devices that are in perfect condition and of sufficient lifting capacity Never stand under suspended loads Always use the proper tools and workshop equipment in good condition when performing maintenance or repairs on the machine Always use specially designed safety ladders and working platforms when working above floor level Never use machine parts as a ...

Page 22: ...g or grinding operations Inspect hydraulic hoses at regular intervals and immediately replace if they show signs of chafing cracking brittleness deformation blistering fitting separation leakage corrosion or other damage which may affect their function or strength Do not work on hydraulic system while the engine is running and the system is under pressure The hydraulic system remains pressurized e...

Page 23: ...ake sure that the compactor does not slide off the edge of the ramp Keep the deck clear of mud oil ice or snow or other materials that can make the deck slippery Position the compactor on the trailer or transport vehicle centered from side to side and apply the brake Shut off the engine and lock all lockable compartments Block the drums or tires and lock the articulation lock bar Chain the machine...

Page 24: ......

Page 25: ...SPECIFICATIONS ...

Page 26: ......

Page 27: ......

Page 28: ...ithout ROPS 11 540 kg 25 440 lbs Load on front axle 6 340 kg 13 975 lbs Load on rear axle 6 530 kg 14 395 lbs Dimensions Overall length 5 940 mm 234 in Overall width 2 245 mm 88 in Overall height with ROPS 3 250 mm 128 in without ROPS 2 375 mm 94 in Wheelbase 3 540 mm 139 in Compaction width 2 000 mm 79 in Front drum width dia 2 000 mm 1 400 mm 22 mm 79 in 55 in 0 9 in Rear drum width dia 2 000 mm...

Page 29: ...ear pressure Front drum 311 N cm 178 lbs in Rear drum 320 N cm 183 lbs in Dynamic linear pressure Front drum Low amplitude 4 000 vpm 1 111 N cm 634 lbs in 3 000 vpm 761 N cm 434 lbs in 2 500 vpm 626 N cm 357 lbs in High amplitude 3 000 vpm 1 196 N cm 683 lbs in 2 500 vpm 926 N cm 529 lbs in Rear drum Low amplitude 4 000 vpm 1 120 N cm 640 lbs in 3 000 vpm 770 N cm 440 lbs in 2 500 vpm 635 N cm 363...

Page 30: ...ssurized water forced circulation Cooling fan type Inhale Electrical system Alternator 12 V 130 A Starter 12 V 4 8 kW Battery 12 V N Aah 760CCA 2 pcs 12 V Dry weight 390 kg 860 lbs Drive system Transmission Type Hydrostatic Speed 2 speed shifts Reverser Switching the direction of flow delivered from the variable pump Differential type Front N A Rear N A Final drive Front Planetary gear Rear Planet...

Page 31: ......

Page 32: ...11 930 kg 26 300 lbs Load on front axle 6 520 kg 14 375 lbs Load on rear axle 6 730 kg 14 835 lbs Dimensions Overall length 5 940 mm 234 in Overall width 2 325 mm 92 in Overall height with ROPS 3 250 mm 128 in without ROPS 2 375 mm 94 in Wheelbase 3 540 mm 139 in Compaction width 2 130 mm 84 in Front drum width dia 2 130 mm 1 400 mm 22 mm 84 in 55 in 0 9 in Rear drum width dia 2 130 mm 1 400 mm 22...

Page 33: ...ear pressure Front drum 311 N cm 171 lbs in Rear drum 310 N cm 177 lbs in Dynamic linear pressure Front drum Low amplitude 4 000 vpm 1 112 N cm 635 lbs in 3 000 vpm 760 N cm 434 lbs in 2 500 vpm 619 N cm 354 lbs in High amplitude 3 000 vpm 1 169 N cm 667 lbs in 2 500 vpm 901 N cm 515 lbs in Rear drum Low amplitude 4 000 vpm 1 122 N cm 641 lbs in 3 000 vpm 770 N cm 440 lbs in 2 500 vpm 629 N cm 359...

Page 34: ...ssurized water forced circulation Cooling fan type Inhale Electrical system Alternator 12 V 130 A Starter 12 V 4 8 kW Battery 12 V N Aah 760CCA 2 pcs 12 V Dry weight 390 kg 860 lbs Drive system Transmission Type Hydrostatic Speed 2 speed shifts Reverser Switching the direction of flow delivered from the variable pump Differential type Front N A Rear N A Final drive Front Planetary gear Rear Planet...

Page 35: ...4 5 km h 0 to 2 8 mph 2nd 0 to 11 km h 0 to 6 8 mph 2 3 Hydraulic System Item Standard value Remarks Propulsion High pressure relief valve setting 40 2 1 0 MPa 5 829 145 psi Differential pressure Cut off valve pressure setting 37 3 1 0 MPa 5 409 145 psi Differential pressure Charge relief valve setting 2 5 0 2 MPa 362 29 psi at 2 600 min 1 Front motor flushing valve pressure setting 2 5 MPa 362 ps...

Page 36: ...ke pedal and floorboard when pressed down 82 mm 3 2 in Note 2 See dimensions Propulsion motor inner brake wear limit Thickness of 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 Capacities Item Standard value Remarks Engine oil pan 12 0 L 3 2 gal ...

Page 37: ... VG46 Over VI 140 ISO VG68 Over VI 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 CJ4 Gear oil API GL 5 Hydraulic oil ISO VG 46 Grease NLGI 2 CHEVRON DELO 400 LE RPM Universal Gear Lubricants Rando HDZ 46 Multifak EP 2 BP BP Energear HYPO U Bartran HV 46 BP Energrease LS EP 2 CASTROL Tection Extr...

Page 38: ...43 253 20 2 5 294 217 392 289 539 398 539 398 22 2 5 441 325 539 398 686 506 686 506 24 3 0 539 398 637 470 883 651 883 651 27 3 0 785 579 981 724 1324 977 1324 977 30 3 5 1079 796 1324 977 1765 1302 1765 1302 Metric fine screw 10 1 25 39 29 49 36 69 51 69 51 12 1 25 69 51 88 65 118 87 118 87 14 1 5 108 80 137 101 186 137 186 137 16 1 5 167 123 206 152 284 209 284 209 18 1 5 245 181 294 217 392 28...

Page 39: ...ENGINE AND CONTROLS ...

Page 40: ......

Page 41: ...3 Base 11 Bolt M 8 20 4 Base 12 Bracket 5 Engine 13 Bolt M12 35 6 Bolt M12 35 14 Bolt M16 50 7 Bolt M12 30 15 Damper 8 Bolt M12 80 16 Bolt M12 25 N m 6 Bolt M12 35 108 N m 80 lbf ft 13 Bolt M12 35 108 N m 80 lbf ft 7 Bolt M10 30 78 N m 58 lbf ft 14 Bolt M16 50 265 N m 195 lbf ft 8 Bolt M12 80 108 N m 80 lbf ft 16 Bolt M12 25 108 N m 80 lbf ft 11 Bolt M 8 20 31 N m 23 lbf ft ...

Page 42: ... OUT OUT IN OUT IN IN Drain 1 Hose Fuel gear pump drain Fuel tank return 8 Fuel pre filter 2 Fuel unit 9 Fuel tank 3 Hose Fuel tank suction Fuel pre filter IN 10 Plug 4 Hose Fuel pre filter OUT Fuel gear pump IN 11 Fuel gear pump 5 Hose Fuel filter OUT Fuel gear pump IN 12 Cap 6 Hose Fuel gear pump OUT Fuel filter IN 13 Filter 7 Fuel filter ...

Page 43: ...ply grease 1 Apply grease 1 Apply grease 1 Apply grease 1 Apply grease 2 11 9 10 8 7 6 5 4 1 F R lever switch 6 Washer 11 F R lever potentiometer 1 2 F R lever 7 Nut 12 Spring pin 3 Backup buzzer switch 8 Washer 13 Nut M16 4 F R lever potentiometer 2 9 Disc spring 14 Screw 5 Bush 10 Collar Do not apply grease 1 Lithium based grease 2 Molybdenum based grease ...

Page 44: ...1 2 3 4 5 8 6 7 SECTION A A VIEW B A A B 1 Bolt M10 50 5 Housing M12 80 2 Bolt 3 8 16UNC 22 6 Bolt M20 45 3 Hub 7 Pump 4 Flange 8 Bolt M12 35 N m 1 Bolt M10 50 60 N m 44 lbf ft 6 Bolt M20 45 539 N m 398 lbf ft 2 Bolt 3 8 16UNC 22 69 N m 51 lbf ft 8 Bolt M12 35 86 N m 63 lbf ft ...

Page 45: ...hub 3 with bolt 8 N m 8 Bolt M12 35 86 N m 63 lbf ft Secure flange 4 to engine flywheel with eight bolts 2 N m 2 Bolt 3 8 16UNC 22 69 N m 51 lbf ft Position housing 5 as shown in the figure and secure to engine flywheel housing with twelve bolts 1 and washers N m 1 Bolt M10 50 60 N m 44 lbf ft Engage hub 3 with flange 4 Secure pump 7 to housing 5 with four bolts 6 and washers N m 6 Bolt M20 45 539...

Page 46: ......

Page 47: ...HYDRAULIC SYSTEMS ...

Page 48: ......

Page 49: ......

Page 50: ...Reservoir vented Filter or strainer Heat exchanger lines in dicate flow of coolant Quick disconnect Connected with mechan ically opened checks Disconnected Sloping arrow through a symbol at 45 indicates that a component can be adjusted or varied Pump Motors and Cylinders DESCRIPTION SYMBOL Hydraulic pumps Fixed displacement Unidirectional Bidirectional Variable displacement Unidirectional Bidirect...

Page 51: ...es providing various flow path options for the fluid The multiple square moves to represent how flow paths change when the valving element is shifted within the compo nent Valves with infinite posi tioning between certain limits are symbolized with lines parallel to the squares Methods of Operation DESCRIPTION SYMBOL Spring Manual Pressure compensated Reversing motor Pilot pressure Internal supply...

Page 52: ......

Page 53: ...rum Front Propulsion motor Rear Propulsion motor Front Propulsion pump Vibrator pump Vibrator motor Rear Vibrator motor Front Valve block Rear Valve block Front Orbitrol 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 34 0 MPa 34 0 MPa 34 0 MPa 34 0 MPa 1 2 1 2 1 4 1 2 3 4 3 4 2 5 MPa 1 5 MPa 1 2 1 2 1 2 1 2 1 3 MPa i 39 000 i 39 000 65 7 cc rev 65 7 cc rev 16 0 cc rev 16 0 cc rev 1 3 MPa Vibration LO 4000 rpm 30...

Page 54: ......

Page 55: ... C B E E The letters and figures such as PVT and PDV show each port and the arrow symbols show the hose connection and the direction of the flow of the oil Hydraulic oil tank PMB PMA Coupling Reverse side gauge port PVB VX1 Hose PX1 VX1 VX2 Propulsion pump Hose LOB PVP PDO PDV PT1 Hose PX2 VX2 Coupling Forward side gauge port VIEW A A PX1 PX1 PX2 Coupling D LOB LO1 LOP 2 PROPULSION HYDRAULIC SYSTE...

Page 56: ......

Page 57: ...ose FMD PDM Hose PVR FMP Hose PVR FMP FMD FMP Hose PBR BSB Hose PAR BSA Hose BSP RMP Hose RMD TPD Hose BSA RMB PBF PDM RAF PAR VDM The letters and figures such as PAR and BSA show each port and the arrow symbols show the hose connection and the direction of the flow of the oil VIEW D VIEW A VIEW E VIEW F DETAIL C VIEW B Hose TBD BSD Hose PVR BSP Hose RMD TPD PBR F A D E A C B Front Rear Hose BSB R...

Page 58: ......

Page 59: ......

Page 60: ...n vibrator SW880 04001 2 2 2 2 3 1 1 1 2 1 3 1 2 1 1 10 1 11 1 12 2 10 2 11 2 12 2 15 2 14 1 13 1 16 Pump circuit diagram a 1 1 1 2 1 9 1 13 2 7 2 1 2 6 2 5 1 16 1 10 2 3 2 10 2 2 2 13 2 8 1 5 1 12 1 6 1 7 b a b 1 15 1 14 2 13 2 16 2 8 1 9 1 4 1 5 1 6 back of 1 7 2 5 back of 2 6 2 7 1 0 1 0 2 4 2 9 1 8 ...

Page 61: ...7 3 MPa 5 409 psi 2 Vibrator pump 2 1 Port A2 Rear low amplitude VA2 1 1 16 12UN 2 2 Port B2 Rear high amplitude VB2 1 1 16 12UN 2 3 Drain port PT3 1 1 16 12UN 2 4 Vibrator pump proportional solenoid valve a High amplitude 2 5 Port B1 Front high amplitude VB1 1 1 16 12UN 2 6 Port A1 Front low amplitude VA1 1 1 16 12UN 2 7 Charge pump suction port VPS 1 5 16 12UN 2 8 Filter port From filter PF2 3 4...

Page 62: ...ort B 9 16 18UNF 11 Charge pressure gauge port 7 16 20UNF 6 High pressure gauge port For Port A 9 16 18UNF SW880 1 04002 1 11 5 10 4 2 3 6 Motor circuit diagram Flow of oil 1 2 Clockwise rotation 2 1 Counterclockwise rotation Motor specifications Displacement 65 7 cm3 rev 4 0 cu in rev Maximum working pressure 41 8 MPa 6 063 psi Brake release pressure 1 5 MPa 218 psi Allowable motor case pressure ...

Page 63: ...006 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 Carrier 7 6 Brake stopper 8 6 Planetary gear 1st 7 7 Friction plate 8 7 Needle roller 7 8 Separate plate 8 8 Sun gear 2nd 7 9 Piston brake 8 9 Sun gear 1st 7 10 Journal bearing 7 11 Speed sensor ...

Page 64: ...6 5 4 8 5 3 5 91 5 3 5 High Lo 8 5 3 5 91 5 3 5 High Lo 8 5 3 5 91 5 3 5 A 1 Port B Forward RMB SAE 1 7 Motor 2 Port A Reverse RMA SAE 1 8 Reduction gear 3 Parking brake pilot port RMP 9 16 18UNF 9 Filler cap 4 Drain port RMD 7 8 14UNF 10 Speed sensor 7 8 14UNF 5 High pressure gauge port For Port B 9 16 18UNF 6 High pressure gauge port For Port A 9 16 18UNF SW880 1 04003 Flow of oil 1 2 Clockwise ...

Page 65: ...or 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 Carrier 7 6 Brake stopper 8 6 Planetary gear 1st 7 7 Friction plate 8 7 Needle roller 7 8 Separate plate 8 8 Sun gear 2nd 7 9 Piston brake 8 9 Sun gear 1st 7 10 Journal bearing 7 11 Speed sensor ...

Page 66: ...t T PVT 9 16 18UNF 4 Port MA PVA 9 16 18UNF 12 Port X1 VX1 9 16 18UNF 5 Port G1 Forward side 9 16 18UNF 13 Port MB PVB 9 16 18UNF 6 Port G2 Reverse side 9 16 18UNF 14 Bypass valve 7 Nut 15 Connector 8 Neutral solenoid valve 7 Nut 4 9 N m 3 6 lbf ft 8 Neutral solenoid valve 34 3 N m 25 1 2 2 lbf ft 9 Brake solenoid valve 34 3 N m 25 1 2 2 lbf ft 14 Bypass valve 45 6 N m 33 2 4 4 lbf ft Specificatio...

Page 67: ...f the flow of the oil VIEW A A Hose VF1 LS2 Coupling Hose LO2 VF2 Hose Hydraulic oil tank VPS VPS PF3 Coupling Vibrator pump Hydraulic oil filter 2 LO2 LS2 Hydraulic oil tank Vibrator valve block Rear PF2 Vibrator valve block Front 3 VIBRATOR HYDRAULIC SYSTEM 3 1 Vibrator Hydraulic Piping 3 1 1 Vibrator hydraulic piping 1 4 013 HYDRAULIC SYSTEMS ...

Page 68: ......

Page 69: ...2 VF1 FVB Hose FM1 FVA Hose FM1 FVA Hose FM2 FVB Hose FM2 FVB Vibrator valve block Front Front drum high amplitude side gauge port Coupling Front drum low amplitude side gauge port B B A A Vibrator pump Hydraulic oil tank C D Hose FD1 T4 Hose VDT T1 Hose VDT T1 VA1 PT3 VDT Hose VA1 VF1 Hose VFT FD2 Hose VFT FD2 Hose FM1 FVA Hose FM2 FVB Hose VDT T1 Hose VFT FD2 Hose VB1 VF2 VB1 T4 T1 FD1 FD1 FD2 3...

Page 70: ......

Page 71: ...uge port Coupling Rear drum low amplitude side gauge port SECTION A A Hose BSF RD2 Hose Vibrator motor Rear RD1 BSL RVA Hose VB2 VR2 RVA Hose BSH RVB Hose VA2 VR1 B B A A C Hose RM2 BSH Hose VRT BSF Hose RM1 BSL TVD Hose RD1 TVD The letters and figures such as VB2 and VR2 show each port and the arrow symbols show the hose connection and the direction of the flow of the oil D DETAIL D 3 1 3 Vibrato...

Page 72: ......

Page 73: ...0 04015 1 1 2 2 3 3 4 4 Motor circuit diagram A VIEW A Flow of oil 1 Drain port T1 FD1 RD1 G1 2 2 Drain port T2 FD2 RD2 M12 1 5 3 Port B FVB RVB 1 1 16 12UN 2B 4 Port A FVA RVA 1 1 16 12UN 2B Specifications Displacement 16 cm3 rev 0 98 cu in rev Working pressure 22 5 MPa 3 263 psi Allowable motor case pressure 0 15 MPa 21 6 psi Weight 5 4 kg 11 9 lbs ...

Page 74: ...1 M1 T M2 R2 R1 Sol a Sol b Sol c V2 4 5 6 7 8 Electrical circuit diagram 3 10 Vibrator solenoid valve a b 12 Vibrator solenoid valve c 4 9 Relief valve R1 R2 Valve block circuit diagram 3 2 6 8 14 7 13 5 4 9 10 3 12 3 5 1 11 10 9 3 1 10 1 3 2 10 2 G1 7 8 14UNF 2A 7 8 14UNF 2A 12 1 12 2 4 1 9 1 ...

Page 75: ...ort G2 High amplitude side 9 16 18UNF 14 Port G1 Low amplitude side 9 16 18UNF 3 1 Nut 3 5 N m 2 6 lbf ft 3 2 Nut 90 N m 66 lbf ft 4 Relief valve R2 44 N m 32 lbf ft 4 1 Nut 13 5 N m 10 lbf ft 5 1 Bolt M6 30 14 N m 10 lbf ft 9 Relief valve R1 44 N m 32 lbf ft 9 1 Nut 13 5 N m 10 lbf ft 10 1 Nut 3 5 N m 2 6 lbf ft 10 2 Nut 90 N m 66 lbf ft 12 1 Nut 3 5 N m 2 6 lbf ft 12 2 Nut 50 N m 37 lbf ft Speci...

Page 76: ......

Page 77: ...k SCD SRL SLR Hose SRF SLD SLG SLD SRF SRD Hose T BSR Hose BSS P Steering cylinder R Steering cylinder L Hydraulic oil tank LS1 Hose BSR LS1 Steering Charge pump Steering Charge pump From steering charge pump The letters and figures such as SCD and BSS show each port and the arrow symbols show the hose connection and the direction of the flow of the oil Hose SLG SRD 4 STEERING SYSTEM 4 1 Steering ...

Page 78: ......

Page 79: ...ock handle 6 Bolt M10 35 2 Tilt ASSY 7 Orbitrol 3 Column shaft 8 Bolt M10 25 4 Nut M12 P 1 25 9 Bolt M10 25 5 Steering wheel 4 Nut M12 P 1 25 64 N m 47 lbf ft 6 Bolt M10 35 49 N m 36 lbf ft 8 Bolt M10 25 49 N m 36 lbf ft 9 Bolt M10 25 49 N m 36 lbf ft Steering wheel ASSY weight 18 kg 40 lbs ...

Page 80: ...l SW880 04007 4 3 4 3 1 2 1 2 5 Orbitrol circuit diagram L T P R 1 Port L L 3 4 16UNF 2 Port R R 3 4 16UNF 3 Port P P 3 4 16UNF 4 Port T T 3 4 16UNF 5 Relief valve Specifications Displacement 400 cm3 rev 24 4 cu in rev Relief valve setting 15 0 MPa 2 175 psi Weight 8 kg 18 lbs ...

Page 81: ...harge pump SV540 04004 2 3 Hydraulic circuit diagram A VIEW A 3 1 2 1 Pump 2 Outlet port SCD 7 8 14UNF 3 Inlet port SCS 1 5 16 12UN Specifications Displacement 24 9 cm3 rev 1 5 cu in rev Rated pressure 20 6 MPa 2 987 psi Weight 3 8 kg 8 4 lbs ...

Page 82: ......

Page 83: ...ELECTRICAL SYSTEM ...

Page 84: ......

Page 85: ...50 Corrugate Ǟ70 GB 100 CB104 58X 2F 200 Ǟ13 770 63 CorrugateǞ10 Brw 9 GB 63 LY 38 SWP 4㧲 Mark S Starter relay harness P 5 017 J P 5 005 BrR GL Fuel sensor Wire color Reference page Marking Reference page 24 1 25 BR Wire color AVS wire size Wire number 7 28 LgW R2 BR R1 C B ACC 24 1 25BR 4 26 Lg STARTER SWITCH 26 Lg 5G 5BY The pin or socket layout of mating connectors are symmetrical either vertic...

Page 86: ...rown White stripe BrR Brown Red stripe BrY Brown Yellow stripe BrB Brown Black stripe BrG Brown Green stripe BrL Brown Blue stripe Sb Sky blue L Blue LW Blue White stripe LR Blue Red stripe LY Blue Yellow stripe LB Blue Black stripe LG Blue Green stripe P Pink PB Pink Black stripe Lg Light green LgR Light green Red stripe LgY Light green Yellow stripe LgB Light green Black stripe LgW Light green W...

Page 87: ...ATER SPRAY MODE SELECT SWITCH WATER SPRAY MODE SELECT SWITCH WATER SPRAY TIMER SWITCH WATER SPRAY TIMER WATER SPRAY PUMP RELAY PUMP 1 WATER SPRAY PUMP RELAY PUMP 2 WATER SPRAY PUMP SWITCH R WATER SPRAY PUMP SWITCH F WATER SPRAY PUMP SWITCH F R BrR 205 LR 204 ENGINE ECM CM2250 J4 24PIN 1 2 TEMPERATURE SENSOR B X AUTO SPEED INDICATOR LAMP B 140 WR 206 R 138 B 140 W 145 R 138 F R LEVER POTENTIOMETER2...

Page 88: ......

Page 89: ...nal 5 Grid heater 2 Cord Battery Ground 3 Cord Battery Battery relay COM 10 Alternator 4 Grid heater relay 11 Cord Starter motor Ground Alternator 5 Cord Fuse Grid heater relay terminal 3 12 Starter motor 6 Battery relay 13 Cord Battery Starter motor terminal 30 7 Cord Battery relay NO Fuse 14 Cord Starter motor Ground Battery 8 Fuse 250A 15 Cord Battery Battery 16 Cord Battery Battery ...

Page 90: ......

Page 91: ...14 Backup buzzer B RY Floor board harness P 5 026 Flood lamp B RL Water spray pump R harness P 5 030 P 5 031 Diode unit P 5 006 P 5 006 P 5 006 Battery harness P 5 016 Vibrator pump proportional solenoid b Lo Vb B Br Head lamp B RW F R lever harness P 5 020 Temperature sensor BrR LR Ground B Vibrator solenoid R B BrB Vibrator solenoid F B LB Front frame harness P 5 018 Hydraulic oil filter switch ...

Page 92: ......

Page 93: ...arness R P 5 024 Panel harness L P 5 022 Horn GR Combination meter COM Horn switch GR Mark LH Panel harness R P 5 024 Main harness P 5 008 010 Foot brake switch COM B NC R COM WY NC LgY Mark D C Mark DIS Mark COM Mark RH1 RH2 RH3 RH4 Water spray timer switch TIM 1 GB 2 GL 3 G 4 GR 5 GL B BR BW W Water spray pump switch R RP 1 LY 2 W 3 L 4 LR 5 Y Water spray pump switch F FP 1 LW 2 W 3 G 4 RG 5 Y M...

Page 94: ......

Page 95: ...er relay 1 LgY 2 LgB 3 LgY 4 LgR 5 BW Starter switch relay 1 1 25BR 2 B 3 LgR 5 GB Propulsion pump neutral holding relay 1 Lg 2 B 3 LY 5 WL Propulsion pump neutral relay 2 1 BrY 2 B 3 Br 4 Lg Propulsion pump neutral relay 1 1 LgR 2 B 3 LY 5 Br Water spray pump relay pump 1 1 GB 2 B 3 2WB 5 2W Water spray pump relay pump 2 1 GR 2 B 3 2LB 5 2Y Water spray pump relay F 2 1 G 2 B 3 2GW 4 2RG 5 2LW Fus...

Page 96: ... 121 12 11 10 9 8 7 MC024B 6 5 4 3 2 1 1 2 3 4 5 6 MC024A 0 5B 129 0 5BW 0 5Gr 0 5W 0 5G 0 5Y 12 162 139 210 17 128 25 0 5GW 0 5WB 0 5B X 0 5Lg 73 7 8 9 10 11 12 120 Tape 120 Tape 50 Tape 50 Tape D C DIS 250 Corrugate 100 Tape RH4 RH3 RH2 RH1 58X 4F SWP 14F SWP 8F 58Y 1F R 200 BrY 196 RW 192 L 190 BrR 189 LgY 187 RY 184 RB 180 RW 179 BrY 74 WL 67 WR 66 WY 65 LgW 64 B X 1 25LB 56 1 25BR 52 BrR 39 Y...

Page 97: ...OM 16M M2 WB 0 5WB 2WB 8 E5 DIS MC024A MC024B 2 MC050 P C RES2 BrB 2 E1 LH LB 2 E1 LH GB 3 COM 12F M2 L3 YW 5 D C L3 LH M3 RH1 G 0 5G 3 LH MC050 RES1 NO SIZE COLOR CONTACT POINTS CONNECTION L 0 5L 3 LH MC050 RES1 Br 0 5Br 4 FRONT ROLL LH MC050 RES1 YB 0 5YB 3 L3 MC050 RES1 GB 0 5GB 3 LH MC050 RES1 YL 0 5YL 3 LH MC050 RES1 GY 0 5GY 3 L3 MC050 RES1 BrR 0 5BrR 3 MC050 RES1 RH1 GW 0 5GW 3 LH MC050 RES...

Page 98: ... 145 0 5B 121 12 11 10 9 8 7 MC024B 6 5 4 3 2 1 1 2 3 4 5 6 MC024A 0 5B 129 0 5BW 0 5Gr 0 5W 0 5G 0 5Y 12 162 139 210 17 128 25 0 5GW 0 5WB 0 5B X 0 5Lg 73 7 8 9 10 11 12 120 Tape 120 Tape 50 Tape 50 Tape D C DIS 250 Corrugate 100 Tape RH4 RH3 RH2 RH1 58X 4F SWP 14F SWP 8F 58Y 1F R 200 BrY 196 RW 192 L 190 BrR 189 LgY 187 RY 184 RB 180 RW 179 BrY 74 WL 67 WR 66 WY 65 LgW 64 B X 1 25LB 56 1 25BR 52...

Page 99: ...M4 2RG 2 L2 M4 Gr 0 5Gr 4 L4 M2 MC024A MC050 LgY 2 M3 NC BW 2 E3 M3 NO SIZE COLOR CONTACT POINTS CONNECTION LgB 0 5LgB 3 DIS M3 MC024B GR 2 L4 M3 2LW 2 L1 M4 2LY 2 L1 M4 GR 2 FRONT ROLL LH BY 3BY 3 E4 M3 TRQ W 2 M3 Engine diagnosis connector BR 2 E3 M3 G 2 E2 M1 RW 2 E3 RH2 RB 2 E3 RH2 GW 2 E3 M1 LW 2 E2 M1 LR 2 E2 M1 RY 2 E3 RH2 RB 0 5RB Twist pair cable with shield AVSSCS 0 75 5 E3 MC050 TRQ Eng...

Page 100: ...holding relay Horn relay Parking Interlock relay Starter motor relay Interlock relay Water spray pump relay pump1 Water spray pump relay pump2 Water spray pump relay F 2 Water spray pump relay R 2 1 2 3 4 5 6 7 Relay box 1 8 9 10 11 12 13 14 Relay box 2 15 16 17 18 Relay box 3 30 199 183 181 1 25BY 1 25BR LR GW 22 182 181 B X LW GW 192 178 181 RW 187 G GW LgY 13 178 181 200 WL R G GW 24 64 47 X YG...

Page 101: ...3 Br 2 Relay box 2 8 5 2 9 3 Lg 3 M3 Relay box 2 9 4 2 10 1 BrY 3 M2 Relay box 2 9 1 2 12 1 2LB 2 Fuse box F1 Relay box 3 16 3 O 2 DIO M3 NO SIZE COLOR CONTACT POINTS CONNECTION 2W 2 M5 Relay box 3 15 5 2Y 2 M5 Relay box 3 16 5 2GW 2 M7 Relay box 3 17 3 2LW 2 M7 Relay box 3 18 3 5WL 2 M6 Fuse box F2 G 3 M2 Relay box 3 17 1 3 18 1 1 25Y 2 Relay box 2 12 3 2 13 5 2LR 2 M4 Relay box 3 18 4 2RG 2 M4 R...

Page 102: ...00 Tape E7 LgB 193 YB 194 WB 195 200 Corrugate Twist cable 58X 2F S2 50 Tape 199 X 2BR 2B Lg 126 Br 124 B 123 L 122 B 121 G 120 Lg 73 WL 67 WR 66 58X 4M 2BR 199 2GW 82 2G 81 2WB 25 5WL 93 5WR 10 58Y 2M 3BY 172 5L 49 1 25BR 52 LgB 47 LB 27 BrB 26 GB 23 Y 17 LgR 15 58Y 2F Battery harness P 5 016 P 5 028 B3 5R 5R 86 203 3BY 172 2WB 25 1 25BR R 155 52 SWP 2F 58X 2M 58Y 2F 46 5R 10 5WR 93 5WL 58Y 2M 58...

Page 103: ...0pin connector 6 RB 2 E3 Engine ECM J3 60pin connector 8 GW Twist cable 3 E3 Engine ECM J3 60pin connector 13 Grid heater relay LW 2 E2 Engine ECM J3 60pin connector 14 LR 2 E2 Engine ECM J3 60pin connector 15 RY 2 E3 Engine ECM J3 60pin connector 16 RB Twist pair cable with shield AVSSCS 0 75 3 E3 Engine ECM J3 60pin connector 17 Terminating resistor 120Ω RY 3 E3 Engine ECM J3 60pin connector 18 ...

Page 104: ... 2WL 50 7124 9681 30A 3BY 50 3BW 50 7124 9681 RG 50 5A R 50 7124 9681 160 25 155 156 171 172 80 Tape 80 Tape 110 Tape 85 45 202 172 156 51 58Y 2F X 52 11 92 160 Ground LE104 NO LA208 NO LA308 COM LA308 COM LA308 COM LA308 NO LA308 COM LA208 COM LA108 COM LA308 BR LE104 Battery relay 171 3BW 49 5L 70 Tape 160 Corrugate 300 Corrugate 200 Corrugate 1 25BR 50 B 50 2WL 100 5WB 100 5W 100 5Y 150 5Y 150 ...

Page 105: ...L 2 E7 Fusible link 65A 5WG 2 CO Fusible link 65A 1 25BR 3 B5 BR Diode 5Y 2 CO Fusible link 65A NO SIZE COLOR CONTACT POINTS CONNECTION 5R 2 B2 Fusible link 65A 5WB 2 NO Fusible link 65A 5WL 2 B3 Fusible link 65A R 2 B5 Fuse 5A RG 2 CO Fuse 5A 2WL 2 NO Fuse 15A 3BW 2 E7 Fuse 30A 3BY 3 B4 CO Fuse 30A 5Y 2 CO Fusible link 65A 5R 2 B2 Fusible link 65A 5 017 ELECTRICAL SYSTEM ...

Page 106: ...20 Tape 70 Tape 70 Tape 100 Corrugate 250 Corrugate 230 Corrugate 220 Corrugate 200 Corrugate 120 Tape 120 Tape 120 Tape 23 23 27 LB X B B X LB 27 B X LB 27 26 BrB X B 26 BrB X B B X BrB 26 FBR NEU B X Lg 73 PRO 17 Y 23 GB 26 BrB 27 LB 73 Lg 101 GR 102 GY 124 Br 126 Lg 164 BW 204 LR 205 BrR 211 G 212 B 213 L 214 B SWP 6F 58X 3M SWP 16M DT06 2S CE05 W2S P012 54200207 F2 F1 B 214 G 213 L 211 212 164...

Page 107: ...ydraulic oil filter 1 2 BrB 4 F1 Vibrator solenoid R 3 LB 4 F1 Vibrator solenoid F 3 Lg 2 F1 NEU 2G 2 F2 FP1 2GW 2 F2 FP2 NO SIZE COLOR CONTACT POINTS CONNECTION GR Twist cable 2 F1 Fuel sensor GY 2 F1 Fuel sensor Br 2 F1 Vb Lg 2 F1 Va BW 2 F1 PRO LR 2 F1 Temperature sensor BrR 2 F1 Temperature sensor G 2 F1 PRO B 2 F1 PRO L 2 F1 PRO B 2 F1 PRO 5 019 ELECTRICAL SYSTEM ...

Page 108: ... switch R Water spray pump switch F Water spray mode select switch Water spray timer switch LE204 5 LE204 4 LE204 3 LE204 2 80 157 83 79 2W 50 2G 50 2RG 50 2Y 50 2W 50 2L 50 2LR 50 2Y 50 L4 58X 4F 58X 4M SWP 8F Water spray timer G 152 GB 28 G 152 B X 152 LE204 1 LE204 2 LE204 3 GB 50 G 50 GL 50 151 28 LE204 1 2LW 50 168 LE204 1 2LY 50 169 O 50 78 GL 50 GR 50 LE204 4 LE204 5 167 151 169 2LY 168 2LW...

Page 109: ...YB 2 L3 LVR GY 2 L3 LVR GR 2 L3 LVR GW 2 1 L3 O 3 4 FNO L4 2W 3 FP L1 RP 2Y 3 FP L1 RP NO SIZE COLOR CONTACT POINTS CONNECTION 2G 2 FP L2 2L 2 L2 RP R 3 L4 POT1 POT2 B 3 L4 POT1 POT2 W 2 L4 POT1 GL 4 2 5 TIM 2 G 4 L3 TIM 3 2LR 2 L2 RP 2RG 2 FP L2 Gr 2 L4 RNC GR 2 L4 TIM 2LW 2 FP L1 2LY 2 L1 RP WR 2 L4 POT2 5 021 ELECTRICAL SYSTEM ...

Page 110: ...3 YL 70 GB 70 YW 70 YW 70 37 5 31 4 36 3 5 4 3 1 1 31 Vibration change switch Vibration mode select switch Vibration frequency select switch Vibration drum select switch 42 6 R1 25 3 5 31 6 BrW 100 1 YW 100 IPF select switch YW 100 YW 100 LW 100 GW 100 31 5 R1 25 3 5 41 4 R1 25 3 5 31 3 R1 25 3 5 5 4 3 2 2 R1 25 3 5 40 IPF LH 250 Corrugate 80 Tape AUT 50 Tape 26 BrB 27 LB 31 YW 32 G 33 L 34 Br 36 ...

Page 111: ...H LB 2 F R 5 LH YW 11 C A 1 4 FRQ 1 4 F R 1 4 IPF 1 3 5 LH L H 1 G 2 FRQ 3 LH L 2 FRQ 6 LH Br 2 LH L H 2 NO SIZE COLOR CONTACT POINTS CONNECTION GB 2 C A 3 LH YL 2 C A 5 LH GW 2 IPF 2 LH LW 2 IPF 4 LH BrW 2 IPF 6 LH GB 2 AUT LH GR 2 LH L H 3 5 023 ELECTRICAL SYSTEM ...

Page 112: ... 2RL 5 2W 70 Main harness P 5 008 010 250 Corrugate 64 180 CB104 CA104 LgW 50 RB 50 ENG 50 Tape ENGINE STOP lamp 64 184 CB104 CA104 LgW 50 RY 50 WAR 50 Tape WARNING lamp 64 179 CB104 CA104 LgW 50 RW 50 WAI 50 Tape WAIT TO START lamp EGT WARNING lamp 50 Tape EGT B 50 R 50 CA104 CB104 X 200 1 2 196 187 LA104 1 LA104 2 LgY 70 BrY 70 70 Tape DIA Diagnostic switch 70 Tape PAR 50 Tape EME Emergency swit...

Page 113: ...H1 S M 3 5L 2 KEY B RH4 1 25BR 2 KEY BR RH1 1 25LB 2 KEY C RH1 LgW 5 ENG KEY ACC RH2 WAI WAR WY 2 EME 2 RH2 NO SIZE COLOR CONTACT POINTS CONNECTION WR 2 EME 1 RH2 WL 2 EME 3 RH2 2W 2 LIT 4 RH3 BrY 2 PAR 2 RH2 RW 2 RH2 WAI RB 2 ENG RH2 RY 2 RH2 WAR LgY 2 DIA 2 RH2 BrR 2 RH2 SPE 6 L 2 RH2 SPE 5 YR 2 SPE 3 4 RW 2 RH2 SPE 1 BrY 2 DIA 1 RH2 R 2 EGT RH2 5 025 ELECTRICAL SYSTEM ...

Page 114: ...Y 100 100 Tape 200 Corrugate 300 Corrugate 50 Tape 2350 Corrugate 2750 Corrugate 50 Tape 2B X2 2RL 5 2B X2 2RL 5 2B X2 2RW 2 2B X2 2RW 2 Head lamp R L R L Flood lamp LA208 CB104 Ground bolt Backup buzzar X2 6 6 CA104 5 2RL 2 2RW X2 3B FL1 FL2 DT06 2S EP06 DT06 2S EP06 DT06 2S EP06 W2S PO12 4 9 Floor Bord Harness 5 026 ELECTRICAL SYSTEM ...

Page 115: ...5 027 ELECTRICAL SYSTEM NO SIZE COLOR CONTACT POINTS CONNECTION 2B 3B 6 FL1 Flood lamp L R Ground bolt Head lamp L R 2RW 3 FL1 Head lamp L R 2RL 3 FL1 Flood lamp L R RY 2 FL2 Backup buzzer ...

Page 116: ...ess 58X 2M S1 S2 50 Tape 50 Tape 58Y 2M 5W 208 5BW 209 2B X 2B 100 2BR 100 5BW 130 5W 150 150 Corrugate Starter relay LA205 X LA205 199 LA308 209 LA308 208 2BR 199 NO SIZE COLOR CONTACT POINTS CONNECTION 2B 2 S2 Starter relay 2BR 2 S2 Starter relay 5W 2 S1 Starter relay 5BW 2 S1 Starter relay ...

Page 117: ...0 186 RY 185 RB 172 BY 188 L 197 B R 173 B 197 RY 186 RB 185 L 188 Twist pair cable with shield AVSSCS 0 75 Twist pair cable with shield AVSSCS 0 75 R 50 BY 50 172 173 NO SIZE COLOR CONTACT POINTS CONNECTION BY 2 TRQ Fuse 5A R 2 Fuse 5A Torque control box RB Twist pair cable with shield AVSSCS 0 75 2 TRQ Torque control box RY 2 TRQ Torque control box L 2 TRQ Torque control box B 2 TRQ Torque contr...

Page 118: ...84 RP1 2B1 RP2 2B2 2L 100 5B 50 Water spray pump R 1 Water spray pump R 2 140 B 138 R 139 W 210 YW YW 50 Tape 50 Tape SPD X1 SPR 2B 100 2B 100 2LW 100 1800 Corrugate 1300 Corrugate SWP 4M 139 W 210 138 R 140 B 2L 2LW 83 84 NO SIZE COLOR CONTACT POINTS CONNECTION 2B 5B 3 2B1 2B2 X1 2L 2 RP1 SPR 2LW 2 RP2 SPR R 2 SPR Speed sensor W 2 SPR Speed sensor B 2 SPR Speed sensor YW 2 SPR Speed sensor ...

Page 119: ...hite Black Vin RL Output 90 50 10 45 0 Cw 45 Angle A 120 ５ Output voltage ratio R W B Red white and black indicate harness colors Schematic Output characteristics Electrical travel Total electrical travel Shaft return direction Starting shaft position Stop position with return spring Mechanical travel Harness side POT2 POT1 138 145 140 R W B B WR R 140 206 138 ...

Page 120: ...2 Exact Meter SW880 1 05017 DIS 128 GW 129 B 130 B 141 YW 25 X B WB 165 LgB Harness side SwP 8M SwP 6M Cap SwP 6F SwP 8F 1 2 3 4 5 6 7 8 Pin NO Wire NO Function 1 CAN 2 CAN 3 CAN GND 4 12 V OUT 5 12 V 6 GND 7 Exact meter relay 8 ...

Page 121: ...SwP12F 1 SwP12F 2 SwP12F 3 SwP12F 4 SwP12F 5 SwP12F 6 SwP12F 12 SwP12F 10 SwP12F 11 SwP12F 9 SwP12F 8 SwP12F 7 SwP3F 3 300Ω 300Ω 300Ω 300Ω 300Ω 300Ω 300Ω 300Ω 300Ω 300Ω 300Ω 5 6Ω 5 6Ω 5 6Ω Harness side Harness side Resistor harness for emergency propulsion VCTF 0 75 2 wires Shunt resistance output harness VCTF 0 5 12 wires 25 65 32 33 34 35 36 37 38 39 40 41 42 X 34 Br 38 GY GW LW 42 BrW 41 40 YL ...

Page 122: ...5019 4 3 1 2 2 1 3 L O B G R Y Electrical circuit Harness side LVR 31 YW 31 YW 31 YW 35 YB 38 GY 43 GR 31 O 31 G 31 Y 35 L 38 B 43 R 1 F R lever auto speed set switch White 2 F R lever vibration switch Green 3 F R lever water spray switch Blue 4 Handle ...

Page 123: ...se switch Horn relay CIS option WG Lighting switch W Lighting switch WR Water spray pump relay pump 2 LB Water spray pump relay pump 1 WB Engine diagnosis connector W Engine ECM CM2250 J3 60pin BR Battery relay WR Battery relay WL Parking interlock relay GY Starter switch relay GB Battery relay Fuse 30A Torque control box BY 1 2 3 4 5 6 7 8 9 10 11 20 A 20 A 20 A 20 A 20 A 5 A 10 A 15 A 15 A 15 A ...

Page 124: ...ine oil pressure warning Coolant temp SEL 1 Coolant temp SEL 2 Hydraulic oil filter warning REV ratio SEL 3 REV ratio SEL 4 Side marker lamp Combination meter ilumination Preheating Side marker lamp indicator Engine oil pressure warning indicator Charge warning indicator Hydraulic oil filter warning indicator Preheating indicator Harness side Harness side SWP 16F SWP 16F SWP 16M SWP 12M SWP 12M SW...

Page 125: ...VIBRATORY DRUM ...

Page 126: ......

Page 127: ...substances from getting in Before removing piping for hydraulic oil or coolant or removing related parts satisfactorily release internal pressure 2 Precautions for installation work Tighten bolts and nuts sleeve nuts to the specified torque screw tightening torque table When installing hoses do not twist them or allow them to interfere with other parts Replace gaskets O rings split cotter pins and...

Page 128: ...fe coolant to the specified level Start the engine and allow the coolant to circulate through the piping Then add coolant again to the specified level If hydraulic equipment has been removed and reinstalled fill with hydraulic oil to the specified level Start the engine and allow the oil to circulate through the piping Then add oil again to the specified level ...

Page 129: ...ined posture Also to firmly secure the vehicle body use a support stand of sufficient strength 3 Lift the frames with a crane With the drum lifted a little off the ground place support stands under both sides of each frame to hold the vehicle body in place The front and rear frames are structurally identical Front frame Rear frame SW880 1 6 340 kg 13 975 lbs 6 530 kg 14 395 lbs SW990 1 6 520 kg 14...

Page 130: ...left and right 7 Lift the member 8 and water spray pipe cover 9 with a crane and hold them Remove the two bolts 10 left and right Lift the member 8 water spray pipe cover 9 and the brackets 11 left and right and remove them Weight of parts to be lifted 75 kg 165 lbs 3 4 SW880 06004 3 4 SW880 06004 7 5 6 SW880 06005 7 5 6 SW880 06005 10 8 9 11 SW880 06006 10 8 9 11 SW880 06006 ...

Page 131: ...he bolt 14 fixing the drain cap chain Remove the four cover fixing bolts 15 left and right Remove the covers 16 left and right 10 Remove the two bolts 17 left and right Pull out the tank stoppers 18 left and right 12 13 SW880 06007 12 13 SW880 06007 SW880 06008 14 15 16 SW880 06008 14 15 16 18 17 SW880 06009 18 17 SW880 06009 ...

Page 132: ...d compressed immediately after the vehicle is stopped Disconnecting the hydraulic hoses in this condition can cause burns Wait for the hydraulic oil to cool down before starting the work 13 Disconnection of piping Propulsion motor piping Remove the hydraulic hose clamp 26 Disconnect the four hydraulic hoses 22 23 24 and 25 connecting to the propulsion motor NOTICE Plug both ends of the disconnecte...

Page 133: ...ent other actions to prevent entry of foreign matter 14 Remove twelve bolts 33 15 Lift off vibratory drum 32 from frame 32 Drum SW880 1 3 100 kg 6 834 lbs SW990 1 3 215 kg 7 088 lbs 16 Put chocks or the like under the removed drum 32 to prevent it from moving Vibrator motor 28 30 29 31 27 SW880 06013 Vibrator motor 28 30 29 31 27 SW880 06013 32 33 SW880 06014 32 33 SW880 06014 32 Chock SW880 06015...

Page 134: ...alling the vibratory drum pay particular attention to the following precaution WARNING If the engine is run at high speed or the cylinder is operated to full stroke when the engine is started for the first time after the work is completed the piston packing or other items may be damaged by air entering into the cylinder NOTICE Fill the hydraulic oil tank to the specified level to make up for any o...

Page 135: ...34 O ring 5 Vibrator bearing 35 Cover 6 Sleeve 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 Spring pin 14 Bolt M16 50 44 Spring pin 15 Housing 45 Retaining ring 16 Bracket 46 Drum 17 Bolt M12 45 47 O ring 18 Damper 48 Bracket 19 Bolt M12 45 49 Bolt ...

Page 136: ......

Page 137: ...rength to securely support the drum 2 Lift the vibratory drum with a crane and stand it with its vibrator motor side facing up as shown on the right Vibratory drum assembly SW880 1 3 100 kg 6 834 lbs SW990 1 3 215 kg 7 088 lbs WARNING Carry out the work in an unstrained posture using a work stool or the like 3 Remove the four bolts 30 Remove the vibrator motor 27 Remove the breather 24 27 Vibrator...

Page 138: ...rts 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 16 18 22 and 32 Total weight of parts to be lifted 290 kg 639 lbs 6 Pull out the sleeve 42 Remove the sixteen bolts 14 Lifting bolt Nut SW880 06020 Lifting bolt Nut SW880 06020 32 16 22 23 18 SW880 06021 32 16 22 23 18 SW880 06021 42 14 SW880 0...

Page 139: ...it NOTICE In order not to lift the eccentric shaft together with the axle shaft subassembly tap on the eccentric shaft end with a wooden hammer via a wooden bar during lifting Axle shaft subassembly 140 kg 309 lbs SW800 06018 Pulling bolt 13 SW800 06018 Pulling bolt 13 13 Lifting bolt SW800 06019 13 Lifting bolt SW800 06019 Wooden hammer Wooden bar Axle shaft subassembly Lift with crane SW880 0602...

Page 140: ...ric shaft to remove it 11 Eccentric shaft 60 kg 132 lbs 11 Remove the twelve bolts 9 12 Lift the housing 8 using two pulling bolts M16 50 SW800 06022 11 Lift with crane Lifting bolt SW800 06022 11 Lift with crane Lifting bolt 9 SW800 06023 9 SW800 06023 8 Pulling bolt SW800 06024 8 Pulling bolt SW800 06024 ...

Page 141: ... work in a natural unstrained posture 15 Lift the vibratory drum with a crane and reverse it Then stand the drum with its propulsion motor side facing up Weight of vibratory drum in the illustrated condition SW880 1 2 570 kg 5 666 lbs SW990 1 2 640 kg 5 820 lbs SW800 06025 8 Lifting bolt SW800 06025 8 Lifting bolt Housing subassembly Lift with crane 8 4 SW800 06026 Housing subassembly Lift with cr...

Page 142: ... 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 48 55 56 and 59 Total weight of parts to be lifted 250 kg 551 lbs 18 Remove the sixteen bolts 50 Lifting bolt Nut SW880 06025 Lifting bolt Nut SW880 06025 56 55 48 54 59 SW880 06026 56 55 48 54 59 SW880 06026 50 SW880 06027 50 SW88...

Page 143: ...r 53 20 Lift the propulsion motor 53 with a crane to remove it 53 Propulsion motor 200 kg 441 lbs 21 Remove the sixteen bolts 1 53 Lifting bolt SW880 06028 53 Lifting bolt SW880 06028 Lift with crane 53 SW880 06029 Lift with crane 53 SW880 06029 1 SW880 06030 1 SW880 06030 ...

Page 144: ...stall lifting bolts M20 on the housing 2 24 Lift the housing 2 with a crane to remove it 2 Housing 80 kg 176 lbs 2 Pulling bolt SW880 06031 2 Pulling bolt SW880 06031 2 Lifting bolt SW880 06032 2 Lifting bolt SW880 06032 2 Lift with crane SW880 06033 2 Lift with crane SW880 06033 ...

Page 145: ...28 Remove the cover 29 and shim 26 27 Place a protection plate on the end face of the axle shaft 13 and set a puller on the housing 15 Separate the housing 15 together with the roller bearing from the axle shaft 13 35 36 SW800 06037 35 36 SW800 06037 29 26 28 SW800 06038 29 26 28 SW800 06038 13 15 Puller Protection plate SW800 06039 13 15 Puller Protection plate SW800 06039 ...

Page 146: ...the housing subassembly on a stand as shown 8 and 4 Total weight of parts to be lifted 100 kg 220 lbs 15 Lifting bolt SW800 06040 15 Lifting bolt SW800 06040 15 13 Lift with crane SW800 06041 15 13 Lift with crane SW800 06041 Lift with crane and put on stand Stand Housing subassembly 8 4 SW800 06042 Lift with crane and put on stand Stand Housing subassembly 8 4 SW800 06042 ...

Page 147: ...Bearing puller SW800 06043 Bearing puller SW800 06043 SW880 06059 300 Nut Nut Nut M16 M16 M16 250 54 15 30 t 16 M16 2 0 M16 2 0 M16 2 0 C 2 C 2 C 2 C 3 4 C 2 4 18 φ16 50 157 110 110 270 50 162 75 8 Plate Puller Two shafts Two tabs SW880 06059 300 Nut Nut Nut M16 M16 M16 250 54 15 30 t 16 M16 2 0 M16 2 0 M16 2 0 C 2 C 2 C 2 C 3 4 C 2 4 18 φ16 50 157 110 110 270 50 162 75 8 Plate Puller Two shafts T...

Page 148: ...entric shaft 4 lifted with a crane on wooden blocks 36 Remove the retaining ring 45 Lift with crane Lifting bolt 8 SW800 06046 Lift with crane Lifting bolt 8 SW800 06046 8 4 Lift with crane and put on wooden blocks Wooden block SW800 06047 8 4 Lift with crane and put on wooden blocks Wooden block SW800 06047 45 SW800 06048 45 SW800 06048 ...

Page 149: ...n wooden blocks 39 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 8 4 Lift with crane SW880 06034 8 4 Lift with crane SW880 06034 8 Wooden block SW800 06050 8 Wooden block SW800 06050 8 5 Wooden bar Hammer SW800 06051 8 5 Wooden bar Hammer SW800 06051 ...

Page 150: ...g bolts screw in the threads fully before using Lift the housing subassembly with a crane and reverse it Install lifting bolts M20 Housing subassembly 80 kg 176 lbs WARNING When standing the drum use wooden blocks of sufficient strength to securely support the drum 2 Stand the drum 46 with its propulsion motor mounting side facing up NOTICE The side on which no weld bead is installed is the propul...

Page 151: ...using subassembly to the drum with the sixteen bolts 1 and washers N m 1 Bolts M20 60 540 N m 398 lbf ft 5 Attach a bearing inner race fixture to the housing subassembly with two bolts M20 35 and washers Housing subassembly SW800 06055 Housing subassembly SW800 06055 1 Housing subassembly SW800 06056 1 Housing subassembly SW800 06056 Bearing inner race fixture Bolt SW800 06057 Bearing inner race f...

Page 152: ...r motor side facing up NOTICE The side on which a weld bead is installed is the vibrator motor side 46 Drum SW880 1 2 150 kg 4 740 lbs SW990 1 2 250 kg 4 960 lbs 8 Put the eccentric shaft 11 vibrator motor side on wooden blocks with its splined portion facing up Drive the spring pin 44 into the eccentric shaft Bearing inner race fixture Secure bearing inner race SW800 06058 Bearing inner race fixt...

Page 153: ...er surface of the bearing 5 NOTICE Take care not to damage the bearing when installing it Reverse the housing subassembly and install lifting bolts M16 on it Put the eccentric shaft 4 propulsion motor side on the wooden blocks with its splined position facing up 5 8 SW800 06060 5 8 SW800 06060 Lifting bolt Housing subassembly SW800 06061 Lifting bolt Housing subassembly SW800 06061 4 Wooden block ...

Page 154: ...nfirm that the retaining ring 45 is securely fitted in the groove Drive the spring pin 7 into the sleeve 6 Apply gear oil to the inner surface of the sleeve 6 and the splined portion of the eccentric shaft 4 Install the sleeve 6 on the eccentric shaft 4 NOTICE When installing the sleeve 6 take care not to plug the positioning hole in the eccentric shaft 4 with the spring pin 7 4 Lift with crane Ho...

Page 155: ...or bearing 10 and the bearing mounting surface of the eccentric shaft 11 Slowly lower the eccentric shaft 11 with a crane and install it in the housing 8 NOTICE Install the eccentric shaft taking care not to tilt the vibrator bearing inner race 11 Eccentric shaft 60 kg 132 lbs When installing the eccentric shaft 11 in the housing 8 insert the spring pin 44 on the shaft into the positioning hole in...

Page 156: ...N m 9 Bolts M16 50 265 N m 195 lbf ft Lifting jig Eccentric shaft subassembly SW800 06069 Lifting jig Eccentric shaft subassembly SW800 06069 40 75 75 22 30 9 2 M16 2 0 M16 2 0 Nut Nut Bracket L75 75 9 4 18 80 250 300 710 22 30 24 Eyebolt Lifting jig Two shafts SW880 06061 40 75 75 22 30 9 2 M16 2 0 M16 2 0 Nut Nut Bracket L75 75 9 4 18 80 250 300 710 22 30 24 Eyebolt Lifting jig Two shafts SW880 ...

Page 157: ...aring 12 to be press fitted Drive the vibrator bearing 12 into the axle shaft 13 NOTICE Take care not to damage the bearing when installing it 13 3 Lift the axle shaft subassembly with a 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 80 kg 176 lbs ...

Page 158: ...3 6 Apply sufficient amount of lithium based grease to the roller surface of the inner race of the roller bearing 37 Drive the roller bearing 37 into the housing subassembly until the roller surface of its inner race comes into contact with the outer race 37 39 Axle shaft subassembly SW800 06076 37 39 Axle shaft subassembly SW800 06076 Lift with crane Lifting bolt Housing subassembly Axle shaft su...

Page 159: ...luctuates NOTICE Tighten four of the eight bolts 28 alternately in the diagonal directions NOTICE Push in the inner race while rotating the bearing Otherwise even strongly trying to push the inner race the bearing rollers will not be pushed up and therefore bearing will not be seated Remove the four bolts 28 Remove the cover 29 and shim 26 26 28 15 29 Clearance SW800 06079 26 28 15 29 Clearance SW...

Page 160: ...f the preload adjusting shim thickness A 0 1 mm and reinstall the cover 29 Then secure the cover with the eight bolts 28 with washers N m 28 Bolts 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 mounting surface SW800 06082 There must be no gap 28 29 A SW800 06082 There must be no gap 28...

Page 161: ... on the axle shaft subassembly 15 Apply a thin coat of grease to the entire periphery of the O ring 40 Install the O ring 40 on the axle shaft subassembly 35 36 15 SW800 06085 35 36 15 SW800 06085 Lifting bolt Axle shaft subassembly SW800 06086 Lifting bolt Axle shaft subassembly SW800 06086 40 Axle shaft subassembly SW800 06087 40 Axle shaft subassembly SW800 06087 ...

Page 162: ...de from the fitting groove Axle shaft subassembly 140 kg 309 lbs NOTICE When installing the axle shaft subassembly pay attention to the positional relationship between the weld bead 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 N m 14 Bolts M16 50 265 N m 195 lbf ft SW800 06088 11 Pipe Axle shaft subassembly SW800 06088 11 Pipe A...

Page 163: ...e is an axial play of 1 to 2 mm 0 04 to 0 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 11 Lifting bolt SW800 06091 11 Lifting bolt SW800 06091 Lift with crane SW800 06092 Lift with crane SW800 06092 18 32 22 16 Lifting bolt Nut SW880 06042 18 32 22 16 Lifting bolt Nut SW880 06042 ...

Page 164: ...lation to the position of the breather mounting hole in the housing 23 Secure the bracket subassembly to the housing with the sixteen bolts 23 and washers N m 23 Bolts M20 60 540 N m 400 lbf ft Wind seal tape around the threaded portion of the breather 24 Install the breather 24 Lift with crane SW880 06043 Lift with crane SW880 06043 Breather mounting hole Align with hole SW880 06044 Breather moun...

Page 165: ...grease to the O ring 34 Install the O ring 34 on the vibrator motor 27 26 Secure the vibrator motor 27 in place with the four bolts 30 NOTICE When installing the vibrator motor take care not to allow the O ring to protrude from the fitting groove N m 30 Bolts M10 30 60 N m 44 lbf ft SW880 06046 42 SW880 06046 42 SW880 06047 34 27 SW880 06047 34 27 30 27 SW880 06048 30 27 SW880 06048 ...

Page 166: ...t Then stand the drum with the propulsion motor side facing up 46 Drum SW880 1 2 690 kg 5 930 lbs SW990 1 2 760 kg 6 085 lbs 28 Remove the bearing inner race fixture 29 Install a lifting bolt M10 on the shaft end of the eccentric shaft 4 46 Wooden block SW800 06100 46 Wooden block SW800 06100 SW800 06101 Bearing inner race fixture SW800 06101 Bearing inner race fixture SW880 06049 4 Lifting bolt S...

Page 167: ...mm 0 04 to 0 08 in 31 Apply a thin coat of grease to the O ring 52 Install the O ring 52 on the propulsion motor 53 32 Install lifting bolts M20 on the propulsion motor 53 Lift with crane SW800 06103 Lift with crane SW800 06103 SW800 06104 52 53 SW800 06104 52 53 SW880 06050 Lifting bolt 53 SW880 06050 Lifting bolt 53 ...

Page 168: ...motor 200 kg 441 lbs 34 Secure the propulsion motor 53 with the bolts 50 and washers N m 50 Bolts M20 60 540 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 53 Lift with crane SW880 06051 53 Lift with crane SW880 06051 53 50 SW880 06052 53 50 SW880 06052 59 56 48 55 Lifting bolt Nut SW880 06053 59 56 48 5...

Page 169: ...he propulsion motor 53 NOTICE Be sure to install the bracket subassembly correctly in relation to the position of the propulsion motor 53 38 Secure the bracket subassembly to the propulsion motor 53 with the sixteen bolts 54 and washers N m 54 Bolts M20 60 540 N m 398 lbf ft Lift with crane SW880 06054 Lift with crane SW880 06054 53 SW880 06055 53 SW880 06055 53 54 SW880 06056 53 54 SW880 06056 ...

Page 170: ...bs 40 Remove the plugs 39 1 and 39 2 Supply gear oil from the oil supply port and check that the oil drips from the gauge port Gear oil 22 L 5 8 gal Reinstall the plugs 39 1 and 39 2 Oil supply plug Chock Chock Gauge port drain plug Weld bead SW880 1 06003 Oil supply plug Chock Chock Gauge port drain plug Weld bead SW880 1 06003 39 2 39 1 Oil supply port Gauge port drain port SW880 06058 39 2 39 1...

Page 171: ...BRAKE ...

Page 172: ......

Page 173: ...7 001 BRAKE 1 BRAKE PEDAL 0568 51803 0 11251 0 2 5 4 3 1 1 Brake pedal 4 Nut M10 P 1 25 2 Foot brake switch 5 Return spring 3 Stopper bolt M10 25 P 1 25 ...

Page 174: ...rking brake solenoid valve when brake is ON without solenoid excited Brake Brake ON condition Brake Brake ON condition Parking brake solenoid valve when brake is OFF with solenoid excited The arrow symbol shows the direction of the hydraulic oil flow 1 4 3 2 5 15A Fuse EXACT meter relay Foot brake switch Condition in which brake pedal pressed COM NO NC ...

Page 175: ...OPERATOR STATION ...

Page 176: ......

Page 177: ...ll grease SECTION C C VIEw D D C C B B 1 Dashboard 10 Nut M10 2 Lever 11 Pedal 3 Pin 12 Bolt M10 20 4 Swing bearing 13 Rod end M10 left hand thread 5 Bolt M10 50 14 Nut M10 left hand thread 6 Bolt M10 50 15 Rod 7 Pin 16 Nut M10 8 Spring 17 Rod end M10 9 Bolt pedal stopper M10 40 N m 5 Bolt M10 50 49 N m 36 lbf ft 12 Bolt M10 20 49 N m 36 lbf ft 6 Bolt M10 50 49 N m 36 lbf ft ...

Page 178: ...n the dashboard Depress the pedal 11 and check that the lock is smoothly released If the above checks and show no problem tighten the nuts 14 and 16 to fix the pedal Pedal released Pedal depressed The numbers in parentheses that appear in the above sentences and the numbers in the above illustrations are consistent with the lead line numbers shown in 1 1 Structure of Operator Station page 8 001 SW...

Page 179: ...WATER SPRAY SYSTEM ...

Page 180: ......

Page 181: ... Cover Hose Tee Pump 1 IN Hose Tee Pump 2 IN Filter Nozzle Tee Hose Tee Pump 2 IN Filler cap Gauge Water spray tank IN OUT IN OUT IN Strainer OUT SECTION B B DETAIL C VIEW A VIEW D Water spray diagram The letters and figures such as Pump 1 and Pipe 1 show each port and the arrow symbols show the hose connection and the direction of the flow of the water OUT IN OUT IN Pipe 1 Pipe 2 Filter Tank P Pu...

Page 182: ......

Page 183: ...INSPECTION AND ADJUSTMENT ...

Page 184: ......

Page 185: ...fan V belt or exhaust system parts while the engine is running may cause serious injury 1 2 Preparation for Inspection and Adjustment Prepare the necessary measuring instruments In addition particularly when measuring pressure values make sure to prepare the appropriate hoses adapters and a plug removal tool for the pressure reading port Make sure that the instruments to be used operate normally W...

Page 186: ... G1 1 Reverse side port G2 2 Pressure gauge 0 to 50 MPa 0 to 7 250 psi Set propulsion speed change switch to Set vibration frequency select switch to 2 500 vpm Start the engine and set throttle switch to the Full Establish a condition in which machine propulsion load becomes maximum Pressure does not build up unless propulsion load is applied With propulsion load at maximum slowly move F R lever t...

Page 187: ...lockwise Pressure drop Pressure change rate 10 MPa turn 1 450 psi turn If there is no evidence of nut having loosened remove cut off valve Check removed cut off valve for trapped dirt and scratches on its seat If trapped dirt is present disassemble and clean cut off valve If a scratch is found on seat replace cut off valve After adjustment measure pressure again and check that pressure reaches max...

Page 188: ...having loosened remove high pressure relief valve Check removed high pressure relief valve for trapped dirt and scratches on its seat If trapped dirt is present disassemble and clean high pressure relief valve If a scratch is found on seat replace high pressure relief valve After adjustment measure pressure again and check that pressure reaches maximum circuit pressure range 5 Nut 20 N m 15 lbf ft...

Page 189: ... 18UNF M16 Adapter for hose ⓢ M16 P 2 0 Pressure gauge connector ⓤ M16 G3 8 Pressure gauge 0 to 5 MPa 0 to 725 psi Apply parking brake by pressing parking brake switch button Start the engine and set throttle switch to Full Then read pressure indicated by pressure gauge Standard charge relief valve setting 2 5 0 2 MPa 362 29 psi The number 1 10 appearing in above illustrations is consistent with l...

Page 190: ...nce of nut having loosened remove charge relief valve Check the removed charge relief valve for trapped dirt and scratches on its seat If trapped dirt is present disassemble and clean charge relief valve If a scratch is found on seat replace charge relief valve After adjustment measure pressure again and check that pressure reaches standard charge relief valve pressure setting range 1 Nut 44 N m 3...

Page 191: ...er Pressure gauge 0 to 5 MPa 0 to 725 psi Apply parking brake by pressing parking brake switch button Start the engine and set throttle switch to Full Operate F R lever and then read pressure indicated by pressure gauge With parking brake applied ON measured pressures of 2 and 3 are same With parking brake released OFF measured pressures of 2 and 3 are different Standard charge relief valve settin...

Page 192: ...tor Attach pressure gauge through adapter ⓦ Adapter ⓦ 4 4LOHL6G5TP Parker part number Pressure gauge 0 to 5 MPa 0 to 725 psi Confirm that F R lever is in N properly Apply parking brake by pressing parking brake switch button Start the engine and set throttle switch to Full Release parking brake by pressing parking brake switch button Then brake release pressure indicated by pressure gauge Brake re...

Page 193: ...ont drum high amplitude side gauge port 2 Rear drum low amplitude side gauge port 3 Rear drum high amplitude side gauge port 4 Pressure gauge 0 to 50 MPa 0 to 7 250 psi Apply parking brake by pressing parking brake switch button Set vibration mode select switch to Set vibratory drum selector switch to Start the engine and set throttle switch to Full Press F R lever vibration switch ON Then read pr...

Page 194: ...just pressure Adjustment screw turned clockwise Pressure rise Adjustment screw turned counterclockwise Pressure drop Pressure change rate 4 3 MPa turn 623 psi turn If there is no evidence of high pressure relief valve having loosened remove it Check removed high pressure relief valve for trapped dirt and scratches on its seat If trapped dirt is present disassemble and clean high pressure relief va...

Page 195: ... as a port relief valve To adjust pressure loosen nut and turn adjustment screw 11 Adjustment screw turned clockwise Pressure rise Adjustment screw turned counterclockwise Pressure drop Pressure change rate 14 MPa turn 2 030 psi turn If there is no evidence of nut having loosened remove high pressure relief valve Check removed high pressure relief valve for trapped dirt and scratches on its seat I...

Page 196: ...onnector ⓤ M16 G3 8 Pressure gauge 0 to 5 MPa 0 to 725 psi Apply parking brake by pressing parking brake switch button Start the engine and set throttle switch to Full Then read pressure indicated by pressure gauge Standard charge relief pressure setting 2 5 0 2 MPa 362 29 psi The numbers 2 10 appearing in above illustrations is consistent with lead line numbers shown in illustration of vibrator p...

Page 197: ...setting range after valve is disassembled and cleaned replace charge relief valve After inspection measure pressure again and check that pressure reaches standard charge relief pressure setting range 2 16 Charge relief valve 90 N m 66 lbf ft NOTICE Carefully disassemble and reassemble after taking steps to prevent foreign material from getting in The number 2 16 appearing in above illustrations is...

Page 198: ...e hose 1 or 2 from cylinder Attach pressure gauge through adapter ⓧ Adapter ⓧ 6 4LOHL6G5TP Parker part number Pressure gauge 0 to 25 MPa 0 to 3 625 psi Confirm that F R lever is N properly Start the engine and set throttle switch to Full Turn steering wheel to operate relief valve Then read pressure indicated by pressure gauge Standard maximum circuit pressure orbitrol relief pressure charge relie...

Page 199: ...relief valve for trapped dirt scratches on its seat and other abnormalities If trapped dirt is present disassemble and clean relief valve If a scratch or any other abnormality is found on seat replace relief valve After inspection measure pressure again and check that pressure reaches standard maximum circuit pressure range NOTICE Carefully disassemble and reassemble after taking steps to prevent ...

Page 200: ...5 MPa 0 to 725 psi Set propulsion speed change switch to Set vibration frequency select switch to 2 500 vpm Start the engine and set throttle switch to FULL Establish a condition in which machine propulsion load becomes maximum Pressure does not build up unless propulsion load is applied With propulsion load at maximum measure pressure when speed change switch is in and and F R lever is in N F and...

Page 201: ...LOHL6G5TF Parker part number Pressure gauge 0 to 5 MPa 0 to 725 psi Apply parking brake by pressing parking brake switch button Set vibration mode select switch to Set vibratory drum selector switch to Start the engine and set throttle switch to Full Press F R lever vibration switch ON Measure pressure when vibration select switch is in and and vibration frequency select switch 2 500 3 000 and 4 0...

Page 202: ...speed change switch to Set vibration frequency select switch to 2 500 vpm Start the engine and set throttle switch to Full Establish a condition in which machine propulsion load becomes maximum Pressure does not build up unless propulsion load is applied With propulsion load at maximum measure pressure when speed change switch is in and and F R lever is in N F and R respectively Allowable motor ca...

Page 203: ...r ⓥ 8 4LOHL6G5TP Parker part number Pressure gauge 0 to 5 MPa 0 to 725 psi Apply parking brake by pressing parking brake switch button Set vibration mode select switch to Set vibratory drum selector switch to Start the engine and set throttle switch to Full Press F R lever vibration switch ON Measure pressure when vibration select switch is in and and vibration frequency select switch 2 500 3 000 ...

Page 204: ... a right angle 12 1 1 Adjustment of disc spring tension NOTICE Ends of forward switch 1 and reverse switch 3 must not be in contact with F R lever cam Screw 7 must not be in contact with F R lever Apply lithium based grease to shaft of potentiometer 1 4 and potentiometer 2 6 Place F R lever in the temporary neutral position Adjust with nut 5 so that F R lever operating force reading becomes the fo...

Page 205: ...toward forward position and screw rides out of detent in F R lever cam F R lever operating force standard value when steel ball rides out of detent 40 0 0 2 N 9 0 0 45 lbf Adjust with screw 7 so that F R lever operating force reading becomes the following standard value when F R lever is moved further toward forward position after screw rides out of detent F R lever operating force standard value ...

Page 206: ...rew rides out of detent and then release lever slowly reverse direction only Adjust the angle of potentiometer 1 so that the mid value between maximum and minimum voltages becomes 2 500 V and the range difference between maximum and minimum voltages becomes 0 010 V Example When maximum voltage is 2 505 V and minimum voltage is 2 495 V Mid value 2 505 V 2 495 V 2 2 500 V Range between maximum and m...

Page 207: ... NOTICE Acceptable range for voltage when forward switch operates is 2 415 to 2 425 V Forward switch must be installed with its centerline aligned with centerline of F R lever cam After adjustments are made make sure about following points F R lever cam must not push in forward switch until it bottoms when F R lever is moved toward forward position F R lever must automatically return to neutral wh...

Page 208: ... voltage when reverse switch operates is 2 575 to 2 585 V Reverse switch must be installed with its centerline aligned with centerline of F R lever cam After adjustments are made make sure about following points F R lever cam must not push in reverse switch until it bottoms when F R lever is moved toward reverse position F R lever must automatically return to neutral when F R lever is released at ...

Page 209: ...TROUBLESHOOTING ...

Page 210: ......

Page 211: ...ay cause a serious accident When inspecting the engine make sure to exchange the appropriate cues and hand signal with the person at the operator station to avoid any accidents CAUTION Before inspecting inside of the engine compartment always stop the engine Contact with the fan V belt or exhaust system parts while the engine is running may cause serious injury 1 2 Important Information for Troubl...

Page 212: ...erating it Check the problem yourself 4 Identify the problem with either a mechanical hydraulic or electrical system source 5 Isolate the problem to a particular component or circuit 6 Eliminate the simplest or easiest to check possibilities first to prevent unnecessary disassembly of components 7 Following repair or replacement of any parts perform operational tests to verify that the problem has...

Page 213: ... 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 connections Check by disconnecting and reconnecting related connectors several times Before proceeding to the next step be sure to return the disconnected connectors to their original condition When dia...

Page 214: ... equipment A measuring resistance between terminals 1 and 3 1 2 3 3 4 2 5 1 2 3 1 2 3 1 Equipment A Connector Harness Equipment A Ohmmeter tester Equipment B Main power source of equipment B Signal from equipment A Power to equipment A Ground of equipment A TS 10002 Inspection procedure Disconnect the connector of equipment A Connect the test probe to connector terminal 1 of equipment A and the te...

Page 215: ...rness such as broken wire 10 Ω or higher measured value 1 3 Measuring resistance of grounding wire measuring resistance between terminal 5 of equipment B and ground 1 2 3 4 5 5 1 Connector A Harness Ohmmeter tester Main power source of equipment B Equipment B Battery Equipment B TS 10004 Inspection procedure Disconnect the connector of equipment B Connect the test probe to connector terminal 5 of ...

Page 216: ...A Power to equipment A Equipment B Equipment B Equipment A TS 10005 Inspection procedure Connect the connectors of equipment A and that of equipment B Connect the test probe to connector terminal 3 of equipment A and the test probe to connector terminal 1 of equipment A and measure the voltage Note that reversing the connector terminals between the probes and changes the result of the measurement ...

Page 217: ...onnected in position contact the tester probes to the terminals without disconnecting the connector The following methods are available Measurement using a test harness Prepare the test harness for the measurement Measurement from the backside of connector Insert a wire from the backside of the connector Measurement on a lead cable Remove the bundling tape from the harness to separate each cable a...

Page 218: ... procedure Disconnect the connector of equipment A and connect the test harness Connect the test probe to connector terminal 1 harness side of equipment A and the test probe to connector terminal 1 equipment side of equipment A and measure the current Note that reversing the connector terminals between the probes and changes the result of the measurement Be sure to connect the probe to the power s...

Page 219: ...of burning or of an odor investigate as described follows 2 3 How to find cause of failure when fuse blown is reproduced Turn the starter switch OFF and remove the connector from the load valve pump Referring to the circuit diagram remove electrical parts that are connected to the circuit such as relays timers and diodes Turn the starter switch ON and see whether the conditions can be reproduced f...

Page 220: ...dentify the location section to which 24 V or 12 V reaches Then replace the harness or take other action 5 Solenoid valve inspection Check ON OFF operation by sound Conduct without running the engine If you run the engine you cannot hear the sound of operation Sound heard The electrical system is normal No sound heard Check with a tester Continuity Turn the starter switch OFF temporarily disconnec...

Page 221: ...imately 0 5 seconds each ENGINE STOP Lamp The ENGINE STOP lamp provides critical operator messages These messages require immediate and decisive operator response The ENGINE STOP lamp is also used to flash out diagnostic fault codes WARNING Lamp The WARNING lamp provides important operator messages These messages require timely operator attention The WARNING lamp is also used to delineate diagnost...

Page 222: ... flash the first fault code after the switch is turned on Each active fault shall flash out twice wrapping around to the first fault code at the end Flashing of fault codes The diagram below depicts the pattern of the fault code flash out scheme as indicated by the ENGINE STOP lamp A blink is equivalent to the ENGINE STOP lamp being on for 0 5 seconds and off for 0 5 seconds A pause between fault ...

Page 223: ...tor pedal or lever position sensor circuit Voltage below normal or shorted to low source Remote accelerator will not operate Remote accelerator position will be set to zero percent 135 Orange Engine oil rifle pressure 1 sensor circuit Voltage above normal or shorted to high source None on performance No engine protection for oil pressure 141 Orange Engine oil rifle pressure 1 sensor circuit Voltag...

Page 224: ...r supply 2 circuit Voltage below normal or shorted to low source Engine power derate 195 Orange Coolant level sensor 1 circuit Voltage above normal or shorted to high source None on performance 196 Orange Coolant level sensor 1 circuit Voltage below normal or shorted to low source None on performance 197 Orange Coolant level Data valid but below normal operation range Moderately severe level None ...

Page 225: ...sor circuit Received network data in error The engine will not respond to the remote throttle Engine may only idle The primary or cab accelerator may be able to be used 292 Red Auxiliary temperature sensor input 1 Special instructions Possible engine derate 293 Orange Auxiliary temperature sensor input 1 circuit Voltage above normal or shorted to high source None on performance 294 Orange Auxiliar...

Page 226: ...28 Orange Water in fuel indicator sensor circuit Voltage above normal or shorted to high source None on performance No water in fuel warning available 429 Orange Water in fuel indicator sensor circuit Voltage below normal or shorted to low source None on performance No water in fuel warning available 431 Orange Accelerator pedal or lever idle validation switch Data erratic intermittent or incorrec...

Page 227: ...iliary input output 3 circuit Voltage above normal or shorted to high source None on performance 553 Orange Injector metering rail 1 pressure Data valid but above normal operation range Moderately severe level None or possible engine noise associated with higher injection pressures especially at idle or light load Engine power is reduced 555 Orange Crankcase pressure Data valid but above normal op...

Page 228: ...nformation trip information and maintenance monitor data can be inaccurate 1239 Orange Accelerator pedal or lever position sensor 2 circuit Voltage above normal or shorted to high source Severe derate in power output of the engine Limp home power only 1241 Orange Accelerator pedal or lever position sensor 2 circuit Voltage below normal or shorted to low source Severe derate in power output of the ...

Page 229: ...n performance 2182 Orange Engine brake actuator driver 1 circuit Voltage above normal or shorted to high source Engine brake on cylinders 1 2 and 3 can not be activated 2183 Orange Engine brake actuator driver 1 circuit Voltage below normal or shorted to low source Engine brake on cylinders 1 2 and 3 can not be activated 2185 Orange Sensor supply 4 circuit Voltage above normal or shorted to high s...

Page 230: ... Voltage below normal or shorted to low source None on performance 2375 Orange Exhaust gas recirculation temperature sensor circuit Voltage above normal or shorted to high source EGR valve actuation will be disabled 2376 Orange Exhaust gas recirculation temperature sensor circuit Voltage below normal or shorted to low source EGR valve actuation will be disabled 2377 Orange Fan control circuit Volt...

Page 231: ...hicle speed Abnormal update rate None on performance 3527 Red Accelerator pedal or lever idle validation switch Received network data in error Engine will only idle 3528 Red Accelerator pedal or lever idle validation switch Abnormal update rate Engine will only idle 3616 None Engine VGT nozzle position Mechanical system not responding or out of adjustment Engine power may be derated 3697 Red Engin...

Page 232: ...engine manufacturer 2 3 Error Codes 2 3 1 Description of error codes The traveling working controller constantly monitors the input and output status to control each system The traveling working controller performs the system diagnostics function When any system problem is detected it displays the corresponding error code like as E01 on the multiple display Exact meter SW880 1 11009 R G G Y EXACT ...

Page 233: ...not be changed Fixed in 4000 vpm E22 Faulty IPF selector switch three input signals Automatic speed function does not operate IPF number cannot be changed Fixed in IPF12 E31 Faulty propulsion pump proportional solenoid F output current Engine stop E32 Faulty propulsion pump proportional solenoid R output current E33 Faulty vibration proportional solenoid a Hi output current Vibration does not occu...

Page 234: ...R 206 0 5W 145 0 5Gr 162 0 5Y 17 0 5WR 206 0 5W 145 0 5Lg 0 5Y 17 73 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR EMERGENCY CONNECTOR RESISTOR UNIT EMERGENCY SWITCH EMERGENCY SWITCH 1 ...

Page 235: ...mality is found connector is faulty Replace connector or terminal 2 Harness 1 Measure resistances between switches and traveling controller terminal wires Forward switch terminal NC wire BW and traveling controller terminal 19 wire BW working controller C1 terminal 10 wire BW Reverse switch terminal NC wire Gr and traveling controller terminal 20 wire Gr working controller C1 terminal 11 wire Gr S...

Page 236: ...R 206 0 5W 145 0 5Gr 162 0 5Y 17 0 5WR 206 0 5W 145 0 5Lg 0 5Y 17 73 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR EMERGENCY CONNECTOR RESISTOR UNIT EMERGENCY SWITCH EMERGENCY SWITCH 1 ...

Page 237: ...ror code Pon is displayed and no abnormality is found in connector harness forward switch and reverse switch in above inspection traveling working controller is faulty Replace traveling working controller 6 Clearing Error Code and Judging OK NG after Repair When repair is complete place F R lever F or N Set starter switch to ON When F R lever is F or N traveling working controller cannot be initia...

Page 238: ...R 206 0 5W 145 0 5Gr 162 0 5Y 17 0 5WR 206 0 5W 145 0 5Lg 0 5Y 17 73 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR EMERGENCY CONNECTOR RESISTOR UNIT EMERGENCY SWITCH EMERGENCY SWITCH 1 ...

Page 239: ... 1 wire W F R lever potentiometer 1 terminal wire B and traveling controller terminal 9 wire B F R lever potentiometer 2 terminal wire R and traveling controller terminal 8 wire R F R lever potentiometer 2 terminal wire WR and traveling controller terminal 48 wire WR working controller C2 terminal 2 wire WR F R lever potentiometer 2 terminal wire B and traveling controller terminal 9 wire B Standa...

Page 240: ...R 206 0 5W 145 0 5Gr 162 0 5Y 17 0 5WR 206 0 5W 145 0 5Lg 0 5Y 17 73 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR EMERGENCY CONNECTOR RESISTOR UNIT EMERGENCY SWITCH EMERGENCY SWITCH 1 ...

Page 241: ...bove item 1 is OK and any of measurements in item 2 is NG F R lever potentiometer 2 adjustment is faulty Adjust F R lever potentiometer 2 or replace it even if measurement is out of standard after adjustment 5 Traveling Controller 1 When starter switch is ON measure voltage between traveling controller power supply terminal 2 inlet wire WB and ground terminal 1 outlet wire B Standard voltage 12 V ...

Page 242: ...R 206 0 5W 145 0 5Gr 162 0 5Y 17 0 5WR 206 0 5W 145 0 5Lg 0 5Y 17 73 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR EMERGENCY CONNECTOR RESISTOR UNIT EMERGENCY SWITCH EMERGENCY SWITCH 1 ...

Page 243: ...pair or replace harness 3 Forward Switch 1 When starter switch is OFF and F R lever is N check continuity between forward switch terminal COM and terminal NC There is continuity in normal condition 2 When starter switch is OFF and F R lever is F check continuity between forward switch terminal COM and terminal NC There is no continuity in normal condition If above item 1 or 2 is NG forward switch ...

Page 244: ...R 206 0 5W 145 0 5Gr 162 0 5Y 17 0 5WR 206 0 5W 145 0 5Lg 0 5Y 17 73 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR EMERGENCY CONNECTOR RESISTOR UNIT EMERGENCY SWITCH EMERGENCY SWITCH 1 ...

Page 245: ... Reverse Switch 1 When starter switch is OFF and F R lever is N check continuity between reverse switch terminal COM and terminal NC There is continuity in normal condition 2 When starter switch is OFF and F R lever is R check continuity between reverse switch terminal COM and terminal NC There is no continuity in normal condition If above item 1 or 2 is NG reverse switch is faulty Replace reverse...

Page 246: ...R 206 0 5W 145 0 5Gr 162 0 5Y 17 0 5WR 206 0 5W 145 0 5Lg 0 5Y 17 73 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR EMERGENCY CONNECTOR RESISTOR UNIT EMERGENCY SWITCH EMERGENCY SWITCH 1 ...

Page 247: ...nd traveling controller terminal wires Propulsion pump proportional solenoid b wire G and traveling controller terminal 40 wire G Propulsion pump proportional solenoid a wire L and traveling controller terminal 50 wire L Propulsion pump proportional solenoid a b wire B and working controller C2 terminal 7 and 8 wires B Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Di...

Page 248: ...R 206 0 5W 145 0 5Gr 162 0 5Y 17 0 5WR 206 0 5W 145 0 5Lg 0 5Y 17 73 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR EMERGENCY CONNECTOR RESISTOR UNIT EMERGENCY SWITCH EMERGENCY SWITCH 1 ...

Page 249: ...itch is measure current between propulsion pump proportional solenoid terminal wires positive side and B ground side Propulsion pump proportional solenoid b F wire G positive side and wire B ground side Propulsion pump proportional solenoid a R wire L positive side and wire B ground side While measuring current operate F R lever from N to F or R Standard current 0 mA N Standard current 390 mA or m...

Page 250: ...R 206 0 5W 145 0 5Gr 162 0 5Y 17 0 5WR 206 0 5W 145 0 5Lg 0 5Y 17 73 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR EMERGENCY CONNECTOR RESISTOR UNIT EMERGENCY SWITCH EMERGENCY SWITCH 1 ...

Page 251: ... C2 terminal 4 wire B Exact meter terminal 3 wire B and traveling controller terminal 5 wire B Exact meter terminal 7 wire LgB and working controller C2 terminal 9 wire LgB Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Replace harness 3 Traveling Controller When starter switch is ON measure voltage between traveling controller power supply terminal 2 inlet wire WB an...

Page 252: ...R 206 0 5W 145 0 5Gr 162 0 5Y 17 0 5WR 206 0 5W 145 0 5Lg 0 5Y 17 73 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR EMERGENCY CONNECTOR RESISTOR UNIT EMERGENCY SWITCH EMERGENCY SWITCH 1 ...

Page 253: ...l 4 wire B working controller C2 terminal 4 wire B Exact meter terminal 3 wire B and traveling controller terminal 5 wire B Exact meter terminal 7 wire LgB and working controller C2 terminal 9 wire LgB Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Replace harness 3 Exact Meter When starter switch is ON measure voltage between exact meter terminal 5 outlet wire WB and...

Page 254: ...R 206 0 5W 145 0 5Gr 162 0 5Y 17 0 5WR 206 0 5W 145 0 5Lg 0 5Y 17 73 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR EMERGENCY CONNECTOR RESISTOR UNIT EMERGENCY SWITCH EMERGENCY SWITCH 1 ...

Page 255: ...switch is ON measure voltage between working controller C1 power supply terminal 2 inlet wire WB and ground terminal 1 outlet wire B Standard voltage 12 V or more 2 When starter switch is ON measure voltage between working controller C2 power supply terminal 11 12 inlet wire WB and working controller C1 ground terminal 1 outlet wire B Standard voltage 12 V or more 3 When starter switch is ON measu...

Page 256: ...R 206 0 5W 145 0 5Gr 162 0 5Y 17 0 5WR 206 0 5W 145 0 5Lg 0 5Y 17 73 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR EMERGENCY CONNECTOR RESISTOR UNIT EMERGENCY SWITCH EMERGENCY SWITCH 1 ...

Page 257: ...nd traveling controller terminal 9 wire B Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Replace harness 3 F R Lever Potentiometer 1 1 When starter switch is ON measure voltage between F R lever potentiometer 1 terminal inlet wire R and ground terminal outlet wire B Standard voltage 5 0 5 V 2 When starter switch is ON measure voltage between F R lever potentiometer 1 ...

Page 258: ...R 206 0 5W 145 0 5Gr 162 0 5Y 17 0 5WR 206 0 5W 145 0 5Lg 0 5Y 17 73 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR EMERGENCY CONNECTOR RESISTOR UNIT EMERGENCY SWITCH EMERGENCY SWITCH 1 ...

Page 259: ... wire B Standard voltage 12 V or more 2 When starter switch is ON measure voltage between traveling controller terminal 8 outlet wire R positive side and 9 wire B ground side Standard voltage 5 0 5 V If above item 1 is OK and item 2 is NG traveling controller is faulty Replace traveling controller 6 Clearing Error Code and Judging OK NG after Repair When repair is complete set starter switch to ON...

Page 260: ...R 206 0 5W 145 0 5Gr 162 0 5Y 17 0 5WR 206 0 5W 145 0 5Lg 0 5Y 17 73 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR EMERGENCY CONNECTOR RESISTOR UNIT EMERGENCY SWITCH EMERGENCY SWITCH 1 ...

Page 261: ...und Standard voltage 12 V or more If starter motor does not run even though above items 1 and 2 are OK starter motor is faulty Replace starter motor 4 Battery Relay 1 When starter switch is OFF measure voltage between battery relay primary terminal COM and chassis ground Standard resistance 12 V or more 2 When starter switch is ON measure voltage between battery relay coil terminal BR inlet wire B...

Page 262: ...R 206 0 5W 145 0 5Gr 162 0 5Y 17 0 5WR 206 0 5W 145 0 5Lg 0 5Y 17 73 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR EMERGENCY CONNECTOR RESISTOR UNIT EMERGENCY SWITCH EMERGENCY SWITCH 1 ...

Page 263: ...ard voltage 12 V or more If above item 1 is OK and item 2 is NG reverse switch is faulty Replace reverse switch 8 Interlock Relay 1 When starter switch is ON measure voltage between interlock relay terminal 1 inlet wire Gr and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between interlock relay terminal 3 inlet wire BW and chassis ground Standard voltage...

Page 264: ...R 206 0 5W 145 0 5Gr 162 0 5Y 17 0 5WR 206 0 5W 145 0 5Lg 0 5Y 17 73 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR EMERGENCY CONNECTOR RESISTOR UNIT EMERGENCY SWITCH EMERGENCY SWITCH 1 ...

Page 265: ...tion 3 When starter switch is ON measure voltage between exact meter relay terminal 4 outlet wire LgR and chassis ground Standard voltage 12 V or more If above items 1 and 2 are OK and item 3 is NG exact meter relay is faulty Replace exact meter relay 12 Parking Brake Switch 1 When starter switch is ON measure voltage between parking brake switch terminal 1 inlet wire LgR and chassis ground Standa...

Page 266: ...R 206 0 5W 145 0 5Gr 162 0 5Y 17 0 5WR 206 0 5W 145 0 5Lg 0 5Y 17 73 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR EMERGENCY CONNECTOR RESISTOR UNIT EMERGENCY SWITCH EMERGENCY SWITCH 1 ...

Page 267: ...nal 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 starter lockout relay is faulty Replace starter switch relay 15 Starter Switch Relay 1 When starter switch is ON measure voltage between starter switch relay terminal 1 inlet wire BR and chassis ground Standard resistance 12 V or more 2 When starter switch is ON measure voltage betw...

Page 268: ...T OUT IN OUT IN IN Drain 1 Hose Fuel gear pump drain Fuel tank return 8 Fuel pre filter 2 Fuel unit 9 Fuel tank 3 Hose Fuel tank suction Fuel pre filter IN 10 Plug 4 Hose Fuel pre filter OUT Fuel gear pump IN 11 Fuel gear pump 5 Hose Fuel filter OUT Fuel gear pump IN 12 Cap 6 Hose Fuel gear pump OUT Fuel filter IN 13 Filter 7 Fuel filter ...

Page 269: ...gine may fail Replace fuel in tank with an appropriate one 2 Water Fuel Pre Filter Fuel Filter Pressure Side Check that water does not cover water in fuel WIF sensor in contaminant collection bowl If water covers the sensor engine may not start Drain water Check filter for clogging Insufficient supply of proper fuel due to clogging of filter NOTICE Air bleeding should be performed whenever filter ...

Page 270: ...R 206 0 5W 145 0 5Gr 162 0 5Y 17 0 5WR 206 0 5W 145 0 5Lg 0 5Y 17 73 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR EMERGENCY CONNECTOR RESISTOR UNIT EMERGENCY SWITCH EMERGENCY SWITCH 1 ...

Page 271: ...al grid heater is faulty Replace grid heater 2 Grid Heater Relay 1 When starter switch is ON measure voltage between grid heater relay terminal 1 inlet wire GW and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between grid heater relay terminal 3 inlet wire B and chassis ground Standard voltage 12 V or more 3 When starter switch is ON measure voltage betw...

Page 272: ...R 206 0 5W 145 0 5Gr 162 0 5Y 17 0 5WR 206 0 5W 145 0 5Lg 0 5Y 17 73 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR EMERGENCY CONNECTOR RESISTOR UNIT EMERGENCY SWITCH EMERGENCY SWITCH 1 ...

Page 273: ...rence Fig 2 4 1 Check point Check Cause Action 1 Throttle Switch 1 When throttle switch is IDLE check continuity between throttle switch terminals 1 and 2 4 and 6 There is continuity in normal condition 2 When throttle switch is MID check continuity between throttle switch terminals 1 and 3 4 and 6 There is continuity in normal condition 3 When throttle switch is FULL check continuity between thro...

Page 274: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 275: ...ller terminal 8 wire R F R lever potentiometer 1 terminal wire W and traveling controller terminal 47 wire W working controller C2 terminal 1 wire W F R lever potentiometer 1 terminal wire B and traveling controller terminal 9 wire B F R lever potentiometer 2 terminal wire R and traveling controller terminal 8 wire R F R lever potentiometer 2 terminal wire WR and traveling controller terminal 48 w...

Page 276: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 277: ...nd any of measurements in item 2 is NG F R lever potentiometer 2 adjustment is faulty Adjust F R lever potentiometer 2 or replace it even if measurement is out of standard after adjustment 5 Traveling Controller 1 When starter switch is ON measure voltage between traveling controller power supply terminal 2 inlet wire WB and ground terminal 1 outlet wire B Standard voltage 12 V or more 2 When star...

Page 278: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 279: ...eplace harness 3 Forward Switch 1 When starter switch is OFF and F R lever is N check continuity between forward switch terminal COM and terminal NC There is continuity in normal condition 2 When starter switch is OFF and F R lever is F check continuity between forward switch terminal COM and terminal NC There is no continuity in normal condition If above item 1 or 2 is NG forward switch is faulty...

Page 280: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 281: ...hen starter switch is OFF and F R lever is N check continuity between reverse switch terminal COM and terminal NC There is continuity in normal condition 2 When starter switch is OFF and F R lever is R check continuity between reverse switch terminal COM and terminal NC There is no continuity in normal condition If above item 1 or 2 is NG reverse switch is faulty Replace reverse switch 4 Traveling...

Page 282: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 283: ...ller terminal wires Propulsion pump proportional solenoid b wire G and traveling controller terminal 40 wire G Propulsion pump proportional solenoid a wire L and traveling controller terminal 50 wire L Propulsion pump proportional solenoid a b wire B and working controller C2 terminal 7 and 8 wires B Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Disconnect connectors...

Page 284: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 285: ...is measure current between propulsion pump proportional solenoid terminal wires positive side and B ground side Propulsion pump proportional solenoid b F wire G positive side and wire B ground side Propulsion pump proportional solenoid a R wire L positive side and wire B ground side While measuring current operate F R lever from N to F or R Standard current 0 mA N Standard current 390 mA or more a...

Page 286: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 287: ...inal 4 wire B Exact meter terminal 3 wire B and traveling controller terminal 5 wire B Exact meter terminal 7 wire LgB and working controller C2 terminal 9 wire LgB Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Replace harness 3 Traveling Controller When starter switch is ON measure voltage between traveling controller power supply terminal 2 inlet wire WB and ground...

Page 288: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 289: ... B working controller C2 terminal 4 wire B Exact meter terminal 3 wire B and traveling controller terminal 5 wire B Exact meter terminal 7 wire LgB and working controller C2 terminal 9 wire LgB Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Replace harness 3 Exact Meter When starter switch is ON measure voltage between exact meter terminal 5 outlet wire WB and ground ...

Page 290: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 291: ...ing controller C1 power supply terminal 2 inlet wire WB and ground terminal 1 outlet wire B Standard voltage 12 V or more If above item 1 is OK and 2 is NG working controller C1 is faulty 2 When starter switch is ON measure voltage between working controller C2 power supply terminal 11 12 inlet wire WB and working controller C1 ground terminal 1 outlet wire B Standard voltage 12 V or more 3 When s...

Page 292: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 293: ...ling controller terminal 9 wire B Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Replace harness 3 F R Lever Potentiometer 1 1 When starter switch is ON measure voltage between F R lever potentiometer 1 terminal inlet wire R and ground terminal outlet wire B Standard voltage 5 0 5 V 2 When starter switch is ON measure voltage between F R lever potentiometer 1 terminal...

Page 294: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 295: ...Standard voltage 12 V or more 2 When starter switch is ON measure voltage between traveling controller terminal 8 outlet wire R positive side and 9 wire B ground side Standard voltage 5 0 5 V If above item 1 is OK and item 2 is NG traveling controller is faulty Replace traveling controller 6 Clearing Error Code and Judging OK NG after Repair When repair is complete set starter switch to ON Place F...

Page 296: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 297: ... Speed sensor terminal 4 wire R and traveling controller terminal 8 wire R Speed sensor terminal 5 wire B and traveling controller terminal 9 wire B Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 3 Speed Sensor 1 When starter switch is ON measure voltage between speed sensor terminal 4 inlet wire R and ground terminal 5 outlet wire B Standard...

Page 298: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 299: ...es between engine ECM and traveling controller terminal wires Engine ECM terminal 17 wire RB and traveling controller terminal 6 wires RB Engine ECM terminal 18 wire RY and traveling controller terminal 7 wire RY Standard resistance 10 Ω or less If resistance is abnormal harness is faulty NOTICE Since shielded twist wires are used for traveling controller terminal harness repair is not approved Be...

Page 300: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 301: ...al 6 wire WL Reverse switch terminal COM wire WG and fuse box terminal 5 wire WG Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 3 Forward Switch When starter switch is OFF and F R lever is N check continuity between forward switch terminal COM and terminal NC There is continuity in normal condition If there is no continuity forward switch is ...

Page 302: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 303: ...terminal 6 wire WL Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 3 Forward Switch 1 When starter switch is OFF and F R lever is N check continuity between forward switch terminal COM and terminal NC There is continuity in normal condition 2 When starter switch is OFF and F R lever is F check continuity between forward switch terminal COM and...

Page 304: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 305: ...rd resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 3 Reverse Switch 1 When starter switch is OFF and F R lever is N check continuity between reverse switch terminal COM and terminal NC There is continuity in normal condition 2 When starter switch is OFF and F R lever is F check continuity between reverse switch terminal COM and terminal NC There is no ...

Page 306: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 307: ... terminal 4 wire B Exact meter terminal 3 wire B and traveling controller terminal 5 wire B Exact meter terminal 7 wire LgB and working controller C2 terminal 9 wire LgB Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Replace harness 3 Exact Meter When starter switch is ON measure voltage between exact meter terminal 5 outlet wire WB and ground terminal 6 wire B Standa...

Page 308: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 309: ... pump neutral relay 1 3 Propulsion Pump Neutral Relay 2 1 When starter switch is ON measure voltage between propulsion pump neutral relay 2 terminal 1 inlet wire BrY and chassis ground There is no current in normal condition 2 When starter switch is ON measure voltage between propulsion pump neutral relay 2 terminal 3 inlet wire Br and chassis ground Standard voltage 12 V or more 3 When starter sw...

Page 310: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 311: ...every 0 1 second Traveling working controller could not receive connection verification signals that were regularly sent from exact meter for 1 continuous second Exact meter on transmission side or traveling working controller is faulty NOTICE See check procedures for error code E43 Replace exact meter or traveling working controller 6 Harness Connecting Between Terminals Measure resistance of har...

Page 312: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 313: ...r 3 is NG speed change switch is faulty Replace speed change switch 2 Resistor Unit Measure resistance between resistor unit wire No 39 wire BrR and ground wire Standard resistance 300 Ω If resistance is abnormal resistor unit is faulty NOTICE Resistor unit is used to stabilize contact of switch Replace resistor unit 3 Traveling Controller 1 When starter switch is ON measure voltage between travel...

Page 314: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 315: ... sensor terminal 3 wire W and traveling controller terminal 46 wire W working controller C1 terminal 12 wire W Speed sensor terminal 4 wire R and traveling controller terminal 8 wire R Speed sensor terminal 5 wire B and traveling controller terminal 9 wire B Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 3 Speed Sensor 1 When starter switch i...

Page 316: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 317: ...r Standard resistance 10 Ω or less 2 Measure resistances between switches and fuse box terminal wires Vibration frequency select switch terminal 1 4 wires YW and fuse box terminal 8 wire YW Vibration change switch terminal 1 wire YW and fuse box terminal 8 wire YW Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 3 Vibration Frequency Select Swi...

Page 318: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 319: ...switch terminal 1 inlet wire YW and chassis ground Standard voltage 12 V or more 2 When starter switch is ON and vibration change switch is measure voltage between vibration change switch terminal 3 outlet wire GR and chassis ground Standard voltage 12 V or more 3 When starter switch is ON and vibration change switch is measure voltage between vibration change switch terminal 2 outlet wire Br and ...

Page 320: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 321: ...1 wire B Standard voltage 12 V or more 3 When starter switch is ON and vibration frequency select switch is 3000 measure voltage between traveling controller terminal wires Traveling controller terminal 31 inlet wire G and terminal 1 wire B Traveling controller terminal 32 inlet wire L and terminal 1 wire B Standard voltage 12 V or more 4 When starter switch is ON and vibration frequency select sw...

Page 322: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 323: ... Cause Action E22 1 Connector Check IPF select switch connector and traveling controller connector terminal 37 38 39 for corrosion breakage bending and looseness If any abnormality is found connector is faulty Replace connector or terminal 2 Harness 1 Measure resistances between IPF select switch and traveling controller terminal wires IPF select switch terminal 2 wire GW and traveling controller ...

Page 324: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 325: ...hassis ground Standard voltage 12 V or more 4 When starter switch is ON and IPF select switch is 12 measure voltage between IPF select switch terminal 6 outlet wire BrW and chassis ground Standard voltage 12 V or more 5 When starter switch is ON and IPF select switch is 13 measure voltage between IPF select switch terminal 2 outlet wire GW terminal 4 outlet wire LW and chassis ground Standard volt...

Page 326: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 327: ... controller terminal 38 inlet wire LW and terminal 1 wire B Standard voltage 12 V or more 4 When starter switch is ON and IPF select switch is 12 measure voltage between traveling controller terminal 39 inlet wire BrW and terminal 1 wire B Standard voltage 12 V or more 5 When starter switch is ON and IPF select switch is 13 measure voltage between traveling controller terminal 37 inlet wire GW ter...

Page 328: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 329: ... abnormality is found connector is faulty Replace connector or terminal 2 Harness Measure resistances between engine ECM and traveling controller terminal wires Engine ECM terminal 17 wire RB and traveling controller terminal 6 wire RB Engine ECM terminal 18 wire RY and traveling controller terminal 7 wire RY Standard resistance 10 Ω or less If resistance is abnormal harness is faulty NOTICE Since...

Page 330: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 331: ...inal NO outlet wire GY and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG F R lever auto speed set switch is faulty Replace F R lever auto speed set switch 2 Resistor Unit Measure resistance between resistor unit wire No 38 wire GY and ground wire Standard resistance 300 Ω If resistance is abnormal resistor unit is faulty NOTICE Resistor unit is used to stabili...

Page 332: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 333: ... ON measure voltage between exact meter relay terminal 1 3 inlet wire LgY and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage of coil between exact meter relay terminal 1 and terminal 2 There is no electricity in normal condition 3 When starter switch is ON measure voltage between exact meter relay terminal 4 outlet wire LgR and chassis ground Standard volt...

Page 334: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 335: ... normal condition If there is electricity parking brake switch is faulty Replace parking brake switch 3 Exact Meter Relay When starter switch is ON measure voltage between exact meter relay terminal 4 outlet wire LgR and chassis ground There is no electricity in normal condition If there is electricity exact meter relay is faulty Replace exact meter relay 4 Foot Brake Switch When starter switch is...

Page 336: ... 5G 120 0 5BrW 42 0 5LW 41 0 5GW 40 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5B 123 0 5B 121 0 5WR 206 0 5W 145 0 5W 139 0 5Gr 162 0 5Lg 73 0 5Y 17 0 5G 210 0 5WR 206 0 5W 145 0 5W 139 0 5GB 137 0 5G 210 0 5Lg 73 0 5Y 17 0 5Gr 162 0 5BW 12 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38...

Page 337: ...WY and chassis ground Standard voltage 12 V or more 2 When starter switch is ON and emergency switch is F measure voltage between emergency switch terminal 1 outlet wire WR and chassis ground Standard voltage 12 V or more 3 When starter switch is ON and emergency switch is R measure voltage between emergency switch terminal 3 outlet wire WL and chassis ground Standard voltage 12 V or more If above...

Page 338: ... 35 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5GR 43 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5W 139 0 5G 210 0 5W 139 0 5G 210 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR VIBRATOR PUMP PROPORTIONAL S...

Page 339: ...on E33 or E34 1 Connector Check vibrator pump proportional solenoid connector and working controller C2 connector terminal 5 6 for corrosion breakage bending and looseness If any abnormality is found connector is faulty Replace connector or terminal 2 Harness Measure resistances between vibrator pump proportional solenoid and working controller C2 terminal wires Vibrator pump proportional solenoid...

Page 340: ... 35 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5GR 43 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5W 139 0 5G 210 0 5W 139 0 5G 210 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR VIBRATOR PUMP PROPORTIONAL S...

Page 341: ... proportional solenoid b Lo wire Br positive side and wire B ground side While measuring current operate vibration frequency select switch vibration mode select switch and vibration change switch as below Vibration mode select switch is continuous mode and depress F R lever vibration switch more than 0 05 second vibration frequency select switch is 3000 vpm and vibration change switch is Standard ...

Page 342: ... 35 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5GR 43 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5W 139 0 5G 210 0 5W 139 0 5G 210 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR VIBRATOR PUMP PROPORTIONAL S...

Page 343: ...press F R lever vibration switch and check continuity between F R lever vibration switch terminal COM and NO There is continuity in normal condition If there is no continuity vibration F R lever vibration switch is faulty NOTICE Pressing F R lever vibration switch turns on vibration and vibration is turned off when switch is pressed again Replace F R vibration lever switch 3 Resistor Unit Measure ...

Page 344: ... 35 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5GR 43 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5W 139 0 5G 210 0 5W 139 0 5G 210 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR VIBRATOR PUMP PROPORTIONAL S...

Page 345: ...ect switch terminal 1 4 wires YW vibration change switch terminal 1 wire YW and fuse box terminal 8 wire YW Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 3 Vibration Frequency Select Switch 1 When starter switch is ON measure voltage between vibration frequency select switch terminal 1 4 inlet wires YW and chassis ground Standard voltage 12 ...

Page 346: ... 35 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5GR 43 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5W 139 0 5G 210 0 5W 139 0 5G 210 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR VIBRATOR PUMP PROPORTIONAL S...

Page 347: ...is ground Standard voltage 12 V or more 2 When starter switch is ON and vibration change switch is measure voltage between vibration change switch terminal 2 outlet wire Br and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG vibration change switch is faulty Replace vibration change switch 5 Resistor Unit Measure resistance between resistor unit wires and ground...

Page 348: ... 35 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5GR 43 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5W 139 0 5G 210 0 5W 139 0 5G 210 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR VIBRATOR PUMP PROPORTIONAL S...

Page 349: ...en traveling controller terminal wires Traveling controller terminal 31 inlet wire G and terminal 1 wire B Traveling controller terminal 32 inlet wire L and terminal 1 wire B Standard voltage 12 V or more 4 When starter switch is ON and vibration frequency select switch is 4000 measure voltage between traveling controller terminal 31 inlet wire G and terminal 1 wire B Standard voltage 12 V or more...

Page 350: ... 35 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5GR 43 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5W 139 0 5G 210 0 5W 139 0 5G 210 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR VIBRATOR PUMP PROPORTIONAL S...

Page 351: ...sis ground There is no electricity in normal condition 3 When starter switch is ON and vibration mode select switch is AUTO measure voltage between vibration mode select switch terminal wires and chassis ground Vibration mode select switch terminal 3 outlet wire GB and chassis ground Vibration mode select switch terminal 5 outlet wire YL and chassis ground Standard voltage 12 V If above item 1 is ...

Page 352: ... 35 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5GR 43 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5W 139 0 5G 210 0 5W 139 0 5G 210 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR VIBRATOR PUMP PROPORTIONAL S...

Page 353: ...inal 1 wire B Traveling controller terminal 35 inlet wire YL and terminal 1 wire B There is no electricity in normal condition 3 When starter switch is ON and vibration mode select switch is AUTO measure voltage between traveling controller terminal wires and terminal 1 wire B Traveling controller terminal 36 inlet wire GB and terminal 1 wire B Traveling controller terminal 35 inlet wire YL and te...

Page 354: ... 35 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5GR 43 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5W 139 0 5G 210 0 5W 139 0 5G 210 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR VIBRATOR PUMP PROPORTIONAL S...

Page 355: ...ct switch terminal wires and chassis ground Vibratory drum select switch terminal 2 outlet wire BrB and chassis ground Vibratory drum select switch terminal 5 outlet wire LB and chassis ground There is no electricity in normal condition 3 When starter switch is ON and vibratory drum select switch is measure voltage between vibratory drum select switch terminal 2 outlet wire BrB and chassis ground ...

Page 356: ... 35 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5GR 43 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5W 139 0 5G 210 0 5W 139 0 5G 210 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR VIBRATOR PUMP PROPORTIONAL S...

Page 357: ...controller terminal 46 wire W working controller C1 terminal 12 wire G Speed sensor terminal 4 wire R and traveling controller terminal 8 wire R Speed sensor terminal 5 wire B and traveling controller terminal 9 wire B Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 3 Speed Sensor 1 When starter switch is ON measure voltage between speed senso...

Page 358: ... 35 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5GR 43 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5W 139 0 5G 210 0 5W 139 0 5G 210 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR VIBRATOR PUMP PROPORTIONAL S...

Page 359: ...quency select switch terminal 1 4 wires YW vibration change switch terminal 1 wire YW and fuse box terminal 8 wire YW Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 3 Vibration Frequency Select Switch 1 When starter switch is ON measure voltage between vibration frequency select switch terminal 1 4 inlet wires YW and chassis ground Standard v...

Page 360: ... 35 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5GR 43 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5W 139 0 5G 210 0 5W 139 0 5G 210 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR VIBRATOR PUMP PROPORTIONAL S...

Page 361: ... is measure voltage between vibration change switch terminal 3 outlet wire GR and chassis ground Standard voltage 12 V or more 3 When starter switch is ON and vibration change switch is measure voltage between vibration change switch terminal 2 outlet wire Br and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 or 3 is NG vibration change switch is faulty Replace vibra...

Page 362: ... 35 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5GR 43 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5W 139 0 5G 210 0 5W 139 0 5G 210 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR VIBRATOR PUMP PROPORTIONAL S...

Page 363: ... traveling controller terminal wires Traveling controller terminal 31 inlet wire G and terminal 1 wire B Traveling controller terminal 32 inlet wire L and terminal 1 wire B Standard voltage 12 V or more 4 When starter switch is ON and vibration frequency select switch is 4000 measure voltage between traveling controller terminal 31 inlet wire G and terminal 1 wire B Standard voltage 12 V or more 5...

Page 364: ... 35 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5GR 43 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5W 139 0 5G 210 0 5W 139 0 5G 210 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR VIBRATOR PUMP PROPORTIONAL S...

Page 365: ...ge bending and looseness If any abnormality is found connector is faulty Replace connector or terminal 2 Harness 1 Measure resistances between IPF select switch and traveling controller terminal wires IPF select switch terminal 2 wire GW and traveling controller terminal 37 wire GW IPF select switch terminal 4 wire LW and traveling controller terminal 38 wire LW IPF select switch terminal 6 wire B...

Page 366: ... 35 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5GR 43 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5W 139 0 5G 210 0 5W 139 0 5G 210 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR VIBRATOR PUMP PROPORTIONAL S...

Page 367: ...witch terminal 6 outlet wire BrW and chassis ground Standard voltage 12 V or more 5 When starter switch is ON and IPF select switch is 13 measure voltage between IPF select switch terminal 2 outlet wire GW terminal 4 outlet wire LW and chassis ground Standard voltage 12 V or more 6 When starter switch is ON and IPF select switch is 14 measure voltage between IPF select switch terminal 4 outlet wir...

Page 368: ... 35 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5GR 43 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5W 139 0 5G 210 0 5W 139 0 5G 210 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR VIBRATOR PUMP PROPORTIONAL S...

Page 369: ...ch is 12 measure voltage between traveling controller terminal 39 inlet wire BrW and terminal 1 wire B Standard voltage 12 V or more 5 When starter switch is ON and IPF select switch is 13 measure voltage between traveling controller terminal 37 inlet wire GW terminal 38 inlet wire LW and terminal 1 wire B Standard voltage 12 V or more 6 When starter switch is ON and IPF select switch is 14 measur...

Page 370: ... 35 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5GR 43 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5W 139 0 5G 210 0 5W 139 0 5G 210 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR VIBRATOR PUMP PROPORTIONAL S...

Page 371: ...g controller terminal 4 wire B working controller C2 terminal 4 wire B Exact meter terminal 3 wire B and traveling controller terminal 5 wire B Exact meter terminal 7 wire LgB and working controller C2 terminal 9 wire LgB Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Replace harness 3 Exact Meter When starter switch is ON measure voltage between exact meter terminal ...

Page 372: ... 35 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5GR 43 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5W 139 0 5G 210 0 5W 139 0 5G 210 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR VIBRATOR PUMP PROPORTIONAL S...

Page 373: ... connector or terminal 2 Harness Measure resistances between exact meter and traveling controller terminal wires Exact meter terminal 1 wire GW and traveling controller terminal 3 wire GW working controller C1 terminal 3 wire GW Exact meter terminal 2 wire B and traveling controller terminal 4 wire B working controller C2 terminal 4 wire B Exact meter terminal 3 wire B and traveling controller ter...

Page 374: ... 35 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5GR 43 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5W 139 0 5G 210 0 5W 139 0 5G 210 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR VIBRATOR PUMP PROPORTIONAL S...

Page 375: ... Speed sensor terminal 5 wire B and traveling controller terminal 9 wire B Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 3 Speed Sensor 1 When starter switch is ON measure voltage between speed sensor terminal 4 inlet wire R and ground terminal 5 outlet wire B Standard voltage 5 0 25 V 2 Start engine and rotate vibratory drum Measure pulse b...

Page 376: ... 35 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5GR 43 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5W 139 0 5G 210 0 5W 139 0 5G 210 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR VIBRATOR PUMP PROPORTIONAL S...

Page 377: ...er C2 terminal 4 wire B Exact meter terminal 3 wire B and traveling controller terminal 5 wire B Exact meter terminal 7 wire LgB and working controller C2 terminal 9 wire LgB Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Replace harness 3 Exact Meter When starter switch is ON measure voltage between exact meter terminal 5 outlet wire WB and ground terminal 6 wire B S...

Page 378: ... 35 0 5Br 34 0 5L 33 0 5G 32 0 5BrR 39 0 5GY 38 0 5GR 43 0 5B 129 0 5GW 128 0 5WB 25 0 5WB 25 0 5W 139 0 5G 210 0 5W 139 0 5G 210 0 5B X 0 5B 140 0 5R 138 0 5B 130 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 B GW 129 128 B WB X 25 PROGRAMMING CONNECTOR VIBRATOR PUMP PROPORTIONAL S...

Page 379: ...nces between exact meter and traveling controller terminal wires Exact meter terminal 1 wire GW and traveling controller terminal 3 wire GW working controller C1 terminal 3 wire GW Exact meter terminal 2 wire B and traveling controller terminal 4 wire B working controller C2 terminal 4 wire B Exact meter terminal 3 wire B and traveling controller terminal 5 wire B Exact meter terminal 7 wire LgB a...

Page 380: ...PUMP RELAY PUMP 2 WATER SPRAY PUMP SWITCH R WATER SPRAY PUMP SWITCH F WATER SPRAY PUMP SWITCH F R 0 5GW 77 0 5WB 25 0 5B X 0 5GR 43 0 5WB 25 0 5WB 25 0 5W 145 0 5Gr 162 0 5Lg 73 0 5W 145 0 5Gr 162 0 5BW 12 0 5B X 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 ENGINE STUD BOLT BATTERY...

Page 381: ...ch for front and rear drums Pressing F R lever water spray switch turns on power and power is turned off when switch is pressed again Replace the water spray pump F 1 F 2 R 1 or R 2 2 F R Lever Water Spray Switch Depress F R lever water spray switch and check continuity between F R lever water spray switch terminal COM and NO There is continuity in normal condition If there is no continuity F R le...

Page 382: ...PUMP RELAY PUMP 2 WATER SPRAY PUMP SWITCH R WATER SPRAY PUMP SWITCH F WATER SPRAY PUMP SWITCH F R 0 5GW 77 0 5WB 25 0 5B X 0 5GR 43 0 5WB 25 0 5WB 25 0 5W 145 0 5Gr 162 0 5Lg 73 0 5W 145 0 5Gr 162 0 5BW 12 0 5B X 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 ENGINE STUD BOLT BATTERY...

Page 383: ... terminal 1 inlet wire GB and chassis ground Standard voltage 12 V 2 When starter switch is ON and depress F R lever water spray switch once measure voltage between water spray pump relay pump 1 terminal 3 inlet wire WB and chassis ground Standard voltage 12 V 3 When starter switch is ON and depress F R lever water spray switch once measure voltage between water spray pump relay pump 1 terminal 5 ...

Page 384: ...PUMP RELAY PUMP 2 WATER SPRAY PUMP SWITCH R WATER SPRAY PUMP SWITCH F WATER SPRAY PUMP SWITCH F R 0 5GW 77 0 5WB 25 0 5B X 0 5GR 43 0 5WB 25 0 5WB 25 0 5W 145 0 5Gr 162 0 5Lg 73 0 5W 145 0 5Gr 162 0 5BW 12 0 5B X 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 ENGINE STUD BOLT BATTERY...

Page 385: ...h is ON and depress F R lever water spray switch once measure voltage between water spray pump switch R terminal 2 inlet wire W terminal 5 inlet wire Y and chassis ground Standard voltage 12 V 2 When starter switch is ON and depress F R lever water spray switch once measure voltage between water spray pump switch R terminal wires and chassis ground Center position both pumps Water spray pump switc...

Page 386: ...PUMP RELAY PUMP 2 WATER SPRAY PUMP SWITCH R WATER SPRAY PUMP SWITCH F WATER SPRAY PUMP SWITCH F R 0 5GW 77 0 5WB 25 0 5B X 0 5GR 43 0 5WB 25 0 5WB 25 0 5W 145 0 5Gr 162 0 5Lg 73 0 5W 145 0 5Gr 162 0 5BW 12 0 5B X 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 ENGINE STUD BOLT BATTERY...

Page 387: ...controller terminal wires and ground terminal wires Traveling controller power supply terminal 2 inlet wire WB and ground terminal 1 outlet wire B Working controller C1 power supply terminal 2 inlet wire WB and ground terminal 1 outlet wire B Working controller C2 power supply terminal 11 12 inlet wires WB and working controller C1 ground terminal 1 outlet wire B Standard voltage 12 V or more 2 Wh...

Page 388: ...PUMP RELAY PUMP 2 WATER SPRAY PUMP SWITCH R WATER SPRAY PUMP SWITCH F WATER SPRAY PUMP SWITCH F R 0 5GW 77 0 5WB 25 0 5B X 0 5GR 43 0 5WB 25 0 5WB 25 0 5W 145 0 5Gr 162 0 5Lg 73 0 5W 145 0 5Gr 162 0 5BW 12 0 5B X 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 ENGINE STUD BOLT BATTERY...

Page 389: ...age between water spray timer switch terminal 2 inlet wire GL and chassis ground Standard voltage 12 V or more 2 When starter switch is ON and depress F R lever water spray switch once measure voltage between water spray timer switch terminal 3 outlet wire G and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG water spray timer switch is faulty Replace water spra...

Page 390: ...PUMP RELAY PUMP 2 WATER SPRAY PUMP SWITCH R WATER SPRAY PUMP SWITCH F WATER SPRAY PUMP SWITCH F R 0 5GW 77 0 5WB 25 0 5B X 0 5GR 43 0 5WB 25 0 5WB 25 0 5W 145 0 5Gr 162 0 5Lg 73 0 5W 145 0 5Gr 162 0 5BW 12 0 5B X 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 ENGINE STUD BOLT BATTERY...

Page 391: ... starter switch is ON and depress F R lever water spray switch once measure voltage between water spray pump relay R 2 terminal 5 inlet wire LY and chassis ground Standard voltage 12 V or more 3 When starter switch is ON and depress F R lever water spray switch once measure voltage between water spray pump relay R 2 terminal 3 outlet wire LW and chassis ground Standard voltage 12 V or more If abov...

Page 392: ...PUMP RELAY PUMP 2 WATER SPRAY PUMP SWITCH R WATER SPRAY PUMP SWITCH F WATER SPRAY PUMP SWITCH F R 0 5GW 77 0 5WB 25 0 5B X 0 5GR 43 0 5WB 25 0 5WB 25 0 5W 145 0 5Gr 162 0 5Lg 73 0 5W 145 0 5Gr 162 0 5BW 12 0 5B X 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 ENGINE STUD BOLT BATTERY...

Page 393: ... COM and NC There is continuity in normal condition 2 When starter switch is OFF and F R lever is R check continuity between reverse switch terminal COM and NO There is continuity in normal condition If above item 1 or 2 is NG reverse switch is faulty Replace reverse switch 3 Water Spray Mode Select Switch 1 When starter switch is ON and F R lever is F or R measure voltage between water spray mode...

Page 394: ... 2 0 5GW 77 0 5YL 148 0 5WB 25 0 5B X 0 5WB 25 0 5WB 25 0 5Gr 162 0 5Gr 162 0 5B X 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 WAIT TO START LAMP WARNING LAMP ENGINE STOP LAMP ENGINE STUD BOLT BATTERY RELAY AV60 B AV60 R STARTER SWITCH RELAY ENGINE OIL PRESSURE SWITCH RELAY EGT WA...

Page 395: ...ch 1 When starter switch is ON measure voltage between lighting switch terminal 1 inlet wire WR terminal 4 inlet wire W and chassis ground Standard voltage 12 V or more 2 When starter switch is ON and lighting switch is measure voltage between lighting switch terminal 3 outlet wire RW and chassis ground Standard voltage 12 V or more 3 When starter switch is ON and lighting switch is measure voltag...

Page 396: ... 2 0 5GW 77 0 5YL 148 0 5WB 25 0 5B X 0 5WB 25 0 5WB 25 0 5Gr 162 0 5Gr 162 0 5B X 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 WAIT TO START LAMP WARNING LAMP ENGINE STOP LAMP ENGINE STUD BOLT BATTERY RELAY AV60 B AV60 R STARTER SWITCH RELAY ENGINE OIL PRESSURE SWITCH RELAY EGT WA...

Page 397: ... between lamp check relay terminal 3 and terminal 5 There is no continuity in normal condition If above items 1 and 2 are OK and item 3 is NG lamp check relay is faulty If above item 2 is NG alternator is faulty Repair or replace lamp check relay or alternator 3 Combination Meter Lamp check 1 When starter switch is ON measure voltage between combination meter terminal wires and ground terminal wir...

Page 398: ... 2 0 5GW 77 0 5YL 148 0 5WB 25 0 5B X 0 5WB 25 0 5WB 25 0 5Gr 162 0 5Gr 162 0 5B X 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 WAIT TO START LAMP WARNING LAMP ENGINE STOP LAMP ENGINE STUD BOLT BATTERY RELAY AV60 B AV60 R STARTER SWITCH RELAY ENGINE OIL PRESSURE SWITCH RELAY EGT WA...

Page 399: ...tems 1 and 2 are OK and pulse is NG in item 3 tachometer sensor is faulty If above items 1 and 2 are OK and tachometer reading is NG in item 3 combination meter is faulty Replace tachometer sensor or combination meter 2 Harness Connecting Between Terminals Measure resistance of harness connecting between terminals Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair ...

Page 400: ... 2 0 5GW 77 0 5YL 148 0 5WB 25 0 5B X 0 5WB 25 0 5WB 25 0 5Gr 162 0 5Gr 162 0 5B X 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 WAIT TO START LAMP WARNING LAMP ENGINE STOP LAMP ENGINE STUD BOLT BATTERY RELAY AV60 B AV60 R STARTER SWITCH RELAY ENGINE OIL PRESSURE SWITCH RELAY EGT WA...

Page 401: ...of harness connecting between terminals Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 2 9 6 Fuel meter is abnormal Reference Fig 2 9 1 Check point Check Cause Action 1 Fuel Unit Disconnect harness and measure resistance of fuel unit Standard resistance 13 5 Ω with float in F 80 0 Ω with float in E If resistance is abnormal fuel unit is fault...

Page 402: ... 2 0 5GW 77 0 5YL 148 0 5WB 25 0 5B X 0 5WB 25 0 5WB 25 0 5Gr 162 0 5Gr 162 0 5B X 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 WAIT TO START LAMP WARNING LAMP ENGINE STOP LAMP ENGINE STUD BOLT BATTERY RELAY AV60 B AV60 R STARTER SWITCH RELAY ENGINE OIL PRESSURE SWITCH RELAY EGT WA...

Page 403: ...ity in normal condition If there is continuity hydraulic oil filter switch 1 or 2 is faulty Replace hydraulic oil filter switch 1 or 2 3 Combination Meter Hydraulic oil filter warning indicator lamp 1 When starter switch is ON measure voltage between combination meter terminal wires and ground terminal wire Battery terminal inlet wire No 155 inlet wire R and ground terminal wire B Starter switch t...

Page 404: ... 2 0 5GW 77 0 5YL 148 0 5WB 25 0 5B X 0 5WB 25 0 5WB 25 0 5Gr 162 0 5Gr 162 0 5B X 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 WAIT TO START LAMP WARNING LAMP ENGINE STOP LAMP ENGINE STUD BOLT BATTERY RELAY AV60 B AV60 R STARTER SWITCH RELAY ENGINE OIL PRESSURE SWITCH RELAY EGT WA...

Page 405: ...witch is ON measure voltage between engine oil pressure switch relay terminal 1 inlet wire LW and chassis ground There is no electricity in normal condition 2 When starter switch is ON check continuity between engine oil pressure switch relay terminal 3 and terminal 5 There is no continuity in normal condition If above item 1 is OK and item 2 is NG engine oil pressure switch relay is faulty Replac...

Page 406: ... 2 0 5GW 77 0 5YL 148 0 5WB 25 0 5B X 0 5WB 25 0 5WB 25 0 5Gr 162 0 5Gr 162 0 5B X 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 WAIT TO START LAMP WARNING LAMP ENGINE STOP LAMP ENGINE STUD BOLT BATTERY RELAY AV60 B AV60 R STARTER SWITCH RELAY ENGINE OIL PRESSURE SWITCH RELAY EGT WA...

Page 407: ...and chassis ground Lamp check relay terminal 2 and chassis ground Standard resistance 100 kΩ or more If resistance is abnormal harness is faulty Repair or replace harness 2 Lamp Check Relay 1 Measure voltage between lamp check relay terminal 2 inlet wire LgB and chassis ground Standard voltage 12 V or more 2 Check continuity between lamp check relay terminal 3 and terminal 5 There is no continuity...

Page 408: ... 2 0 5GW 77 0 5YL 148 0 5WB 25 0 5B X 0 5WB 25 0 5WB 25 0 5Gr 162 0 5Gr 162 0 5B X 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 WAIT TO START LAMP WARNING LAMP ENGINE STOP LAMP ENGINE STUD BOLT BATTERY RELAY AV60 B AV60 R STARTER SWITCH RELAY ENGINE OIL PRESSURE SWITCH RELAY EGT WA...

Page 409: ...ode select switch is or AUTO measure voltage between working controller C2 output terminal 4 outlet wire YL and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG working controller C2 is faulty Replace working controller 3 Combination Meter Vibration indicator lamp 1 When starter switch is ON measure voltage between combination meter terminal wires and ground term...

Page 410: ... 2 0 5GW 77 0 5YL 148 0 5WB 25 0 5B X 0 5WB 25 0 5WB 25 0 5Gr 162 0 5Gr 162 0 5B X 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 WAIT TO START LAMP WARNING LAMP ENGINE STOP LAMP ENGINE STUD BOLT BATTERY RELAY AV60 B AV60 R STARTER SWITCH RELAY ENGINE OIL PRESSURE SWITCH RELAY EGT WA...

Page 411: ...tandard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 2 Combination Meter Water spray indicator lamp 1 When starter switch is ON measure voltage between combination meter terminal wires and ground terminal wire Battery terminal wire No 155 inlet wire R and ground terminal wire B Starter switch terminal wire No 64 inlet wire LgW and ground terminal wi...

Page 412: ... 2 0 5GW 77 0 5YL 148 0 5WB 25 0 5B X 0 5WB 25 0 5WB 25 0 5Gr 162 0 5Gr 162 0 5B X 0 5WB 25 0 5B X 12 4 7 5 11 6 8 9 10 1 2 6 5 10 4 11 3 12 2 7 1 46 40 39 47 48 50 38 30 26 3 5 4 9 6 8 7 22 13 21 25 31 1 32 2 33 14 34 23 35 17 36 18 37 19 20 24 WAIT TO START LAMP WARNING LAMP ENGINE STOP LAMP ENGINE STUD BOLT BATTERY RELAY AV60 B AV60 R STARTER SWITCH RELAY ENGINE OIL PRESSURE SWITCH RELAY EGT WA...

Page 413: ... parking brake switch is faulty Replace parking brake switch 3 Combination Meter Parking brake indicator lamp 1 When starter switch is ON measure voltage between combination meter terminal wires and ground terminal wire Battery terminal wire No 155 inlet wire R and ground terminal wire B Starter switch terminal wire No 64 inlet wire LgW and ground terminal wire B Standard voltage 12 V or more 2 Wh...

Page 414: ...P BUZZER 3B X2 RY 6 5WR 10 WG 7 WG 7 B X GR 9 Lg 8 3B X2 F L 65A F L 65A FUSE BOX TO INTERLOCK RELAY REVERSE SWITCH HORN SWITCH HORN HORN RELAY ENGINE STUD BOLT BATTERY RELAY AV60 B AV60 R 12V BATTERY 12V BATTERY E COM BR NO 20 A 20 A 20 A 20 A 15 A 15 A 15 A 15 A 20 A BR B R1 ACC R2 C F R LEVER FORWARD REVERSE C O M N O N C 1 3 2 5 B ACC BR C OFF ON ST STARTER SWITCH ...

Page 415: ...minals Measure resistance of harness connecting between terminals Standard resistance 10 Ω or less If resistance is abnormal harness is faulty Repair or replace harness 2 9 14 Backup buzzer does not sound Reference Fig 2 10 1 Check point Check Cause Action 1 Backup Buzzer Disconnect backup buzzer and directly connect battery positive terminal to backup buzzer terminal wire RY side and negative ter...

Page 416: ...ipes and components in order to prevent foreign substances from entering Never leave the openings exposed or put a shop cloth into them There is the danger of foreign substances entering or of leaking oil causing environmental contamination Do not dispose of waste oil on site Either deliver it to the customer and request disposal or take it back with you and dispose of it 4 Prevent entry of foreig...

Page 417: ...ve Propulsion pump cannot discharge oil because oil does not flow into servo cylinder chamber due to faulty propulsion pump proportional solenoid valve Measure pressure in servo cylinder chamber If low repair propulsion pump proportional solenoid valve or replace it if necessary 5 Neutral Solenoid Valve If spool of neutral solenoid valve is stuck pressure in both sides of servo cylinder chamber is...

Page 418: ...rd or backward Check point Cause Check Action High Pressure Relief Valve Low circuit pressure due to incorrect high pressure relief setting or internal leakage of high pressure relief valve Interchange two high pressure relief valves If faulty condition is accordingly reversed check and adjust high pressure relief valve or replace it if necessary 3 2 3 Slow machine speed or small drive force 1 2 C...

Page 419: ...e is insufficient due to efficiency degradation of propulsion pump Measure discharge flow rate of propulsion pump with flow meter If discharge flow rate is not within specified range repair propulsion pump or replace it if necessary Discharge flow rate is insufficient due to wear of propulsion pump drive shaft splines Replace propulsion pump Propulsion circuit pressure is not held in propulsion pu...

Page 420: ...vy relief valve opens causing temperature of hydraulic oil in circuit to rise Measure propulsion circuit pressure If high decrease propulsion load 5 Suction Filter for Steering Charge Pump Load of steering charge pump increases due to clogged filter causing temperature of hydraulic oil in circuit to rise Clean suction filter or replace it if necessary 6 Hydraulic Oil Filter 1 Charge circuit pressu...

Page 421: ... not obtain required pressure because setting pressure of high pressure check relief is low Measure vibrator circuit pressure If low check and clean high pressure check relief valve or replace it if necessary 6 Vibrator Solenoid Valve for Bypassing Vibrator pressure is bypassed because vibrator solenoid valve spool does not switch If vibrator solenoid valve spool does not switch repair vibrator so...

Page 422: ...arge pump discharge Repair vibrator charge pump or replace it if necessary 3 Vibrator Solenoid Valve for Bypassing Vibrator pressure is bypassed due to internal leakage of vibrator solenoid valve Repair vibrator solenoid valve or replace it if necessary 4 Suction Filter for Vibrator Charge Pump Vibrator charge pump flow is reduced due to clogged filler Clean suction filter or replace it if necessa...

Page 423: ...shing Valve Hydraulic oil in vibrator closed circuit is insufficiently cooled due to flushing valve shuttle spool sticking Repair flushing valve or replace it if necessary Hydraulic oil in vibrator closed circuit is insufficiently cooled because flushing valve relief setting pressure is excessively high Check dust or damage in flushing relief valve and replace it if necessary Hydraulic oil in vibr...

Page 424: ...brator sound of hydraulic hose is generated because clamp securing hydraulic hose is loose Tighten bolts of loose hydraulic hose clamp to specified torque 3 Suction Filter for Vibrator Charge Pump Cavitation is occurring in vibrator charge pump due to clogged filter Clean suction filter or replace it if necessary 4 Vibrator Motor Internal bearing of vibrator motor is damaged Repair vibrator motor ...

Page 425: ...ng cylinder Repair steering cylinder or replace it if necessary 5 Suction Filter for Steering Charge Pump Steering charge pump discharge rate decreases due to clogged filter Clean suction filter or replace it if necessary 6 Steering Charge Pump Discharging pressure is insufficient due to efficiency degradation of steering charge pump Measure steering circuit pressure If low replace steering charge...

Page 426: ... is excessively heavy relief valve is open causing temperature of hydraulic oil in circuit to rise Measure steering circuit pressure If high decrease steering load 4 Suction Filter for Steering Charge Pump Load of steering charge pump increases due to clogged filter causing temperature of hydraulic oil in circuit to rise Clean suction filter or replace it if necessary 3 4 5 Abnormal noise from ste...

Page 427: ......

Page 428: ... Printed in Japan 2015 7 50 0 H S 0568 99009 0 31443 A SAKAI HEAVY INDUSTRIES LTD Head office Seiwa Bldg 4 8 Shibadaimon 1 chome Minato ku Tokyo Japan Telephone 81 3 3434 3401 Global Service Division 2500 Takayanagi Kuki shi Saitama Japan Telephone 81 480 52 1111 ...

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