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Sakai R2-4, Руководство по ремонту

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2. SYSTEM CIRCUIT DIAGRAM

2-1. Electrical Circuit Diagram

0634-99372-0-11506-A

GROUND

20

A

15

A

15

A

15

A

15

A

15

A

20

A

20

A

20

A

20

A

28

BrR

CAN

15 BY

FLOOD

LAMP

RELAY

 

11

Gr

23

3B

R

4 R

4 R

20 BrW

30

A

3G

R

66

RESISTOR

(120Ω

）

50

3W

R

E33 A-VCC2

G
e

g

B

30
86

85

87

7

2L

1.25L

7

1.25L

7

1.25Br

55

(O.P.T)

(O.P.T)

FOOT

BRAKE 

SWITCH

155

156

BR

RW
RB

012

Sb

3RG

3GR

3GR

2W

G

44

73

L

52 5WL

50 8WR

FUSE 

BOX

41

3LB

66

66

1.25GW

18

1.25GW

18

42 1.25BrB

1.25BrB

1.25 O

1.25 O

78 RW

78 RW

77 2RY

77 RY

77 2RY

44 WG

44 2WG

1.25RW

16

1.25RB

24

1.25RW

   

BACKUP

BUZZER 

SWITCH

F-R

LEVER 

SWITCH

2 B

LIGHTING

RELAY

   

LIGHTING

LO/HI RELAY

B

2

f

c

a

b

e

1.25RG

FLOOD

LAMP (R,L)

(55W)

 

R

38

1.25RG

38

FLOOD

LAMP (R,R)

(55W)

 

R

FLOOD

LAMP (F,L) 

(55W)

 

R

FLOOD

LAMP (F,R) 

(55W)

 

R

Lg

3

1

2

5

HORN

SWITCH

WB
22

31

R

Y

60 BW

33 GY

B

B

2

2

NC NOCOM

5
2

1

3

BRAKE

RELAY

STOP LAMP

RELAY

COM

NO

NC

COM

NO NC

5W

L

51

52

65A

5W

L

38

2 B

3

1

2

5

30

A

PARKING

BRAKE SWITCH

2 B

B

2

2 B

L

167

NEUTRAL

RELAY

3 BW

B

2

5
2

1

3

ECU

AIR FLOW SENSOR

ENGINE CONNECTOR

ECU

AIR FLOW POW.(1)

AIR FLOW GND(2)

AIR FLOW VO(3)

AIR FLOW (+)(4)

AIR FLOW (-)(5)

V71 A-VCC12(MAX10mA)

E45 DIFF SEN. SIG.

E44 INLET DOC

E63 OUTLET DOC

E43 OUTLET DPF
E57 A-GND3

R

B

W

210

209

208

R

204

R

202

B

201

B

201

0.5B

211

B

201

R

200

B

1.25W

1.25G

1.25R

1.25R

B

1.25G

1.25B

1.25W

1.25B

100
106
106
100

2

111
115
121
125

2

INJ4-DRV(6) B11

INJ3-DRV(7) B10

INJ2-DRV(8) B09

INJ1-DRV(9) B08

SHIELD GND B12

SHIELD GND B06

INJ4-COM(1) B05

INJ3-COM(2) B04

INJ2-COM(3) B03

INJ1-COM(4) B02

2 B

2 2B

1.25G

r

2 B

 

SPEED PULSE

ON/OFF RELAY

   

POTENTIO

METER

   

010 5W

2

W

025

20 BrW

5A

37

WY

5A

5A

032

2Y

003

3W

B

5A

5A

3W

48

20A

3RW

001

ECU

ECU

Br

8

8 Br

8

B

r

RB

130

3BY

15

W

025

LB

140

64 5R

GW

031

WB

003

L

020

Y

018

L

231

W

230

G

232

WB

003

WB

003

BR

012

3WB

003

3R

134

BrR

88

Y

65

Y

65

2Y

032

G

168

0.5B

0.5W

0.5B

0.5W

0.5R

164

165

161

162

166

BrW
Br

158
157

WB

WB

Y

003

003

65

GW

LB

031

140

G

L

Y

L

W

GL

YG

G

L

BrR

021

020

018

231

230

47

32

232

167

88

B

2

0.5B

2

0.5WB

0.5L

0.5G

003

213

212

E69 AFS-SIG

V49 INTAKE TEMP

V45 A-GND10

V40/V60 SIGNAL GND

V20/V39/V79/V80/V59 GND

GrR

B

038

0.5W

E54 G-GND

091

0.5R

E78 A-GND6

063

L

E66 COOLANT TEMP

039

BrW

158

WR

E67 BOOST SENSOR

042

Br

157

L

G

E56 A-GND1

E47 INTAKE AIR TEMP

053

052

0.5W

E49/E68 PFUEL1/2

066

0.5B

E13 A-VCC1

061

GB

E48 FUEL TEMP

043

0.5B

E73 G-SIG

090

0.5B

V65 A-GND11

209

Lg

V29 OIL-SW

060

GW

E58 A-GND5

044

0.5B

061

0.5R

E72/E75 NE(12)-GND

094

0.5W

V48 INTAKE THROTTLE

219

0.5W

E52 NE(12)-SIG

144

0.5R

Gr

E53 G-VCC

092

E76 A-GND2

040

0.5R

V50 A-VCC10

163

WB

E77 A-GND4

041

L

 E21 INTAKE THRO.(-)

217

Gr

045

E09/E29 SCV(+)

W

E01 INTAKE THRO.(+)

216

BR

E10/E30 SCV(-)

047

2B

2

2B

2

EGR VALVE(1) A31

INTAKE TEMP(2) A30

INTAKE TEMP(1) A29

RAIL PRESSURE(2) A28

RAIL PRESSURE(1) A26

FUEL TEMP(1) A24

CAM SHAFT(1) A23

INTAKE THRO.(4) A22

OIL SW(1) A21

FUEL TEMP(2) A20

CRANK SHAFT(1) A19

CRANK SHAFT(2) A18

INTAKE THRO.(3) A17

CRANK SHAFT(3) A15

CAM SHAFT(3) A14

COOLANT TEMP(2) A13

INTAKE THRO.(2) A12

SENSOR BOOST(1) A09

INTAKE THRO.(6) A08

SCV(2) A07

EGR VALVE(4) A06

INTAKE THRO.(5) A04

SCV(1) A03 

EGR VALVE(3) A02

SHIELD GND A01

E16/E36 INJ DRVTWV3

E19/E39 INJ DRVTWV2

E20/E40 INJ DRVTWV4

E15/E35 INJ DRVTWV1

E38 INJ COMMON

E18 INJ COMMON

E34 INJ COMMON

E14 INJ COMMON

2 B

OIL PRE.LAMP V06

HEATER LAMP V07

DPF ACTIVE LAMP V26

DPF REQUEST LAMP V28

STOP LAMP V08

WARNING LAMP V09

OVERHEAT LAMP V27

PARKING SW.V75

N-SW. V30

STOP-SW. V32

DPF SW. V56

DPF INHIBIT SW. V74

ST-SW V12

STARTER V05

HEATER RLY V24

DPF

ACTIVE

LAMP

DPF

REQUEST

LAMP

   

OVER

HEAT

LAMP

    

ENGINE

STOP

LAMP

ENGINE

WARNING

LAMP

   

3

2

1

f

c

a

b

e

ECU MAIN

RELAY

   

GND2

SIG2

+V2

GND1

SIG1

+V1

GND

12V

CAN-L

CAN-H

     

CAN

(SERVICE

TOOL)

    

FUEL
PUMP

GLOW

HEATER

 

GLOW

RELAY

STARTER

RELAY

87
85

86

30

BATTERY

RELAY

E

BR

NO

COM

E

B

IG

L

STARTER MOTOR

S
B

E

65A

WATER SPRAY

PUMP (150W)

 

f

c

a

b

e

PROPULSION

PUMP 

NEUTRAL

SOLENOID

PARKING

BRAKE SOLENOID

 

SPEED

CHANGE SLENOID

AV

60 B (HEB 60)

65A

10

60 BW

42

22 WB

2 B

2 B

2 B

19 3LW

2 B

19 3LW

48

5W

1

5W

14

8W

R

50

8W

R

28 BrR
21 LgR
49 15B

21 LgR

64 5R

BATTERY

63

5B

R

ALTERNATOR

75A

COMBINATION METER

 1_12F

 2_12F

 3_12F

 4_12F

 5_12F

 6_12F

 7_12F

 8_12F

 9_12F

10_12F

11_12F

12_12F

 1_16M

 2_16M

 3_16M

 4_16M

 5_16M

 6_16M

 7_16M

 8_16M

 9_16M

10_16M

11_16M

12_16M

13_16M

14_16M

15_16M

16_16M

12V 115D31R

R2

R1

ACC

BR

B

C

HEAD LAMP (F,L)

60/55W

  

R

W

TURN SIGNAL

LAMP (F,L) (21W)

SIDE MARKER

LAMP (F,L) (5W)

Y

G

HEAD LAMP (F,R)

60/55W

  

R

W

TURN SIGNAL

LAMP (F,R) (21W)

SIDE MARKER

LAMP (F,R) (5W)

G

Y

R

G

GR

RY

TURN SIGNAL

LAMP (R,R) (21W)
BACKUP

LAMP (R) (21W)

STOP LAMP

(R) (21W)

TAIL LAMP

(R) (5W)

   

LICENSE

LAMP (10W  2)

 

TAIL LAMP

(L) (5W)

 

STOP LAMP

(L) (21W)

TURN SIGNAL

LAMP (R,L) ( 21W)

BACKUP

LAMP (L) (21W)

BACKUP

BUZZER

R
G

GR

RY

TURN

SIGNAL

SWITCH 

GB(5)

RY(6)
RW(7)
RB(8)

G(3)

GR(4)

LIGHTING SWITCH

4

1

5

6

3

2

HAZARD SWITCH

4

1

5

6

2

3

FLOOD

LAMP

SWITCH

2

1

3

FLASHER

UNIT

   

L

B

E

3

1

2

5

  

HORN

RELAY

HORN

THERMO

UNIT

FUEL

UNIT 

   

4

1

5

6

3

2

WATER SPRAY

RELAY

G
g

e

B

2

4

3 1

WATER

SPRAY

TIMER

5
2

1

3

PARKING INTERLOCK

RELAY

5

6

2

3

4

1

22

1.25W

B

22 1.25WB

33 GY

10

22 WB

33 GY

39 YL

39

YL

31 RY

31 RY

2 B

37

WY

3

B

W

15

3B

Y

3 BW

23

3B

R

41 LB

41 LB

41 3LB

41 LB

34 LY

27 LR

27 LR

34 LY

2 B

19

LW

44

2W

G

44

45

36

RL

45 RL

45 RL

45 RL

45 RL

45 RL

31 RY

BrW

R

45

RL

45

RL

16

16

24

24

11

11 Gr
11 Gr

12 P

13 GY

6

G

6

6

G

G

40 GB

26 GR

6 G

40 GB
26 GR

26 GR

26 GR

40 GB

40 GB

67

38 1.25RG

38 1.25RG

40

GB

26

GR

38

RG

25

YB

46

YW

32

YG

47

GL

48

48 W

21 LgR

STARTER

SWITCH

28

BrR

2

B

2

B

73 L

65

Y

2 B

2 B

2 B

2 B

2 B

2 B

2 B

88 BrR

5W

WG

DPF

METER

6

4

1

2
3

5

B

2

Y

65

ECO LAMP

 (12V)

L

341

Y

65

MAIN V03/V23

CAN2-H V37

+BF V01/V21

IG-SW V13/V33

+BP V18/V58/V38/V78

CAN1-H V36

CAN1-L V16

A-VCC11(+5V) V51

APS1(SIG) V47

A-GND12 V46

APS2(SIG) V67

A-GND13 V66

SPEED SENSOR V14

TACHMETER PULSE V34

GND #16

SUB-ECU LAMP #13

LOAD #12

INHIBIT SWITCHOUT #39

CAN-L #24

CAN-H #23

B) #22

ACC #44

LOAD ON/OFF #35

SUB-ECU

SUB-ECU

LAMP

 

DPF SWITCH

GR

401

LR

402

R

134

BrW

404

Br

403

GY

405

WB

003

B

2

O

10

GY

405

SPEED CHANGE

SWITCH

3
2

1

  

LOAD

RELAY

3

1

2

5

R

R

SOL

CAN-H
CAN-L

406 LY
401 GR

003 WB

407 BrY

2 B

407 BrY

LOAD

SOLENOID

WB

003

Br

403

BrW

404

LR

402

406 LY

SWP16F

SWP12M

COMBINATION METER

COOLANT TEMP. SEL.2 (OPEN)

COOLANT TEMP. SEL.1 (OPEN)

REV. RATIO SEL.4 (OPEN)

REV. RATIO SEL.3 (OPEN)

REV. RATIO SEL.2 (GND)

REV. RATIO SEL.1 (OPEN)

PREHEATING

CHARGE WARNING

ENGINE OIL PRESSUER WARNING

HYDRAULIC OIL FILTER WARNING

PARKING BRAKE

LAMP CHECK

TEMPERATURE METER

FUEL METER

REV. PULSE INPUT  2

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

VIBRATOR

LIQUID SPRAY

WATER SPRAY

FLOOD LAMP

SIDE MARKER LAMP

TURN SIGNAL (L)

TURN SIGNAL (R)

COMBINATION METER ILLUMINATION

REV. PULSE INPUT  1

STARTER SWITCH (ACC)

BATTERY (24V)

BATTERY (12V)

12

11

10

9

8

7

6

5

4

3

2

1

1.25RB

1.25RB

1.25RW

SENSOR BOOST(2) A33

EGR VALVE(2) A36

COOLANT TEMP(1) A38

RAIL PRESSURE(3) A39

CAM SHAFT(2) A40

SENSOR BOOST(3) A41

DPF SEN.T2(2) C01
DPF SEN.T2(1) C02
DPF SEN.T1(2) C03
DPF SEN.T1(1) C04
DPF SEN.T0(2) C05
DPF SEN.T0(1) C06

DPF DIFFSEN.(3) C09
DPF DIFFSEN.(2) C10

DPF DIFFSEN.(1) C11

CAN2-L V17

COMBINATION LAMP (F,R)

COMBINATION LAMP (R,R)

COMBINATION LAMP (R,L)

COMBINATION LAMP (F,L)

R

F

371

BY

WB

WR

WY

WL

WG

WB

WR

WY

WL

10

14

12

11

13

9

8

7

6

5

4

3

2

1

BW

WR

WR

WR

WATER SPRAY MODE

SELECT SWITCH

102

2W

SUB POWER

12V/120W

103

10A

2W

102

2B

2

2Br

5-003

ELECTRICAL SYSTEM

Содержание R2-4

Страница 1: ...R2 4 SHOP MANUAL 3498 6634A 0...

Страница 2: ......

Страница 3: ...e machine Improper operation is dangerous and can result in injury or death Sakai Heavy Industries cannot foresee all possible circumstances or varying conditions to which the operator serviceman or m...

Страница 4: ......

Страница 5: ...tarting 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 R2 4 2 001 1 2 R2 4 ROPS 2 004 1 3 R2H 4 2 007...

Страница 6: ...lsion Hydraulic Piping 4 004 2 1 1 Propulsion hydraulic piping 1 4 004 2 1 2 Propulsion hydraulic piping 2 4 005 2 1 3 Propulsion hydraulic piping 3 4 006 2 1 4 Propulsion hydraulic piping R 4 007 2 2...

Страница 7: ...6 Floor Board Harness 5 016 4 7 Engine Harness 5 018 4 8 Starter Switch Harness 5 019 4 9 Control Switch Harness 5 020 4 10 Lighting Switch Harness 5 021 4 11 Hazard Switch Harness 5 022 4 12 F R Lev...

Страница 8: ...9 003 3 MEASUREMENT AND ADJUSTMENT OF PROPULSION CHARGE CIRCUIT PRESSURE 3 1 Measurement 9 004 3 2 Adjustment 9 005 4 MEASUREMENT OF PROPULSION SERVO CIRCUIT PRESSURE 4 1 Measurement 9 006 5 MEASUREME...

Страница 9: ...2 2 Table of the diagnostic trouble code DTC 10 012 2 3 Engine 10 019 2 3 1 Engine will not start Starter motor does not run 1 2 10 019 2 3 1 Engine will not start Starter motor does not run 2 2 10 02...

Страница 10: ...3 Fuel meter is abnormal 10 055 2 6 14 Charge warning lamp remains ON 10 057 2 6 15 Water spray indicator lamp does not light 10 057 2 6 16 Flood lamp indicator lamp does not light 10 059 2 6 17 Side...

Страница 11: ...071 3 3 1 Steering wheel is hard to turn 10 071 3 3 2 Steering response is slow 10 071 3 3 3 Steering wheel backlash or play is large 10 072 3 3 4 Steering system is overheating 10 072 3 3 5 Abnormal...

Страница 12: ......

Страница 13: ...SAFETY...

Страница 14: ......

Страница 15: ...achine 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...

Страница 16: ...guidance of a skilled electrician and according to electrical engineering rules and regulations Work on the frame brakes hydraulic and steering systems must be performed by skilled personnel with spec...

Страница 17: ...eadable Never fill the fuel tank with the engine running or while near an open flame or while smoking Always clean up any spilled fuel Check for any warning tags placed on the machine do not operate t...

Страница 18: ...o 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 ra...

Страница 19: ...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...

Страница 20: ...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 corros...

Страница 21: ...ke 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 o...

Страница 22: ......

Страница 23: ...SPECIFICATIONS...

Страница 24: ......

Страница 25: ......

Страница 26: ...s Load on front axle with operating weight 4 850 kg 10 690 lbs Load on rear axle with operating weight 4 950 kg 10 915 lbs Dimensions Overall length 5 020 mm 198 in Overall width 2 100 mm 83 in Overal...

Страница 27: ...ear pressure Front drum Operating weight 432 N cm 245 lbf in Rear drum Operating weight 441 N cm 250 lbf in Dynamic linear pressure Front drum Operating weight Low amplitude N A N cm N A lbf in High a...

Страница 28: ...er forced circulation Cooling fan type Inhale Electrical system Alternator 12 V 90 A Starter 12 V 3 0 kW Battery 12 V 72 Ah CCA750 1 pc 12 V Dry weight 311 kg 686 lbs Drive system Transmission Type Hy...

Страница 29: ...nt axle with operating weight 5 060 kg 11 155 lbs Load on rear axle with operating weight 5 000 kg 11 025 lbs Dimensions Overall length 5 020 mm 198 in Overall width 2 100 mm 83 in Overall height with...

Страница 30: ...pressure Front drum Operating weight 451 N cm 260 lbf in Rear drum Operating weight 445 N cm 255 lbf in Dynamic linear pressure Front drum Operating weight Low amplitude N A N cm N A lbf in High ampl...

Страница 31: ...water forced circulation Cooling fan type Inhale Electrical system Alternator 12 V 90 A Starter 12 V 3 0 kW Battery 12 V 72 Ah CCA750 1 pc 12 V Dry weight 311 kg 686 lbs Drive system Transmission Type...

Страница 32: ...d on front axle with operating weight 6 760 kg 14 905 lbs Load on rear axle with operating weight 6 940 kg 15 300 lbs Dimensions Overall length 5 020 mm 198 in Overall width 2 100 mm 83 in Overall hei...

Страница 33: ...c linear pressure Front drum Operating weight 602 N cm 345 lbf in Rear drum Operating weight 618 N cm 355 lbf in Dynamic linear pressure Front drum Operating weight Low amplitude N A N cm N A lbf in H...

Страница 34: ...forced circulation Cooling fan type Inhale Electrical system Alternator 12 V 90 A Starter 12 V 3 0 kW Battery 12 V 72 Ah CCA750 1 pc 12 V Dry weight 311 kg 686 lbs Drive system Transmission Type Hydr...

Страница 35: ...lbs Load on front axle with operating weight 7 010 kg 15 455 lbs Load on rear axle with operating weight 7 030 kg 15 500 lbs Dimensions Overall length 5 020 mm 198 in Overall width 2 100 mm 83 in Over...

Страница 36: ...atic linear pressure Front drum Operating weight 625 N cm 355 lbf in Rear drum Operating weight 626 N cm 355 lbf in Dynamic linear pressure Front drum Operating weight Low amplitude N A N cm N A lbf i...

Страница 37: ...irculation Cooling fan type Inhale Electrical system Alternator 12 V 90 A Starter 12 V 3 0 kW Battery 12 V 72 Ah CCA750 1 pc 12 V Dry weight 311 kg 686 lbs Drive system Transmission Type Hydrostatic S...

Страница 38: ...t 0 13 to 0 17 mm 0 005 to 0 007 in Compression pressure 3 92 MPa 569 psi 250 min 1 2 2 Propulsion Item Standard value Remarks Travel speed Forward reverse 1st 0 to 8 km h 0 to 5 0 mph 2nd 0 to 16 km...

Страница 39: ...akes Item Standard value Remarks Clearance between brake pedal and floorboard as released 120 mm 4 7 in Note 1 See dimensions R2H 2 02001 Note 1 Note 2 Clearance between brake pedal and floorboard whe...

Страница 40: ...VI 110 ISO 3448 Grease Lithium type extreme pressure grease NLGI 2 Fuel Diesel oil ASTM D975 2D 3 2 Recommended Lubricants Lubricant Oil company Engine oil Gear oil API GL 5 Hydraulic oil ISO VG 46 Gr...

Страница 41: ...3 253 20 2 5 294 217 392 289 539 398 539 398 22 2 5 441 325 539 398 686 506 686 506 24 3 0 539 398 637 470 883 651 883 651 27 3 0 785 579 981 724 1324 977 1324 977 30 3 5 1079 796 1324 977 1765 1302 1...

Страница 42: ......

Страница 43: ...ENGINE AND CONTROLS...

Страница 44: ......

Страница 45: ...2 Bracket 8 Bolt M12 40 P 1 25 14 Nut M12 P 1 25 3 Bolt M12 40 P 1 25 9 Stopper 15 Stopper 4 Bolt M16 130 10 Bolt M12 45 16 Nut M12 P 1 25 5 Plate 11 Nut M12 17 Damper 6 Damper 12 Bracket N m 3 Bolt M...

Страница 46: ...tial pressure sensor 13 Oil drain plug 24 Flywheel 3 EGR pipe 14 Oil level gauge 25 EGR cooler 4 EGR valve 15 Oil filter cartridge 26 Starter motor 5 Air intake throttle 16 Water drain plug 27 Oil pan...

Страница 47: ...9 10 8 7 11 12 13 14 1 4 5 6 Apply grease IDEL FULL 1 Throttle lever 8 Bush Apply grease 2 Shaft 9 Washer Apply grease 3 Washer 10 Bush Apply grease 4 Coned disc spring Do not apply grease 11 Lock nu...

Страница 48: ...N R C 1 F R lever right 8 Lock nut M8 15 Lock nut M12 2 Shaft 9 Stopper bolt forward M8 25 16 Spring Fill grease 3 Rod end 10 Lock nut M8 17 Steel ball 4 F R lever left 11 Backup buzzer switch 18 Hold...

Страница 49: ...6 5 4 7 8 3 2 1 VIEW A SECTION B B 1 Bolt M10 30 P 1 25 5 Bolt M14 40 2 Flange 6 Pump 3 Hub 7 Bolt M10 25 P 1 25 4 Housing 8 Bolt M12 35 N m 1 Bolt M10 30 P 1 25 49 N m 36 lbf ft 5 Bolt M14 40 167 N m...

Страница 50: ...5 86 N m 63 lbf ft Secure flange 2 to engine flywheel with eight bolts 1 and spring washers and washers N m 1 Bolt M10 30 P 1 25 49 N m 36 lbf ft Secure housing 4 to engine flywheel housing with twelv...

Страница 51: ...HYDRAULIC SYSTEMS...

Страница 52: ......

Страница 53: ......

Страница 54: ...eservoir vented Filter or strainer Heat exchanger lines in dicate flow of coolant Quick disconnect Connected with mechan ically opened checks Disconnected Sloping arrow through a symbol at 45 indicate...

Страница 55: ...s providing various flow path options for the fluid The multiple square moves to represent how flow paths change when the valving element is shifted within the compo nent Valves with infinite posi tio...

Страница 56: ......

Страница 57: ...opulsion pump Valve Orbitrol Suction filter Valve Steering cylinder Oil cooler Propulsion pump R Drum R Drum F R Bypass valve Steering charge pump Propulsion motor F R Drum F L Propulsion motor F L 55...

Страница 58: ......

Страница 59: ...e PB2 RB PA2 RA Propulsion motor F L Propulsion pump Bypass valve Hose PB1 MR1 PA3 BV1 BV2 To propulsion hydraulic piping R The letters and numbers in the figure such as PB1 and MR1 show each port Arr...

Страница 60: ......

Страница 61: ...ed change solenoid valve Propulsion pump neutral solenoid valve VSC VND VNC PNC PD1 T3 T1 BB2 BPD BCS BB1 BT1 BCO SECTION C C DETAIL B DETAIL A CS VDR VPB VCP PND RS RD RP CO E D A B C C E Oil cooler...

Страница 62: ......

Страница 63: ...E E VIEW D MLV MSL PDR PD3 MRP MPL MRV The letters and numbers in the figure such as VSC and MLV show each port Arrow symbols show the hose connection and the direction of the flow of the oil Hose VS...

Страница 64: ......

Страница 65: ...RA Hose RMD RD RP RMP Hose RS RMS Hose RB RMB Propulsion motor R The letters and numbers in the figure such as RMB and RB show each port Arrow symbols show the hose connection and the direction of th...

Страница 66: ......

Страница 67: ......

Страница 68: ...draulic pump assembly propulsion steering charge R2 4 04001 16 2 cc rev 24 9 cc rev 1 3 1 5 1 14 1 13 1 12 1 11 1 15 2 1 16 2 3 2 2 2 1 1 8 1 7 1 9 1 10 1 6 1 5 2 1 1 1 2 1 3 1 1 4 1 2 1 1 1 14 B NA 1...

Страница 69: ...18UNF 1 11 Charge supply port PCS 1 5 16 12UN 1 12 Drain port PD3 1 1 16 12UN 1 13 Drain port PD2 1 1 16 12UN 1 14 Port A Forward PA SAE 1 1 15 Multi function valve Port B 1 16 Multi function valve Po...

Страница 70: ...ing brake pilot port MRP G1 4 10 Shift valve assembly 4 Drain port MLD G1 2 11 Motor 5 Port B2 MLB MRB G1 2 12 Reduction gear 6 Port A2 ML2 MR2 G1 2 13 Plug PF 3 8 7 Drain port MRD G1 2 Motor specific...

Страница 71: ...linder block kit 12 1 Floating seal kit 11 2 Roller bearing 12 2 Angular bearing 11 3 Oil seal 12 3 Shaft B 11 4 Shaft 12 4 Planetary gear B 11 5 Control piston 12 5 Needle roller 11 6 Swash plate ass...

Страница 72: ...t For port B G1 4 10 Reduction gear 5 High pressure gauge port For port A G1 4 11 Plug 7 8 14UNF 6 Parking brake pilot port RMP G1 4 12 Charge pressure gauge port G1 8 Motor specifications Displacemen...

Страница 73: ...n gear 9 1 Cylinder block kit 10 1 Floating seal kit 9 2 Control piston 10 2 Angular bearing 9 3 Bearing 10 3 Planetary gear 2nd 9 4 Oil seal 10 4 Needle roller 9 5 Shaft 10 5 Carrier 9 6 Swash plate...

Страница 74: ...8 9 10 1 Parking brake solenoid valve 6 Port P VCP G1 4 2 Speed change solenoid valve 7 Port A VPB G1 4 3 Propulsion pump neutral solenoid valve 8 Port D VND G1 4 4 Block 9 Port C VNC G1 4 5 Port B V...

Страница 75: ...15 HYDRAULIC SYSTEMS 2 2 5 Block A R2 4 04005 A 1 3 4 5 2 SECTION A A A 1 To propulsion motor F L port A1 PA1 G3 4 2 Body 3 To pipe PA2 G3 4 4 To bypass valve PA3 G3 8 5 From propulsion pump port A 24...

Страница 76: ...16 HYDRAULIC SYSTEMS 2 2 6 Block B R2 4 04006 A 1 3 4 5 A SECTION A A 2 1 To propulsion motor F R port A1 PB1 G3 4 2 Body 3 To pipe PB2 G3 4 4 To bypass valve PB3 G3 8 5 From propulsion pump port B 24...

Страница 77: ...teering cylinder T2 Hose AD4 SR Propulsion pump Hydraulic oil tank Hose AD3 SL SR SL A A SECTION A A SCS SC2 SC1 The letters and numbers in the figure such as AD4 and SR show each port Arrow symbols s...

Страница 78: ......

Страница 79: ...ering Wheel 0634 32802 0 20337 A 1 7 2 3 6 4 5 1 Column shaft 5 Nut M12 P 1 25 2 Steering wheel 6 Column shaft 3 Nut M12 P 1 25 7 Roller chain 4 Steering wheel N m 3 Nut M12 P 1 25 64 N m 47 lbf ft 5...

Страница 80: ...2 4 04002 1 3 4 2 1 2 4 5 3 Hydraulic circuit diagram 1 Port L L 3 4 16UNF 2 Port R R 3 4 16UNF 3 Port P P 3 4 16UNF 4 Port T T 3 4 16UNF 5 Relief valve Specifications Displacement 277 cm3 rev 16 9 cu...

Страница 81: ...03 4 3 5 6 1 2 5 6 4 1 Hydraulic circuit diagram 1 Port B G3 4 2 Block 3 Solenoid valve 4 Port A G3 4 5 Port T VT G3 4 6 Port P VP G3 4 Specifications Maximum flow 75 L min 19 8 gal min Maximum pressu...

Страница 82: ......

Страница 83: ...ELECTRICAL SYSTEM...

Страница 84: ......

Страница 85: ...50 Corrugate 70 GB 100 CB104 58X 2F 200 13 770 63 Corrugate 10 Brw 9 GB 63 LY 38 SWP 4 Mark S Starter relay harness P 5 017 J P 5 005 BrR GL Fuel sensor Wire color Reference page Marking Reference pa...

Страница 86: ...ripe GY Green Yellow stripe GB Green Black stripe GL Green Blue stripe Gy Gr Gray GyR Gray Red stripe Y Yellow YR Yellow Red stripe YB Yellow Black stripe YG Yellow Green stripe YL Yellow Blue stripe...

Страница 87: ...P LAMP ENGINE WARNING LAMP 3 2 1 f c a b e ECU MAIN RELAY GND2 SIG2 V2 GND1 SIG1 V1 GND 12V CAN L CAN H CAN SERVICE TOOL FUEL PUMP GLOW HEATER GLOW RELAY STARTER RELAY 87 85 86 30 BATTERY RELAY E BR N...

Страница 88: ......

Страница 89: ...Flood lamp F L RG BrW Flood lamp R L B GR GY RL RY B BR W Combination lamp R L P 5 014 Frame harness R P 5 030 Combination lamp harness F R B GB RL Combination lamp F R B 2 G L WB Air flow sensor AFS...

Страница 90: ......

Страница 91: ...ay mode select switch Water spray timer B LB LR LY Water spray harness P 5 028 B RB RW 2 RY Lighting LO HI relay LIG B BW GY WB Stop lamp relay BRA B G Gr Flasher unit FLA P Horn switch L B LB LW LY W...

Страница 92: ...orrugate 600 Corrugate 100 Corrugate 200 Corrugate 500 Corrugate 300 Corrugate 200 Corrugate 200 Corrugate 400 Corrugate 300 Corrugate 003 WB 10 13 1 250 GY 16 1 25RW 21 LgR 24 1 25RB 42 1 25BrB 407 B...

Страница 93: ...STR 2 WB 3WB 15 A E LOA MAI Fuse 5A 5 2 8 5W 2 GLO H 2 BR 3 MAI 1 2 W 2 STR Fuse 5A 2 GW 2 GLO 1 1 2Y 2 ECA Fuse 5A 2 GrR 2 ECA 1 1 L 2 ECA 1 1 Gr 2 ECA 1 1 WB 2 ECA 1 1 WR 2 ECA 1 1 GB 2 ECA 1 1 GW...

Страница 94: ...7 1 25L1 25Br 55 SWP 2M 100 Tape SWP 2F CAP 50 Tape ENG P 5 026 003 WB 018 Y 020 L 021 G P 5 028 ENGINE WARNING lamp harness Water spray harness 34 LY 2 B 41 LB O 50 Tape 0 5R 163 0 5W 165 164 0 5B 0...

Страница 95: ...1 1 GY 2 1 BRA 2262 1 LY 2 O WAT 2 Lg 2 H LIG 4643 2 WY 3 9 2 INT COM 3 RG 3RG 4 2 FLO Combination meter 12F 2 YL 2 S P Combination meter 16M 2 GB 5 2 G Combination meter 12F Turn signal switch 3 LB 3...

Страница 96: ...59 2 CAN Machine side connector Engine side connector CAN Service tool 174257 2 100 Corrugate CAN 157 Br 2 B 158 BrW 65 Y ECU 230 Corrugate 230 Corrugate G R W W G R V10 V70 E10 E70 G 100 R 111 W W G...

Страница 97: ...E73 1 0 5W 2 1 ECU E54 1 0 5R 2 1 ECU E53 1 0 5R 3 1 ECU E72 E75 2 G 4 2 ECU E14 E34 2 W 4 2 ECU E18 E38 2 R 3 1 ECU E15 E35 2 R 3 1 ECU E20 E40 2 G 3 1 ECU E19 E39 2 W 3 1 ECU E16 E36 2 RB 2 1 ECU V...

Страница 98: ...0 150 150 150 5W 5W 8WR 8WR 14 1 50 48 64 63 5BR 5R 5WL 5WL 51 52 100 300 150 75A gray 65A black Fusible link 65A black 65A black Horn Battery relay 63 LA308 14 LA308 1 LA308 21 LA104 8WR 200 5W 180 L...

Страница 99: ...sible link 75A 1 25RW 3 A Head lamp F L F R LgR 2 A Battery relay BR 1 25RB 3 A Head lamp F L F R 1 25BrB 3 A NEU PAR NO SIZE COLOR CONTACT POINTS CONNECTION 5W 2 B Fusible link 65A 8WR 2 C Fusible li...

Страница 100: ...BrW 100 1 25RG 100 Flood lamp R L 38 400 650 F G 50 RY GR 45 371 GY 33 31 1 25RG 2 38 BrW RL B 26 40 GB 3LW 19 40 GB 31 RY 45 RL 33 GY 2 B 26 GR 31 RY 45 RL 33 GY 2 B 58X 1F Corrugate 10 Corrugate 10...

Страница 101: ...er spray pump GR 2 F Combination lamp R L RY 3 F Combination lamp R L R R GY 3 F Combination lamp R L R R NO SIZE COLOR CONTACT POINTS CONNECTION 1 25RG 3 F Flood lamp R L R R GB 2 F Combination lamp...

Страница 102: ...45 CB104 300 45 CB104 RL 50 2 5 0 1 5 0 1500 1 25RG 50 1000 50 500 1300 1 25RG 50 38 CB104 RL 100 38 CB104 AFS 0 5WB 003 0 5G 0 5L 213 0 5B 211 212 25 YB 26 GR 38 40 45 RL 2 1 25RG GB 1 25B 211 0 5B...

Страница 103: ...D Combination lamp harness F L F R Fuel gauge unit YB 2 D Fuel gauge unit GR 2 D Combination lamp harness F L 1 25RG 3 D Flood lamp F L F R GB 2 D Combination lamp harness F R RL 4 D Combination lamp...

Страница 104: ...200 5W 50 010 STA Tape 50 AV15 B 100 B 49 LA408 B PB104 S 150 ALT 49 LA406 B 100 Tape 50 6189 0443 58Y 2M Alternator Glow plug Thermo unit Starter motor 3RW 001 010 5W 001 3RW Corrugate 7 Corrugate 7...

Страница 105: ...ness 2 P 5 008 48 23 LCT RL 1A 5W 50 C BR ACC B 21 LgR 4 R 120 Starter switch STA 50 LCR RL 1B LA205 C LA105 ACC LA305 B LA105 BR 3BR 50 3BR 80 R 80 LgR 80 5W 80 SWP 2M Corrugate 10 48 21 23 4 NO SIZE...

Страница 106: ...ing brake switch Speed change switch 10 22 39 22 2 88 BrR 100 B 100 WB 100 YL 100 1 25WB 100 1 25O 100 1 1 Corrugate 10 NO SIZE COLOR CONTACT POINTS CONNECTION B 2 S P Parking brake switch 5 1 25O 2 S...

Страница 107: ...s 2 P 5 008 SWP 3F 50 50 2 1 5 4 3 1 Lighting switch Flood lamp switch 67 66 36 44 45 44 WG 100 RL 100 WG 100 Lg 100 GR 100 Sb 100 Lg WG RL 45 44 36 Corrugate 10 NO SIZE COLOR CONTACT POINTS CONNECTIO...

Страница 108: ...G 6 GR RY GB RY 26 31 40 31 6 G Main harness 2 P 5 008 Hazard switch G 100 50 5 4 2 1 26 6 40 6 G 200 GB 200 G 200 GR 200 Corrugate 10 SWP 6M Bypass NO SIZE COLOR CONTACT POINTS CONNECTION G 4 G 2 Ha...

Страница 109: ...34 09027 0 40466 A NO LE104 COM LE104 F R lever switch CB104 CA104 Main harness 2 P 5 008 60 Tape BW 20 WL 20 BW 30 WL 20 3 3 30 37 30 NO SIZE COLOR CONTACT POINTS CONNECTION BW 2 F R lever switch NO...

Страница 110: ...03 CB104 not in use 503 W 40 W 60 NO LE104 COM LE104 Backup buzzer switch CB104 CA104 Main harness 2 P 5 008 Tape 60 RY 40 WB 40 RY 30 WB 50 31 31 22 22 NO SIZE COLOR CONTACT POINTS CONNECTION WB 2 Ba...

Страница 111: ...09028 0 40467 0 Foot brake switch Main harness 2 P 5 008 60 Tape 22 17 22 17 NO LE104 COM LE104 CB104 CA104 LgB 20 WB 20 LgB 30 WB 60 60 NO SIZE COLOR CONTACT POINTS CONNECTION LgB 2 Footbrake switch...

Страница 112: ...B104 020 CA104 018 CA104 O H E S E W 50 Tape 50 Tape 50 Tape 150 G 50 ENGINE WARNING lamp L G Y 018 WB OVER HEAT lamp Main harness 2 P 5 008 021 003 020 ENGINE STOP lamp ENG 003 CB104 Y 50 L 50 WB 50...

Страница 113: ...R1 25 3 R1 25 3 R1 25 3 231 X2 003 X1 230 X2 232 2 D S DAL DRL 50 Tape 50 Tape 50 Tape 100 Corrugate 7 WB 50 L 50 DPF request lamp DPF switch SWP 6F Main harness 2 P 5 008 DPF 003 1 G 50 W 50 WB 50 W...

Страница 114: ...34 41 LR 100 LY 100 LB 100 LB 100 50 SWP 3F 27 2 LB 34 LR LY B 41 Corrugate 7 Water spray timer P 5 008 Main harness 2 NO SIZE COLOR CONTACT POINTS CONNECTION B 2 O Water spray timer LR 2 Water spray...

Страница 115: ...04 B 30 CA104 Combination lamp F L 2 CB104 CB104 Turn signal lamp F L Side marker lamp F L Ground 400 RL 50 GR 70 45 26 Floor board harness P 5 016 NO SIZE COLOR CONTACT POINTS CONNECTION B 2 Combinat...

Страница 116: ...P 5 016 CB104 CA104 CA104 2 45 40 B 90 RL 70 GB 50 2 CA104 B 30 CB104 CB104 400 RL 50 GB 70 45 40 Turn signal lamp F R Side marker lamp F R Ground NO SIZE COLOR CONTACT POINTS CONNECTION B 2 Combinat...

Страница 117: ...3 2Br Vinyl tube 150 Fuse 10A 102 10A 103 2W 50 2Br 50 2Br 100 2W 500 Vinyl tube Vinyl tube Vinyl tube 2 Fuse box LCT RL 1A 102 Sub power DT04 2P E005 LA208 Ground 2B 600 2 NO SIZE COLOR CONTACT POINT...

Страница 118: ...relay Starter switch BR WR BW WR WR L Option WL WY WR WB WY WR WG WL WB BY BY WY F R lever switch WB 9 8 7 13 6 5 4 3 12 2 1 11 10 14 Sub power Backup buzzer switch Speed change switch Parking brake s...

Страница 119: ...LCD CPU EEPROM CAN interface Tachometer Fuel meter Temperature meter Hour meter Output interface Output interface Illumination LED Water spray indicator Liquid spray indicator Flood lamp indicator Vi...

Страница 120: ......

Страница 121: ...DRUM...

Страница 122: ......

Страница 123: ...nces 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 s...

Страница 124: ...lant 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...

Страница 125: ...M 2 1 Drum F R2 4 0634 24803 0 11400 0 1 6 5 4 3 2 1 Drum F R 3 Bolt M16 50 5 Propulsion motor F R 2 Drum F L 4 Propulsion motor F L 6 Bolt M16 50 N m 3 Bolt M16 50 265 N m 195 lbf ft 6 Bolt M16 50 26...

Страница 126: ...R2H 4 0634 24804 0 11502 0 1 8 7 6 5 4 3 2 1 Drum F R 4 Propulsion motor F L 7 Propulsion motor F R 2 Drum F L 5 Plug 8 Bolt M16 50 3 Bolt M16 50 6 Plug N m 3 Bolt M16 50 265 N m 195 lbf ft 8 Bolt M16...

Страница 127: ...olt M16 70 7 Retaining ring 12 Propulsion motor R 3 Ball bearing 8 Case 13 Bolt M20 60 4 Bolt M16 60 9 Flange 14 Bolt M20 70 5 Bolt M12 40 10 Plate N m 2 Bolt M16 70 265 N m 195 lbf ft 4 Bolt M16 60 2...

Страница 128: ...otor R 2 Plug 7 Retaining ring 12 Bolt M20 60 3 Ball bearing 8 Case 13 Bolt M20 70 4 Bolt M16 60 9 Plate Apply liquid sealant to the threaded area 5 Bolt M12 40 10 Bolt M20 60 N m 4 Bolt M16 60 265 N...

Страница 129: ...BRAKE...

Страница 130: ......

Страница 131: ...RAKE PEDAL 0634 51802 0 11190 A SECTION B B A A B B SECTION A A Shaft Bolt M10 40 P 1 25 Nut M10 Nut M10 Damper Bolt M10 40 Rod end Rod Foot brake switch Bolt M10 50 Brake pedal Return spring 7 001 BR...

Страница 132: ......

Страница 133: ...e is OFF with solenoid excited Parking brake switch Brake OFF condition Fuse Foot brake relay without relay excited Foot brake switch Condition in which brake pedal pressed Propulsion motor R Propulsi...

Страница 134: ......

Страница 135: ...WATER SPRAY SYSTEM...

Страница 136: ......

Страница 137: ...in valve From filter OUT Drain valve Valve Hose Filter OUT Tee Hose Water spray pump Filter IN Filter Drain valve Drain valve Drain valve IN OUT IN OUT Water spray diagram Valve C A B B A D C DETAIL D...

Страница 138: ......

Страница 139: ...INSPECTION AND ADJUSTMENT...

Страница 140: ......

Страница 141: ...n V belt or exhaust system parts while the engine is running may cause serious injury 1 2 Preparation for Inspection and Adjustment Prepare the necessary measuring instruments In addition particularly...

Страница 142: ...arking brake switch button Set speed change switch to Start the engine and set throttle lever to FULL Establish a condition in which machine propulsion load becomes maximum Pressure does not build up...

Страница 143: ...305 psi turn If there is no evidence of nut having loosened remove multifunction valve Check removed multifunction valve for trapped dirt and scratches on its seat If trapped dirt is present disassemb...

Страница 144: ...ug from coupling 1 of propulsion pump Attach pressure gauge with hose and connector Coupling 9 16 18UNF M16 Adapter for hose M16 P 2 0 Pressure gauge connector M16 G3 8 Pressure gauge 0 to 5 MPa 0 to...

Страница 145: ...nge rate 0 39 MPa turn 57 psi turn If there is no evidence of nut having loosened remove charge relief valve Check removed charge relief valve for trapped dirt and scratches on its seat If trapped dir...

Страница 146: ...o 725 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Start the engine and set throttle lever to FULL Operate F R lever and then read pressure indicated by...

Страница 147: ...isconnect hose 1 from valve Attach pressure gauge through adapter Adapter G1 4 Pressure gauge 0 to 5 MPa 0 to 725 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch b...

Страница 148: ...om valve Attach pressure gauge through adapter Adapter G1 4 Pressure gauge 0 to 5 MPa 0 to 725 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Start the eng...

Страница 149: ...uge 0 to 5 MPa 0 to 725 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Start the engine and set throttle lever to FULL Release parking brake by pressing pa...

Страница 150: ...from steering charge pump Attach pressure gauge through adapter Adapter G1 2 Pressure gauge 0 to 25 MPa 0 to 3 625 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch...

Страница 151: ...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...

Страница 152: ...rm that F R lever is N Apply parking brake by pressing parking brake switch button Set speed change switch to Start the engine and set throttle lever to FULL Establish a condition in which machine pro...

Страница 153: ...5 MPa 0 to 725 psi Confirm that F R lever is N Apply parking brake by pressing parking brake switch button Set speed change switch to Start the engine and set throttle lever to FULL Establish a condit...

Страница 154: ...ressing parking brake switch button Set speed change switch to Start the engine and set throttle lever to FULL Establish a condition in which machine propulsion load becomes maximum Pressure does not...

Страница 155: ...rature during measurement 50 5 C 122 9 F Apply grease to shaft of potentiometer 1 Insert potentiometer shaft to the groove on shaft 3 and fix it with two screws 2 NOTICE When fixing potentiometer 1 tu...

Страница 156: ...to standard value with stopper bolt 6 Engine rotational speed 975 25 min 1 After adjustment fix stopper bolt 6 with locknut 5 Set throttle lever 4 to FULL Loosen locknut 7 and adjust engine rotational...

Страница 157: ...ing force at center of throttle lever 4 knob to standard operating force Do not turn nut to the loosening direction Standard operating force 45 N 10 lbf NOTICE In case of loosen nut 10 replace it with...

Страница 158: ...rocedure described below N position of F R lever 1 is positioned by notches Set F R lever in N Attach both ends of control cable 2 Specified dimension a 170 mm 6 69 in Specified dimension b 172 mm 6 7...

Страница 159: ...TROUBLESHOOTING...

Страница 160: ......

Страница 161: ...y cause a serious accident When inspecting the engine make sure to exchange the appropriate cues and hand signal with the person at the operator station to avoid any accidents CAUTION Before inspectin...

Страница 162: ...full details of the trouble ask questions 3 Verify the trouble by warming up the machine and operating it Check the problem yourself 4 Identify the problem with either a mechanical hydraulic or elect...

Страница 163: ...al 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 su...

Страница 164: ...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 fro...

Страница 165: ...ness such as broken wire 10 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 Ohmm...

Страница 166: ...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...

Страница 167: ...nnected 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...

Страница 168: ...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 equ...

Страница 169: ...f burning or of an odor investigate as described follows 2 3 How to find cause of failure when fuse blown is reproduced Turn the starter switch OFF and remove the connector from the load valve pump Re...

Страница 170: ...entify the location section to which 24 V or 12 V reaches Then replace the harness or take other action 5 Solenoid valve inspection Check ON OFF operation by sound Conduct without running the engine I...

Страница 171: ...mp ENGINE WARNING lamp WATER PUMP SEC SPRAY PAUSE TIMER ON OFF INT 0 0 10 20 30 60 1 DTC display procedure using the DPF meter A current or past DTC stored in the engine control unit ECU is displayed...

Страница 172: ...rcuit B 4 Atmospheric pressure sensor Low Short circuit in sensor ECU internal circuit ground 110 0 Overheat Engine overheat Engine water temperature abnormally high 3 Water temperature sensor abnorma...

Страница 173: ...Fuel temperature sensor abnormal Fuel temperature sensor High Open circuit in sensor harness B short circuited 4 Fuel temperature sensor Low Short circuit in sensor harness ground 190 0 Overrun Engine...

Страница 174: ...Low Short circuit in sensor harness ground 3246 0 Exhaust temperature rise abnormal T2 Exhaust temperature rise abnormal T2 DPF outlet temperature T2 abnormally high 3 Exhaust temperature sensor 2 T2...

Страница 175: ...cuit Common 2 system or TWV 2 and 4 3rd and 2nd cylinders simultaneously Open circuit in harness 3 Short circuit in common 2 TWV driving system Short circuit in battery Injector driving circuit at ECU...

Страница 176: ...tion with EGR 523580 2 Intake throttle FB feed back abnormal Intake throttle FB feed back abnormal Intake throttle DC motor feed back abnormal 523582 3 Intake throttle lift sensor abnormal Intake thro...

Страница 177: ...hibit warning Exhaust temperature when abnormally high temperature generated 523602 0 Regeneration frequency abnormally high Regeneration frequency abnormally high Abnormal interval between end of reg...

Страница 178: ...LAY STARTER RELAY 87 85 86 30 BATTERY RELAY E BR NO COM E B IG L STARTER MOTOR S B E 65A AV60 B HEB 60 65A 48 5W 1 5W 14 8WR 50 8WR 28 BrR 21 LgR 49 15B 21 LgR 64 5R BATTERY 6 3 5 B R ALTERNATOR 75A 1...

Страница 179: ...re is continuity between connection O O If there is no continuity starter switch is faulty Replace starter switch 3 Starter Motor 1 When starter switch is ON measure voltage between starter motor term...

Страница 180: ...LAY STARTER RELAY 87 85 86 30 BATTERY RELAY E BR NO COM E B IG L STARTER MOTOR S B E 65A AV60 B HEB 60 65A 48 5W 1 5W 14 8WR 50 8WR 28 BrR 21 LgR 49 15B 21 LgR 64 5R BATTERY 6 3 5 B R ALTERNATOR 75A 1...

Страница 181: ...2 is NG F R lever switch is faulty Replace F R lever switch 7 Parking Interlock Relay 1 When starter switch is ON measure voltage between parking interlock relay terminal 1 inlet wire BrR and chassis...

Страница 182: ...LAY STARTER RELAY 87 85 86 30 BATTERY RELAY E BR NO COM E B IG L STARTER MOTOR S B E 65A AV60 B HEB 60 65A 48 5W 1 5W 14 8WR 50 8WR 28 BrR 21 LgR 49 15B 21 LgR 64 5R BATTERY 6 3 5 B R ALTERNATOR 75A 1...

Страница 183: ...2 Measure voltage between ECU main relay terminal 30 inlet wire R and chassis ground Standard voltage 12 V or more 3 When starter switch is ON measure voltage between ECU main relay terminal 87 outlet...

Страница 184: ...LAY STARTER RELAY 87 85 86 30 BATTERY RELAY E BR NO COM E B IG L STARTER MOTOR S B E 65A AV60 B HEB 60 65A 48 5W 1 5W 14 8WR 50 8WR 28 BrR 21 LgR 49 15B 21 LgR 64 5R BATTERY 6 3 5 B R ALTERNATOR 75A 1...

Страница 185: ...If above items 1 and 2 are OK and item 3 is NG glow relay is faulty Replace glow relay 3 Harness Connecting Between Terminals Measure resistance of harness connecting between terminals Standard resis...

Страница 186: ...LAY STARTER RELAY 87 85 86 30 BATTERY RELAY E BR NO COM E B IG L STARTER MOTOR S B E 65A AV60 B HEB 60 65A 48 5W 1 5W 14 8WR 50 8WR 28 BrR 21 LgR 49 15B 21 LgR 64 5R BATTERY 6 3 5 B R ALTERNATOR 75A 1...

Страница 187: ...voltage 5 0 5 V 3 When starter switch is ON measure voltage between potentiometer terminal SIG1 wire W and potentiometer terminal GND1 wire B When throttle lever is at IDLE position Standard voltage 0...

Страница 188: ...TOP LAMP PARKING BRAKE SWITCH 2 B f c a b e PLOPULSION PUMP NEUTRAL SOLENOID PARKING BRAKE SOLENOID SPEED CHANGE SLENOID 10 60 BW 42 22 WB 2 B 2 B 2 B TO PARKING INTERLOCK RELAY SPEED PULSE ON OFF REL...

Страница 189: ...rminal 1 inlet wire BW and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between brake relay terminal 3 inlet wire GW and chassis ground Standard voltage 12...

Страница 190: ...TOP LAMP PARKING BRAKE SWITCH 2 B f c a b e PLOPULSION PUMP NEUTRAL SOLENOID PARKING BRAKE SOLENOID SPEED CHANGE SLENOID 10 60 BW 42 22 WB 2 B 2 B 2 B TO PARKING INTERLOCK RELAY SPEED PULSE ON OFF REL...

Страница 191: ...rking brake switch terminal 3 outlet wire GW and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG parking brake switch is faulty Replace parking brake switch 3 Harne...

Страница 192: ...TOP LAMP PARKING BRAKE SWITCH 2 B f c a b e PLOPULSION PUMP NEUTRAL SOLENOID PARKING BRAKE SOLENOID SPEED CHANGE SLENOID 10 60 BW 42 22 WB 2 B 2 B 2 B TO PARKING INTERLOCK RELAY SPEED PULSE ON OFF REL...

Страница 193: ...necting Between Terminals Measure resistance of harness connecting between terminals Standard resistance 10 or less If resistance is abnormal harness is faulty Repair or replace harness 2 4 4 Speed ca...

Страница 194: ...48 5W 1 5W 21 LgR BATTERY TO COMBINATION METER 12V 115D31R R2 R1 ACC BR B C WATER SPRAY MODE SELECT SWITCH 4 1 5 6 3 2 WATER SPRAY RELAY G g e B 2 4 3 1 WATER SPRAY TIMER 41 LB 41 LB 41 3LB 41 LB 34...

Страница 195: ...wire LY and chassis ground Standard voltage 12 V or more 2 When starter switch is ON measure voltage between water spray relay terminal G inlet wire LB and chassis ground Standard voltage 12 V or more...

Страница 196: ...48 5W 1 5W 21 LgR BATTERY TO COMBINATION METER 12V 115D31R R2 R1 ACC BR B C WATER SPRAY MODE SELECT SWITCH 4 1 5 6 3 2 WATER SPRAY RELAY G g e B 2 4 3 1 WATER SPRAY TIMER 41 LB 41 LB 41 3LB 41 LB 34...

Страница 197: ...If above item 1 is OK and item 2 is NG water spray timer is faulty Replace water spray timer 2 Water Spray Mode Select Switch 1 When starter switch is ON measure voltage between water spray mode sele...

Страница 198: ...LAMP R 21W TAIL LAMP R 5W LICENSE LAMP 10W 2 TAIL LAMP L 5W STOP LAMP L 21W TURN SIGNAL LAMP R L 21W BACKUP LAMP L 21W R G GR RY TURN SIGNAL SWITCH TO COMBINATION METER GB 5 RY 6 RW 7 RB 8 G 3 GR 4 LI...

Страница 199: ...ing switch is measure voltage between lighting switch terminal 3 outlet wire RL and chassis ground Standard voltage 12 V or more 3 When starter switch is ON and lighting switch is measure voltage betw...

Страница 200: ...LAMP R 21W TAIL LAMP R 5W LICENSE LAMP 10W 2 TAIL LAMP L 5W STOP LAMP L 21W TURN SIGNAL LAMP R L 21W BACKUP LAMP L 21W R G GR RY TURN SIGNAL SWITCH TO COMBINATION METER GB 5 RY 6 RW 7 RB 8 G 3 GR 4 LI...

Страница 201: ...ood lamp does not light 1 2 Reference Fig 2 6 1 Check point Check Cause Action 1 Each Bulb Check that none of lamp bulbs is burned out or has a contact failure Bulb is faulty or poorly connected Repla...

Страница 202: ...LAMP R 21W TAIL LAMP R 5W LICENSE LAMP 10W 2 TAIL LAMP L 5W STOP LAMP L 21W TURN SIGNAL LAMP R L 21W BACKUP LAMP L 21W R G GR RY TURN SIGNAL SWITCH TO COMBINATION METER GB 5 RY 6 RW 7 RB 8 G 3 GR 4 LI...

Страница 203: ...t wire RW and chassis ground Standard voltage 12 V or more If above item 1 is OK and item 2 is NG turn signal switch is faulty Replace turn signal switch 3 Lighting LO HI Relay 1 When starter switch i...

Страница 204: ...LAMP R 21W TAIL LAMP R 5W LICENSE LAMP 10W 2 TAIL LAMP L 5W STOP LAMP L 21W TURN SIGNAL LAMP R L 21W BACKUP LAMP L 21W R G GR RY TURN SIGNAL SWITCH TO COMBINATION METER GB 5 RY 6 RW 7 RB 8 G 3 GR 4 LI...

Страница 205: ...item 2 is NG flasher unit is faulty Replace flasher unit 3 Turn Signal Switch 1 When starter switch is ON and turn signal switch lever is moved measure voltage between turn signal switch terminal inl...

Страница 206: ...LAMP R 21W TAIL LAMP R 5W LICENSE LAMP 10W 2 TAIL LAMP L 5W STOP LAMP L 21W TURN SIGNAL LAMP R L 21W BACKUP LAMP L 21W R G GR RY TURN SIGNAL SWITCH TO COMBINATION METER GB 5 RY 6 RW 7 RB 8 G 3 GR 4 LI...

Страница 207: ...ace hazard switch 3 Harness Connecting Between Terminals Measure resistance of harness connecting between terminals Standard resistance 10 or less If resistance is abnormal harness is faulty Repair or...

Страница 208: ...LAMP R 21W TAIL LAMP R 5W LICENSE LAMP 10W 2 TAIL LAMP L 5W STOP LAMP L 21W TURN SIGNAL LAMP R L 21W BACKUP LAMP L 21W R G GR RY TURN SIGNAL SWITCH TO COMBINATION METER GB 5 RY 6 RW 7 RB 8 G 3 GR 4 LI...

Страница 209: ...ace foot brake switch 3 Stop Lamp Relay 1 When starter switch is ON while foot brake is depressed measure voltage between stop lamp relay terminal a inlet wire BW and chassis ground There is no electr...

Страница 210: ...SEL 2 GND REV RATIO SEL 1 OPEN PREHEATING CHARGE WARNING ENGINE OIL PRESSUER WARNING HYDRAULIC OIL FILTER WARNING PARKING BRAKE LAMP CHECK TEMPERATURE METER FUEL METER REV PULSE INPUT 2 16 15 14 13 1...

Страница 211: ...assis ground Standard voltage 12 V or more If above items 1 and 2 are OK and combination meter does not turn on combination meter is faulty Replace combination meter 2 6 9 Combination meter warning la...

Страница 212: ...SEL 2 GND REV RATIO SEL 1 OPEN PREHEATING CHARGE WARNING ENGINE OIL PRESSUER WARNING HYDRAULIC OIL FILTER WARNING PARKING BRAKE LAMP CHECK TEMPERATURE METER FUEL METER REV PULSE INPUT 2 16 15 14 13 1...

Страница 213: ...ground Standard pulse 3 pulses rotation of engine If above item is OK and tachometer reading is NG combination meter is faulty Replace combination meter 2 Harness Connecting Between Terminals Measure...

Страница 214: ...SEL 2 GND REV RATIO SEL 1 OPEN PREHEATING CHARGE WARNING ENGINE OIL PRESSUER WARNING HYDRAULIC OIL FILTER WARNING PARKING BRAKE LAMP CHECK TEMPERATURE METER FUEL METER REV PULSE INPUT 2 16 15 14 13 1...

Страница 215: ...rness connecting between terminals Standard resistance 10 or less If resistance is abnormal harness is faulty Repair or replace harness 2 6 13 Fuel meter is abnormal Reference Fig 2 6 2 Check point Ch...

Страница 216: ...SEL 2 GND REV RATIO SEL 1 OPEN PREHEATING CHARGE WARNING ENGINE OIL PRESSUER WARNING HYDRAULIC OIL FILTER WARNING PARKING BRAKE LAMP CHECK TEMPERATURE METER FUEL METER REV PULSE INPUT 2 16 15 14 13 1...

Страница 217: ...ck that water spray pump can be activated Reference Fig 2 6 2 Check point Check Cause Action 1 Harness Measure resistance between water spray relay terminal B wire LW and combination meter connector t...

Страница 218: ...NG HYDRAULIC OIL FILTER WARNING PARKING BRAKE LAMP CHECK TEMPERATURE METER FUEL METER REV PULSE INPUT 2 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 VIBRATOR LIQUID SPRAY WATER SPRAY FLOOD LAMP SIDE MARKER...

Страница 219: ...mp indicator lamp does not light combination meter is faulty Replace combination meter 2 6 17 Side marker lamp indicator lamp does not light Check that side marker lamp tail lamp and license lamp ligh...

Страница 220: ...NG HYDRAULIC OIL FILTER WARNING PARKING BRAKE LAMP CHECK TEMPERATURE METER FUEL METER REV PULSE INPUT 2 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 VIBRATOR LIQUID SPRAY WATER SPRAY FLOOD LAMP SIDE MARKER...

Страница 221: ...uity 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 a...

Страница 222: ...NG HYDRAULIC OIL FILTER WARNING PARKING BRAKE LAMP CHECK TEMPERATURE METER FUEL METER REV PULSE INPUT 2 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 VIBRATOR LIQUID SPRAY WATER SPRAY FLOOD LAMP SIDE MARKER...

Страница 223: ...en wire G and wire GB There is continuity in normal condition If there is no continuity turn signal switch is faulty Replace turn signal switch 3 Combination Meter Turn signal indicator lamp 1 When st...

Страница 224: ...31 RY BrW 371 R 20A 15A 15A 15A 15A 15A 20A 20A 20A 20A FUSE BOX WL WG 10 14 12 11 13 9 8 7 6 5 4 3 2 1 BACKUP BUZZER SWITCH HORN SWICTH WB 22 31 RY COM NO NC 1 25Gr BACKUP BUZZER 3 1 2 5 HORN RELAY H...

Страница 225: ...Replace horn switch 4 Harness Connecting Between Terminals Measure resistance of harness connecting between terminals Standard resistance 10 or less If resistance is abnormal harness is faulty Repair...

Страница 226: ...pes and components in order to prevent foreign substances from entering Never leave the openings exposed or put a shop cloth into them There is the danger of foreign substances entering or of leaking...

Страница 227: ...il supply circuit with charge circuit Parking brake solenoid valve Speed change solenoid valve When solenoid is energized check if oil flows in return circuit to tank If oil is flowing repair solenoid...

Страница 228: ...just F R lever linkage or replace it if necessary 2 Multifunction Valve Low circuit pressure due to incorrect high pressure relief setting or internal leakage of multifunction valve Interchange two mu...

Страница 229: ...charge flow rate is insufficient due to wear of propulsion pump drive shaft splines Replace propulsion pump Propulsion circuit pressure is not held in propulsion pump case If pressure in propulsion pu...

Страница 230: ...vely heavy relief valve opens causing temperature of hydraulic oil in circuit to rise Measure propulsion circuit pressure If high decrease propulsion load 5 Suction Filter for Steering Charge Pump Loa...

Страница 231: ...ing 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 r...

Страница 232: ...replace relief valve If load is excessively heavy relief valve is open causing temperature of hydraulic oil in circuit to rise Measure steering circuit pressure If high decrease steering load 4 Sucti...

Страница 233: ......

Страница 234: ...Printed in Japan 2016 3 50 0 H S 0634 99373 0 31526 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 2...

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