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SHOP MANUAL
PREFACE
This shop manual provides instructions, for the most part, on GENERAL
INFORMATION, STRUCTURE/FUNCTION, CHECKING/ADJUSTMENT, and
TROUBLE-SHOOTING of the SAKAI SW300 Series Vibrating Rollers.
This manual is designed to serve as a guide for the operator and maintenance
personnel to acquire correct information and repair procedure on these
machines in order to give a correct decision on problems which the machines
will confront, thus leading to quality repair. Fully understand the contents of the
manual and make the best of it.
We will make utmost efforts to make this manual more useful for you through
revisions.
Your opinions and advices will be particularly welcome and will be
carefully considered.
CONTENTS
SPECIFICATIONS 1-001
STRUCTURE & OPERATION 2-001
TROUBLE-SHOOTING 4-001
SPECIFICATIONS
SPECIFICATIONS
1. External Views and Specifications
1-1. SW300 1-002
1-2. SW320 1-003
1-3. SW330 1-004
1-001
SPECIFICATIONS
1130 (44")
1750 (69")
(10")
250
70
0
(2
7.
5"
) 1950 (77")
1000 (39") 1000 (39")
2650 (104")
SW3001001
1-002
SPECIFICATIONS
1-2. SW320
Unit in mm {in}
1330 (52")
1750 (69")
(10")
250
7
0
0
(2
7
.5
1200 (47") ") 1950 (77") 1200 (47")
2650 (104")
SW3001002
1-003
SPECIFICATIONS
1-3. SW330
Unit in mm {in}
1430 (56")
1750 (69")
(10")
250
70
0(
27
.5
")
1300 (51") 1950 (77") 1300 (51")
2650 (104")
SW3001003
1-004
STRUCTURE & OPERATION
STRUCTURE & OPERATION
1. Location of Engine-related Key Units
1-1. Engine mount 2-003
1-2. Intake system 2-004
1-3. Exhaust system 2-005
1-4. Cooling piping & radiator 2-006
1-5. Fuel piping & fuel tank 2-007
1-6. Fuel controls 2-008
2-001
3. Brake System
3-1. Brake pedal 2-039
3-2. Description and operation of brake circuit 2-040
5.Electric System
5-1. Location of instrument panel and relays 2-043
5-2. Location of electric components 2-044
5-3. Electric wiring diagram 2-045
2-002
Engine-related Units
1
1
SW3002001
2-003
Engine-related Units
3
2
3
3
SW3002002
1. Duct hose
2. Air cleaner
3. Intake hose
2-004
Engine-related Units
VIEW A
1
1
3 3
SW3002003
1. Exhaust pipe
2. Muffler
3. Exhaust pipe
2-005
Engine-related Units
4
1
2
3
6 6
7
7
SW3002004
2-006
Engine-related Units
SW3002005
1. Suction hose
2. Filter
3. Fuel pump
4. Return hose
5. Fuel gauge unit
6. Fuel tank
2-007
Engine-related Units
3
4
DETAIL A VIEW B
B 1
A
SW3002006
1. Throttle lever
2. Control cable
3. Control lever (fuel injection pump)
4. Operating force adjusting nut
2-008
Description and Operation of Hydraulic System
7
6
1 5
8
3
10
SW3002007
1. Port A (forward travel)
2. Port B (reversing)
Specifications
3. High pressure relief valve (forward travel)
Model : DVN28-504
4. High pressure relief valve (reversing)
5. Charge relief valve Displacement : 28cm3/rev
6. Control lever Relief valve setting
7. Brake release solenoid valve : 34.5MPa (5000psi) {350kgf/cm2}
8. Circuit pressure gauge port (forward travel) Charge circuit pressure setting
9. Circuit pressure gauge port (reversing) : 1.9MPa (280psi) {20kgf/cm2}
10. Charge pressure gauge port
2-009
Description and Operation of Hydraulic System
2 4
5 6 7 8 9 10 11 12 13
14
15
17
23
16
22 21 20 19 18 24
SW3002008
Specifications
Model : DCM0280-517
Displacement : 417cm3/rev
Circuit pressure setting : 34.5MPa (5000psi) {350kgf/cm2 }
To be set on propulsion pump side
2-010
Description and Operation of Hydraulic System
5 8 10 11 12
23
15
24
SW3002009
2-011
Description and Operation of Hydraulic System
8
Cam ring (fixed)
(Inner surface has six come profiles.)
10 11
Piston (8 sets)
Cylinder block
(rotates)
Port B 9
Roller
23
Port A
Fp Fp : Hydraulic force
SW3002012 Fn : Vertical reaction from
cam ring
Fs : Rotary force
Fs Fn
SW3002011
2-012
Description and Operation of Hydraulic System
9 8 10 7 9 11
4
13 6 12 5
3
1 2
SW3002013
1. Outlet port (Pump No.1) 6. Drive gear (pump No.2) 11. Front cover
2. Outlet port (Pump No.2) 7. Driven gear (pump No.1) 12. Body
3. Suction port 8. Driven gear (pump No.2) 13. Rear cover
4. Drive gear (pump No.1) 9. Bush
5. Oil seal 10. Bush
Specifications
Model : DIA1414R270
Displacement : 13.7+13.7cm3/rev
Pressure setting : 12.7MPa (1840psi) {130kgf/cm2}
To be set by valve
2-013
Description and Operation of Hydraulic System
1 3
5 6 7 8 9 13
4
A
A 15
SECTION A-A
14 11 12 10
SW3002014
Specifications
Model : SHM1
Displacement : 9cm3/rev
Pressure setting : 12.7MPa (1840psi) {130kgf/cm2}
To be set by valve
2-014
Description and Operation of Hydraulic System
O
together with drive shaft (4), pressurized oil
E
2-015
Description and Operation of Hydraulic System
5
4
2 5
5
3
8
1
6
7 SW302018
Specifications
Displacement : 8.85cm3/rev
Pressure setting : 13MPa (1890psi) {133kgf/cm2}
To be set on Orbitrol side
2-016
Description and Operation of Hydraulic System
2-017
2-018
Description and Operation of Hydraulic System
A
8
5
8
3 1
A
10
11
B
B
5
7
3
8
2 4
5
8
12
6
4
VIEW A-A
VIEW B-B
SW3002020
2-019
Description and Operation of Hydraulic System
5 7 10 6
3 1
4 9 8
2
1 6
VIEW A VIEW B
SW3002021
2-020
Description and Operation of Hydraulic System
4
SECTION B-B
6
C 7
B
B
C 8
SECTION E-E
E A
DETAIL D
A
E
SW3002022
2-021
Description and Operation of Hydraulic System
1. Engine
2. Coupling 7
3. Propulsion pump 6
a. Control valve f
b. Servo piston
c. High pressure relief valve
d. Charge relief valve
f
e. Brake release solenoid valve 8 5
f. Bypass valve
g. Check valve
4. Vibrator pump
5. Rear propulsion motor 4
6. Rear drum
7. Front propulsion motor
8. Front drum
9. Steering pump
10. Steering valve (Orbitrol)
11. Line filter d
12. Oil cooler
13. Suction filter e
f f
g g
c
11 a
b
b
3
2 12
10 1
9
13
SW3002023
2-022
Description and Operation of Hydraulic System
Propulsion motor
A piston motor is used in which the displacement is fixed.
Charge circuit
The propulsion circuit is of a closed circuit, which needs feeding of oil into it for making up deficien-
cy, cooling off or for other purposes.
In the charge circuit, oil from steering pump (9) flows into steering valve (10) (Orbitrol), then the
whole oil goes to propulsion pump (3) via filter (11) irrespective of the steering wheel operation.
The pressure adjustment is achieved by charge relief valve (d) built in the propulsion pump (3).
2-023
Vibrating System
10
10 11
1 12
B
2
11
4
B
A
9 8 7 VIEW A-A
2
6 14
VIEW B-B
DETAIL C
5 13
2
1
VIEW D
SW3002024
2-024
Vibrating System
4 4 8
3 3 7
2 6
1
5
1 5
VIEW A VIEW B
SW3002025
2-025
Vibrating System
12,13
19 18 16 17 16 15 14 11
10
10
8
20
6,7
1 2 3 4 5
Level plug
Drain Plug
VIEW A
SW3002026
2-026
Vibrating System
19 18 16 17 16 15 14
12,13
11
10
9
8
10
6,7
20
1 2 3 4 5
Level Plug
Drain Plug
SW3002027
2-027
Vibrating System
2
1
13
SW3002028
2-028
Vibrating System
Vibrator motor
A radial piston motor is used.
Operation
The vibrator pump discharges oil as long as
it is driven, as it is of a gear type. When the
vibrator is not in use, the pump is put under
no load by vibrator solenoid valves (5) and
(9).
With the vibrator switch ON, valves (5) and
(9) close the unload circuit, making the
vibrator operative. Vibrator motors (6) and
(10) are driven. Oil displaced from the
motors is dumped to the tank via check
valves (8) and (12).
2-029
Steering System
2
7
A
DETAIL A
4
2
5
1
6
SW3002029
2-030
Steering System
6 5
3
1
2 4
6 5 SW3002030
1. Yoke
2. Bearing assy
3. Bracket (upper )
4. Bracket (lower)
5. Ball bearing
6. Cover
7. Grease fitting
2-031
Steering System
22
21
A A
20
19
18
SECTION A-A
9 10 11
7 23
4
14
3 15
16
17
1
12
13
SW3002031
2-032
Steering System
Description
* Valve section
The valve section makes itself a rotary type 8
direction control valve consisting of spool
(1) and sleeve (2) as main components. The
steering wheel is spline-connected to spool
(1). 6
When the steering wheel is not operated, 7
spool (1) and sleeve (2) stay in the neutral 1 Valve section
2
position with each other due to centering
springs (6) with the oil grooves in spool (1) 5
and oil holes in sleeve (2) not aligned. This
blocks oil flow to the steering cylinder. 4
When the steering wheel is turned, the oil 3
Roter section
grooves in spool (1) and oil holes in sleeve
(2) are aligned to feed oil to the cylinder.
SV4002042
* Rotor section
The rotor is an external gear which meshes
3
with the internal gear of stator (3). When the
valve section (spool-sleeve assy) opens,
4
the rotor-stator assy acts as a hydraulic
motor.
The rotation of rotor (4) is conveyed to the
valve section through drive shaft (5) spline-
connected to rotor (4). An extent to which
the valve opens is controlled by the speed SV4002043
at which the steering wheel is rotated.
1. Spool 5. Drive shaft
2. Sleeve 6. Centering spring
3. Stator 7. Cross pin
4. Rotor 8. Check valve
1 2
To tank
Oil groove To steering
cylinder
Oil hole To steering
cylinder
From pump
SV4002044
2-033
Steering System
Operation 6
* Neutral state (Steering wheel not 1
operated)
Centering springs (6) (flat springs) are locat-
2
ed in spring notches provided at end of
spool (1) and sleeve (2).
With the steering wheel not operated, cen- Oil hole
tering springs (6) make the spool-sleeve
assy stay in neutral. Oil grooves
* This steering valve (Orbitrol) is of a load-
sensing, non-load reaction, normal close SV4002045
type. In the neutral position, the oil grooves
and oil holes are not aligned, blocking oil
flow to the steering cylinder.
6
1
Oil hole
Oil groove
SV4002047
2-034
Steering System
2-035
Steering System
Steering wheel rotating speed and Low steering speed High steering speed
controlling the flow
* In the steering mechanism, it is essential to 1
increase or decrease oil flow into the 6
steering cylinder according to the rotating 2
speed of the steering wheel.
2-036
Steering System
11
12
6
10
9
3
11
8
12
7
SW3002034
2-037
Steering System
2
b
1
6
3 4
7 SW3002035
Description:
The steering system is made up of steering pump (2), steering valve (3) (Orbitrol), steering cylinder
(4) and line filter (5).
Operation
Oil from gear pump (2) enters steering valve (3). The valve feeds an amount of oil to steering cylin-
der (4). The amount of oil handled varies with the direction in which the steering wheel is rotated
and with the speed at which the steering wheel is turned.
The fluid fed into steering cylinder (4) moves the piston rod (b) to achieve steering. The oil dis-
placed from the opposite side of the piston flows, through steering valve (3) and line filter (5), to the
charge circuit for propulsion.
Refer to "Charge circuit" under "Description and operation of propulsion system".
Relief valve (a) built in steering valve (3) opens to relieve the pressure if the system pressure
exceeds the setting of the relief valve, thus protecting the circuit.
2-038
Brake System
3. Brake System
3-1. Brake pedal
VIEW A
4 3
3
4
2
A
SW3002036
1. Brake pedal
2. Return spring
3. Rod (for neutral position of F-R lever)
4. Rod (for neutral position of F-R lever)
5. Foot brake switch
2-039
Brake System
3
4
7
9 8
Fuse 5 4
To oil tank
AC Brake released
Starter switch 10
Front wheel
1 3
Brake applied
SW3002037
2-040
Sprinkler and Scraper
1/2
p
3
9
1 7
10
2
4
Sprinkler
DEATIL A Sprinker pipe (F)
pump
Check 8
Filter valve
3-way cock
P
Sprinker pipe (R)
Drain cock
1 3
B
A
5
7
6
2
SW3002038
2-041
Sprinkler and Scraper
4-2. Scraper
A A
A A
3
5 5
4 1
5 5
VIEW A 2
SW3002039
1. Blade (upper)
2. Blade (lower)
3. Bracket (upper)
4. Bracket (lower)
5. Spring
2-042
Electric System
5. Electric System
5-1. Location of instrument panel and relays
2 3
VIEW A
A
D
2 B
VIEW B
7 5
10
9
11
VIEW D-D
VIEW C
SW3002040
2-043
Electric System
3 4 5 6
8
7
2
9
11
12
10
12
16
5
14
13
15
SW3002032
2-044
Electric System
2-045
INSPECTION & ADJUSTMENT
INSPECTION & ADJUSTMENT
1.Standard Value Chart 3-002
3-001
Standard Value Chart
3-002
Inspection & Adjustment
1. Measurement
Hydraulic oil temperature: 505C
(12241F)
Park on level ground. Stop the engine.
Block the wheels. 2
Make certain that the parking brake func-
tions correctly.
3-101
Inspection & Adjustment
2. Adjustment
If the measured value falls outside the per-
missible range, clean or renew pressure relief 8
valves (7) (forward travel) and (8) (reversing).
Tightening torque for valve seat plug (9):
40 - 95 Nm (30 - 70 lbfin) {300 kgfcm}
Carefully perform disassembly and
reassembly taking necessary measures
to prevent ingress of foreign matter. 7
SW3003002
SW3003003
3-102
Inspection & Adjustment
2. Adjustment SV5003003
3-103
Inspection & Adjustment
3-104
Inspection & Adjustment
2. Adjustment
If the measured value is not within the permis-
sible range, adjust as follows: 1
1) Loosen lock nut (1) on the relief valve and
turn adjusting screw (2). Clockwise rotation
raises the pressure. The pressure lowers if
turned counter-clockwise.
2
2) When adjustment is complete, check for
correct setting.
SW3003008
3-105
Inspection & Adjustment
2. Adjustment
If the measured value is not within the permis-
sible range, disassemble and clean or renew
the relief valve assembly built in Orbitrol. The
valve is not adjustable.
Carefully perform disassembly and
reassembly taking necessary means to
avoid ingress of foreign matter.
3-106
Inspection & Adjustment
1. Adjustment
Coolant temperature: Green area on
gauge.
11
10
SW3003012
3-107
Inspection & Adjustment
1. Adjustment
Hydraulic oil temperature: 505C
(12241F)
Inspect the stroke of pump control lever
as described below. Positions of F-R
levers are positively determined by notch
balls.
Check that the F-R lever operates smooth-
ly.
3-108
TROUBLESHOOTING
TROUBLESHOOTING
1. Precautions for Troubleshooting 4-002
4-001
Precautions for Troubleshooting
Troubleshooting is to determine the root cause of troubles, repair faulty parts as quickly as prac-
ticable, and prevent recurrence of the troubles.
Important when conducting troubleshooting practice is of course to well understand the struc-
ture and function of machines to be handled. For effective troubleshooting, however, it is of
prime importance to have a clear picture of the trouble concerned by contacting the operator.
4-002
How to Diagnose the Machine
Procedure 4. Going to site where the faulty Was there any abnormal signs before the trouble
4-003
How to Use this Chapter, "TROUBLESHOOTING" and How to Follow the Troubleshooting Flow
2 General precautions
Under the code No. and fault symptom are precautions (marked ) for the whole items in the
flow chart. Though these precautions are not indicated inside each box ( ) which contains
checking instructions, pay attention to the precautions when making inspections described in the
box ( ).
3 Sub classification
To make diagnosis easier or for simplified flow chart, fault symptom is subclassified. Ex. a)
Starter does not run
NO
4-004
How to Use this Chapter, "TROUBLESHOOTING" and How to Follow the Troubleshooting Flow
As a result of diagnosis, if YES line or NO line directly goes to the description in POSSIBLE
CAUSE column, take necessary action as indicated in REMEDY column.
Under each box ( ) are normal values and conditions necessary for inspection and
adjustment. If the result gives an affirmative answer to the question in the box ( ) or agrees
to the normal value indicated under the box, go to YES line. Otherwise, go to NO line.
The normal values were taken from the standard value list.
For locations of component parts such as relay mentioned in the flow chart, see "Location of
key units". Line colors mentioned in the flow charts are indicated in the electric wiring diagram
shown under the flow charts. In the machine, each harness is identified by color.
4-005
Precautions for Diagnosis of Electric Circuit
2. Before making a diagnosis, check the connectors or harnesses for poor connection.
If a connector is at fault, check it by repeating connection and disconnection several
times.
3. Before proceeding to the next step, reconnect removed connectors or harnesses in place.
Care must be used for the controller circuit. If the power source is switched on with the
connector disconnected, this can cause an incorrect measurement.
4. When making a diagnosis of circuits (measurement of voltage, resistance, current, test for conti-
nuity, etc.), check to see if tester readings vary by shaking connectors or harnesses.
If readings vary, a possible cause is a poor connection of the circuit.
5. For voltage measurement, turn the starter switch ON. For resistance checking, let the switch stay
in the Off position.
If necessary to take a measurement of resistance by energizing relays or other units with
the starter switch ON, necessary instructions are given in the flow charts.
4-006
Troubleshooting for Electric System
4-201
Troubleshooting for Electric System
YES
Is stated voltage
YES YES
present at starter
terminal S that
carries wire BR?
10~14V 5
Turn starter switch
to START. Is stated voltage
present at interlock
relay terminal that
NO
carries wire BR?
3
10~14V
Turn starter switch
YES Is stated voltage
to START.
present at starter
terminal B? NO
10~14V
2
Does battery relay
YES give a click when 9 YES
starter switch is set
from ON to OFF Is stated voltage
and vice versa? present at battery
relay terminal that
NO
carries wire LW?
10~14V NO
1
YES
Are battery voltage
and fluid specific 10
gravity as Is stated voltage
specified? present at battery
relay terminal BR
Higher than 13V. 11 YES
NO that carries wire
LgW? Is stated voltage
Higher than 1.26
present at starter
(specific gravity) 10~14V
switch terminal BR
NO that carries wire
LgR?
10~14V NO
NO
4-202
Troubleshooting for Electric System
To A on page 4-204.
Charge or
Battery capacity lowered.
renew battery.
4-203
Troubleshooting for Electric System
Is specified voltage
Wire WR(W) from battery
fed to starter switch
A relay terminal BR to starter Repair or renew
terminal B that 13 YES
switch tereminal B not wire.
carries wire WR?
Is specified voltage connected or incorrectly Renew fuse.
10~14V fed to battery relay connected (including fuse).
terminal that
NO carries wire W? Wire from battery to battery
Repair or renew
relay not connected or
10~14V wire.
NO incorrectly connected.
Battery
LW
Battery relay
WR 65A W
LgW LgW L
SW3004001
4-204
Troubleshooting for Electric System
2 YES
Engine stop solenoid faulty. Renew.
Is resistance of
YES engine stop
solenoid earth wire
as specified? Engine stop solenoid earth
Repair or renew
wire not connected or
wire.
Lower than 1. NO incorrectly connected.
Disconnect wires
1
from solenoid.
Is specified voltage
4 YES
present at engine To A on this page.
stop solenoid Is stated voltage
terminal that YES present at timer
carries wire GR? connector 4 that Wire LgR (LgW) from starter
3
10~14V carries wire L? switch terminal BR to timer Repair of renew
Is stated voltage connector 3 not connected or wire.
Turn starter switch
present at timer 10~14V NO incorrectly connected Renew fuse.
to START.
connector 1 that Turn starter switch (including fuse).
NO
carries wire GR? to START.
Timer faulty or earth wire not
10~14V
connected or incorrectly Repair or renew.
Turn starter switch NO connected.
to START.
1 YES
Engine stop solenoid faulty. Renew.
Is specified voltage
present at engine
stop solenoid
terminal BR that
carries wire L?
Battery relay defective. Renew.
Lower than 1V.
NO
Starter switch: OFF
4-205
Troubleshooting for Electric System
a) Glow lamp does not become bright. (Other lamps light up.)
The glow indicator should become bright when the starter switch is turned to the
HEAT position, and come off when preheating is complete.
YES
Glow lamp relay faulty. Renew.
2
Does stated
1 YES
Glow plug faulty. Renew.
Does stated
voltage appear at
glow plug terminal
that carries wire Wire WG from starter switch
WG? terminal R2 to glow plug not Repair or renew
connected or incorrectly wire.
10~14V
NO connected.
Turn starter switch
to HEAT.
Glow lamp
timer
3 4 5 6
Starter switch
WL Combination meter
From battery WG Glow indicator
relay
YW
C
WG
Glow plugs 5A Y
B R2
ACC
R1
Fuse
BrB SW3004002
4-206
Troubleshooting for Electric System
YES
Regulator faulty. Renew.
1
Does specified
voltage appear at
alternator terminal
2 YES
IG that carries wire Alternator faulty. Renew.
Does specifed
Y?
voltage appear at
13.5~14.5V
alternator terminal
Run engine at NO
B that carries wire Wire WY from alternator
higher than
WY? terminal B to starter terminal Repair or renew
medium speed.
B not connected or wire.
10~14V NO
incorrectly connected.
Combination meter
Charge lamp WY B
Y
IG Alternator
WR WR
L
Y 5A E
Fuse SW3004003
2 YES
Fuel pump faulty. Renew.
4-207
Troubleshooting for Electric System
2 YES
Reverse alarm faulty. Renew.
YES Is resistance of
reverse alarm
ground wire as
specified? Reverse alarm earth wire not
1 Repair or renew
connected or incorrectly
Does specified wire.
Less than 1 NO connected.
voltage appear at
Disconnect wire from
reverse alarm
reverse alarm.
terminal that
Wire BY from back-up switch
carries wire BY? YES Repair or renew
to reverse alarm not connected
wire.
10~14V 3 or incorrectly connected.
Move F-R lever
Does specified
BACKWARD.
voltage appear at
back-up switch that 4 YES
NO carries wire BY? Back-up switch faulty. Renew.
Is specified voltage
Back-up switch
Fuse NO
Reverse alarm
15A RG BY BY R
SW3004005
4-208
Troubleshooting for Electric System
2 YES
Horn faulty. Renew.
YES
Is resistance of
horn earth wire as
spcified?
1 Horn earth wire not connected Repair or renew
or incorrectly connected. wire.
Is stated voltage Lower than 1. NO
present at horn Disconnect wire
terminal that from horn.
carries wire Lg? Wire Lg from horn to horn
YES Repair or renew
relay not connected or
wire.
10~14V 3 incorrectly connected.
Switch on horn Is stated voltage
switch. present at horn
relay terminal that 4 YES
NO carries wire Lg? To A on this page.
Is stated voltage
7 YES
Horn relay faulty. Renew.
YES Is resistance of
horn switch earth
6 wire as specified?
Horn switch earth wire not
Repair or renew
YES Is resistance connected or incorrectly
between horn Lower than 1. wire.
NO connected.
switch terminals Disconnect wires
normal? from horn switch.
5
Lower than 1
Horn switch faulty. Renew.
Is stated voltage
when switched ON. NO
present at horn
A Disconnect wires
switch terminal that
from horn switch.
carries wire LgW?
Wire LgW from horn relay coil
8 YES Repair or renew
to horn switch not connected
10~14V Is stated voltage wire.
or incorrectly connected.
Switch OFF horn present at horn
switch. relay coil terminal
Horn relay coil defective or
that carries wire
NO wire RG from horn relay coil
LgW?
to fuse ( from branch point) Renew.
10~14V NO not connected or incorrectly
Switch OFF horn connected.
switch.
SW3004006
4-209
Troubleshooting for Electric System
YES
Filament is burnt. Renew.
1
Is filament of bulb
burnt? Poor contact of bulb or earth Repair.
2 YES
wire not connected or Repair or renew
Is stated voltage incorrectly connected. wire.
fed to inoperative
lamp terminal that Wire GB from lighting switch
NO carries wire GB? terminal 2 to headlamps
(from branch point) not
10~14V Repair or renew
NO connected or incorrectly
Lighting switch: connected. wire.
Select headlamp.
Combination meter
SW3004007
4-210
Troubleshooting for Electric System
Vibrator indicator
Vibrator indicator lamp relay Fuse
lamp 15A
Rr RL RL
BrR
Fuse
15A
BrR
SW3004008
4-211
Troubleshooting for Electric System
YES
5
Is resistance of wire RW
YES from vibration mode
selector switch terminal 2
to vibrator relay
connector F as specified?
4
Lower than 1.
Is stated voltage
YES present at vibration Disconnect wire.
About 11.
Disconnect wire.
NO
4-212
Troubleshooting for Electric System
7 YES
Vibrator switch faulty. Renew.
Is resistance of
YES
vibrator switch
earth wire as
specified? Vibrator switch earth wire not
6 Repair or renew
connected or incorrectly
wire.
Is stated voltage Lower than 1. NO connected.
present at vibrator Disconnect wires.
switch that carries
wire Br?
8 YES
Vibrator relay faulty. Renew.
10~14V Is resistance of wire
Br from vibrator
switch to vibrator
NO relay connector H Wire Br from vibrator switch
as specified? to vibrator relay connector H
Repair or renew
not connected or incorrectly
Lower than 1. NO wire.
connected.
Disconnect wires.
Wire RW from vibration mode
selector switch to vibrator
Repair or renew
relay connector F not
wire.
connected or incorrectly
connected.
4-213
Troubleshooting for Electric System
3 YES
To A on this page.
Is resistance of wire BrY
YES from vibration mode
selector switch terminal 5
2 to vibrator relay connector Wire BrY from vibrator relay
Is stated voltage G as specified? connector G to selector Repair or renew
YES present at vibration Lower than 1. switch not connected or wire.
NO
mode selector switch Disconnect wires. incorrectly connected.
1
terminal 5 that carries
Is stated voltage
wire BrY?
present at vibration
10~14V Vibration mode selector switch
mode selector Renew.
NO faulty.
switch terminal 4
that carries wire RL?
4 YES
Vibrator relay faulty. Renew.
Is resistance of wire
GY from vibrator
A relay connector E to
F-R lever switch as Wire GY from vibrator relay
specified? connector E to F-R lever Repair or renew
switch not connected or wire.
Lower than 1. NO
incorrectly connected.
Disconnect wires.
4-214
Troubleshooting for Electric System
2 YES
Sprinkler motor faulty. Renew.
YES Is resistance of
sprinkler motor
earth wire as
specified? Sprinkler motor earth wire not
1 Repair or renew
connected or incorrectly
wire.
Is specified voltage Lower than 1. NO connected.
present at sprinkler Disconnect wire
motor that carries from motor.
Wire LB from sprinkler relay
wire LB?
YES to sprinkler motor not Repair or renew
connected or incorrectly wire.
10~14V 3
connected.
Operate sprinkler
Is specified voltage
switch.
present at sprinkler
relay terminal that 4 YES
NO carries wire LB? To A on this page.
Is specified voltage
10~14V present at sprinkler
Operate sprinkler relay terminal that
switch. NO carries wire LY? Wire LY from fuse to sprinkler
Repair or renew
relay not connected or
wire.
10~14V NO incorrectly connected.
6 YES
Sprinkler relay faulty. Renew.
Is resistance of
YES
sprinkler relay
earth wire as
specified? Sprinkler relay earth wire not
Repair or renew
5 connected or incorrectly
Lower tnan 1. wire.
NO connected.
Is specified voltage Disconnect wire
present at sprinkler from relay.
A relay coil that Wire LW from sprinkler switch
carries wire LW? YES terminal 2 to sprinkler relay Repair or renew
7 coil not connected or wire.
10~14V Is specified voltage incorrectly connected.
Operate sprinkler present at sprinkler
switch. switch terminal 2
8 YES
that carries wire Renew.
NO Sprinkler switch faulty.
LW? Is specified voltage
SW3004009
4-215
Troubleshooting for Electric System
Combination meter
Parking brake
indicator lamp
YL
SW3004010
4-216
Troubleshooting for Electric System
Repair or
3 Fuel unit earth wire incorrectly renew wire.
YES
connected or fuel unit Repair fuel unit
YES Is resistance of fuel malfunctioning. mounting or
renew fuel unit.
unit as shown in
2 table 2?
Table 1 Table 2
Full 10~17.5
Disconnected Empty
Empty 82.5~90
Grounded Full
Fuel unit B
YG YG
SW5004013
4-217
Troubleshooting for Electric System
Repair or
Thermo unit earth wire renew wire.
3 YES incorrectly connected or Repair mounting
YES Is resistance of thermo unit faulty. or renew thermo
unit.
thermo unit as
2 shown in table 2?
Table 1 Table 2
Thermo unit termi- Thermo unit
Gauge reading Resistance ()
nal wire Sb temperature
Disconnected Lowest 50C 150~158
Thermo unit B
Sb Sb
SW5004014
4-218
Troubleshooting for Electric System
Renew
4 YES Tachometer sensor
combination
malfunctions.
Is specifed voltage meter.
fed to tachometer
A
terminal (+) that
carries wire Y? Renew
Feed wire inside combination
combination
10~14V meter is faulty
NO meter.
Tachometer
Starter switch Fuse
BrB 5A
AC
Y +
Tachometer sensor B -
YR YR
P
SW5004015
4-219
MEMO
Fault Finding for Hydraulic and Mechanical Systems
4-401
Fault Finding for Hydraulic and Mechanical Systems
Trouble modes for hydraulic and mechanic systems and sources of trouble
Trouble mode Propulsion
Hydraulic
Unusual Not propelled Speed not gained or low traction
fluid too
sounds a) Forward and b) Either forward a) Forward and b) Either forward
hot
Source-of-trouble units reverse or reverse reverse or reverse
Propulsion pump
Charge pump
(Steering pump)
Servo valve/servo
Pump
linkage
High pressure relief
valve
Charge relief valve
Propulsion Motor unit
Front Negative brake
motor (parking brake)
Drum
Motor unit
Rear Negative brake
motor (parking brake)
Drum
Brake valve
Pump
Motor unit
Rear Vibrator
Vibrator solenoid valve
(pressure relief valve)
Vibrator
Pump
Motor unit
Front Vibrator
Vibrator solenoid valve
(pressure relief valve)
Steering pump
Steering valve (Orbitrol)
Pressure relief valve
Steering
Steering cylinder
Steering mechanism
Steering column
Sprinkler pump
Sprinkler
Hose/Valve/Nozzle/Filter
F-R lever linkage
Oil cooler
Others
Coupling
Filter/piping, etc.
Diagnosis code H-01 H-02 H-03a H-03b H-04a H-04b
4-402
Fault Finding for Hydraulic and Mechanical Systems
4-403
Fault Finding for Hydraulic and Mechanical Systems
YES
Coupling faulty. Repair or renew.
2
Is noise
coming from
Around pump.
front of
3 YES
pump? Loose suction hose clamp. Retighten.
Is pump
suction hose
NO loose?
To A on this page.
NO
1
YES
Filter clogged. Clean or renew.
Where is 4
noise coming
from? Is suction
A filter
clogged? 5 YES Propulsion pump or motor
Inspect.
Are foreign faulty.
materials or
metal chips
NO noticeable in
Operate machine for some
hydraulic oil?
time and inspect change of
NO faulty condition.
1
Such as slow speed Is oil cooler
Is machine and low traction clogged?
NO
handled as
instructed by Collaped or clogged piping. Clean or renew.
operators manual? NO
Improper handling.
Handle correctly.
(Overload operation etc.)
NO
4-404
Fault Finding for Hydraulic and Mechanical Systems
3 YES
To A on this page.
Do pump servo
YES valve and servo
linkage function
2
correctly?
Servo valve and servo linkage
Repair or renew.
YES Does F-R lever NO malfunction.
move adequately?
1
Adjust or renew.
6 YES
Parking brake faulty. Repair or renew.
Release brake by
YES screwing release
bolt. Does machine
5
run?
To B on this page.
YES Is parking brake Do this work NO
release pressure
separately for left
as specified?
and right brake units.
4
See STANDARD
Brake valve faulty. Repair or renew.
Is charge pressure VALUE CHART. NO
A
normal?
YES
Front motor faulty. Repair or renew.
8
4-405
Fault Finding for Hydraulic and Mechanical Systems
3 YES
Leaky pump servo system. Repair or renew.
With F-R lever operated,
YES is there any diffrence in
charge pressure
2 between forward travel
Do servo valve and and reversing? To A on this page.
YES servo linkage of NO
pump function
1 properly?
Clean or adjust.
YES High pressure relief valve
Renew as
faulty.
4 necessary.
Exchange high
pressure relief valve for
A forward travel with that
5 YES
for reversing. Is faulty Front motor faulty. Repair or renew.
condition reversed? Disconnect high
pressure hose from
front motor and block
NO the hose. Does rear
motor run?
Rear motor faulty. Repair or renew.
Engine: Low idle . NO
Raise rear of
machine.
4-406
Fault Finding for Hydraulic and Mechanical Systems
4-407
Fault Finding for Hydraulic and Mechanical Systems
3 YES
Leaky pump servo system. Repair or renew.
With F-R lever operated,
YES is there any diffrence in
charge pressure
2 between forward travel
Do servo valve and and reversing? To A on this page.
YES servo linkage of NO
pump function
1 properly?
Clean or adjust.
YES High pressure relief valve
Renew as
faulty.
4 necessary.
Exchange high
pressure relief valve for
A forward travel with that
5 YES
for reversing. Is faulty Excessive internal leakage. Repair or renew.
condition reversed? Is there any difference
in internal leakage in
motor between forward
NO
travel and reversing? Propulsion motor performance
Repair or renew.
lowered.
Check both motors NO
separately.
4-408
Fault Finding for Hydraulic and Mechanical Systems
1
Which is
faulty? Front
vibrator or 2 Vibrator solenoid valve faulty. Renew.
rear or both? Disconnect outlet
hoses from vibrator
Front solenoid valve and
or reconnect so that
their connecting 3 YES
rear Vibrator motor faulty. Repair of renew.
locations are changed Is relief pressure
with each other. as specified with
hose blocked at
motor inlet port?
Vibrator pump faulty. Repair of renew.
12.7MPa NO
(1840psi)
2
{130kgf/cm )
YES
1 Vibrator solenoid valve faulty. Renew.
VALUE CHART.
4-409
Fault Finding for Hydraulic and Mechanical Systems
YES
Steering mechanism faulty. Repair.
Disassemble
3 YES and clean.
Steering column faulty.
Does steering Renew as
necessary.
YES become light if
steering column is
disassembled and
repaired?
1 Steering mechanism faulty. Repair.
NO
Is relief pressure as
specified?
YES Foreign matter in Orbitrol relief
Clean or renew.
valve or low pressure setting.
3
See STANDARD
Does Orbitrol
VALUE CHART.
restore normal
condition if
NO 4 YES Lowered performance of
disassembled and Renew.
steering pump.
cleaned?
Is leak at steering
cylinder normal?
NO
4-410
Fault Finding for Hydraulic and Mechanical Systems
Is brake release
pressure as
specified?
Parking brake release
Clean or renew.
solenoid valve faulty.
See STANDARD NO
VALUE CHART.
Parking brake
switch: release position.
4-411
Fault Finding for Hydraulic and Mechanical Systems
2 YES
Filter clogged. Renew.
YES
Does filter stay
1 clogged?
4-412
No. 98056-0