Sakai Asphalt Roller SW770/770HF/770ND Tentative Service Manual - PDF DOWNLOAD

SW770/770HF/770ND TENTATIVE SHOP MANUAL This manual is a preliminary version.

Please replace with the officially published version once it is available.

3498-64315-0

SAFETY

SAFETY

1. GENERAL SAFETY 1-1. Understanding the Safety Symbols and Words The words DANGER, WARNING, and CAUTION are used with the safety-alert symbol.

DANGER identifies the most serious hazard. When the symbols DANGER, WARNING and CAUTION are displayed, become alert. Your safety or those around you may be involved.

NOTICE is used to provide important information that is not hazard related.

DANGER: I ndicates an imminently hazardous situation or condition which if not avoided can result in serious personal injury or death.

WARNING: I ndicates a potentially hazardous situation or condition which if not avoided can result in serious personal injury or death.

CAUTION: I ndicates a potentially hazardous situation or condition which if not avoided may result in moderate personal injury or damage to the machine or personal property.

(NOTICE): I ndicates important information about operation or maintenance of the machine that may cause damage, breakdown, or shortened service life of the machine if you fail to observe or important point to maintain of quality in maintenance works. ★: I ndicates 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.

In the assembly operation, tightening torque in locations that require particular N•m attention.

1-2. General • Operators and maintenance personnel must be alert to recognize and avoid potential hazards. They should also have comprehensive training, the required skills and necessary tools to perform the job safely.

• The machine was built in accordance to the latest safety standards and recognized safety rules. Nevertheless, misuse of the machine may result in risk to life and limb of the user or nearby personnel and may cause damage to the machine or other property.

• The machine must only be used for its intended purpose as described in the Operator’s Manual. It must be operated by safety-conscious persons who are fully aware of the risks involved when operating the machine. Any malfunctions especially those affecting the safety of the machine must be corrected immediately.

1-001

SAFETY

• The machine is designed specifically for the compaction of asphalt or soil road construction materials. Use of the machine for other purposes such as towing other equipment is considered contrary to the designated use. The manufacturer cannot be responsible or held liable for any damage resulting from such use. The risk for such use lies entirely with the user.

• Operating the machine within the limits of its designated use also involves compliance with the inspection and maintenance requirements contained in the Operation and Maintenance Manual.

1-3. Qualifications of Operators and Maintenance Personnel • W ork on the machine must be performed by qualified personnel only. Individual responsibilities of personnel regarding operation, maintenance, repair of the machine must be clearly stated.

• D efine the operator’s responsibilities; the operator should have authority to refuse instructions that are contrary to safety.

• Do not allow persons being trained to operate or perform maintenance on the machine without constant supervision by an experienced person.

• Work on the electrical system of the machine must be done only by an experienced person or under the 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 being used.

• The operator or user of the machine must be aware of all applicable or legal and mandatory regulations relevant to accident prevention and environmental protection. These regulations may also deal with handling of hazardous substances, the required proper personal safety and protective equipment and traffic or jobsite regulations.

• Machine operating instructions should also be supplemented with detailed instructions pertaining to the specific jobsite or work location.

• Always be sure the persons working on the machine have read the operating instructions and all safety precautions before beginning work. Reading safety instructions after work has already begun is too late.

• Wear close fitting garments and always tie back and secure long hair, also avoid wearing jewelry such as rings. Injury can result from loose clothing, hair or jewelry being caught up in the machinery or rotating parts.

• Use protective equipment as required by the circumstances or by law.

1-002

SAFETY

• Observe all safety instructions and warnings attached to the machine.

• Make sure all safety instructions and warnings on the machine are complete and perfectly legible.

• Stop the machine immediately in the event of any malfunction. Report any malfunction immediately to the supervisor or other person of authority.

• N ever perform service or maintenance on the machine unless the drums or tires are adequately blocked, articulation lock bar and pin is in the locked position and the parking brake is applied.

• N ever make any modifications to the machine which might affect safety without the manufacturer’s approval.

• Always perform the recommended routine inspections and adjustments according to the prescribed intervals.

1-5. Pre Start Inspection • Inspect your machine daily. Ensure that the routine maintenance and lubrication are properly performed. Repair or replace any malfunctioning, broken or missing parts before using the machine. Refer to the maintenance schedule in the Operator’s Manual.

• Check that all instructions and safety stickers are in place and 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 is damaged or the belt is frayed or nicked or stitching is loose. Check that mounting hardware is tight.

• Clean the steps and operating platform of dirt and foreign matter to reduce danger of slipping.

• Know how to shut-down or stop the machine immediately in case of emergency.

• Know the capabilities and limitations of the machine such as speed, gradeability, steering and braking.

• B e aware of the dimensions of the machine such as height, weight especially for transporting.

1-6. Safety Instructions • Take all necessary precautions to ensure that the machine is used only when in a safe and reliable condition.

• Avoid any operational mode that might compromise safety.

• O perate the machine only if all protective and safety devices are in place and fully functional.

• Always use the hand rails and steps to get on and off your machine maintaining 3-point contact (using both hands).

1-003

SAFETY

1-7. Starting • Start the machine only from the driver’s seat and always wear the seat belt.

• Watch that the warning lights and indicators during start-up and shutdown are working in accordance with operating instructions.

• Watch that no one is in danger before starting and when moving the machine.

• Check that braking, steering, signals and lights are fully functional before starting work or traveling with the machine.

1-8. Operating • Always make sure that there are no obstructions or persons in your line of travel before starting the compactor in motion.

• Never climb on and off the machine while it is in motion.

• Always remain seated with the seat belt fastened when traveling, compacting or loading or unloading the machine.

• Use caution and be very observant when operating in close quarters and congested areas.

• O bey all traffic regulations when working on public roads and make sure machine is compatible with these regulations.

• Never carry passengers.

• Know and use the hand signals for particular jobs and who has the responsibility for signaling.

• Do not work close to edges or in the vicinity of overhanging banks or on grades that could cause the compactor to slide or roll over. Avoid any areas that may be a risk to machine stability.

• Avoid side hill travel. Always operate up and down the slope. Always 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 anyone to stand in the articulation area of the machine when the engine is running.

• Always look in all directions before reversing the direction of travel.

• Always switch on the lighting system (if equipped) during poor visibility conditions and after dark.

• Do not attempt to control the compactor travel speed with the throttle control. Maintain engine speed at the full operating RPM. • Do not run the engine in a closed building for an extended period of time. Exhaust fumes can kill.

1-9. Stopping • Always park the machine in a safe area on solid and level ground. If this is not possible, always park at a right angle to the slope and block the drums or tires.

• Do not leave the operator’s platform with the engine running. Always move the travel lever to neutral position and apply the parking brake then turn the starter switch to OFF. • Lock all lockable compartments.

1-004

SAFETY

• Park behind a safe barrier, use proper flags, and warning devices, especially when parking in areas of heavy traffic.

1-10. Maintenance • In any performing any work concerning the operation, adjustment or modification of the machine or it’s safety devices or any work related to maintenance, inspection or repair, always follow the start-up and shut-down procedures in the Operator’s Manual and the Maintenance Manual.

• Ensure that the maintenance area is safe and secure.

• If the machine is shut down for maintenance or repair work it must be secured against inadvertent starting by removing the starter key and attaching a warning sign to the starter switch.

• The machine must be parked on stable and level ground with the drums or tires blocked to prevent inadvertent movement.

• I mmediately after the engine has stopped, the exhaust system, engine, radiator coolant, engine oil, hydraulic fluid and other lubricants and components will be very hot.

Fluids can be under pressure, removing the radiator cap or draining oil or changing filters can cause serious burns.

Wait until the machine has cooled down.

• U se care when attaching and securing lifting tackle to individual parts and large assemblies being removed or repositioned for repair purposes to avoid the risk of 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 climbing aid.

• Keep all steps, handles, handrails, platforms and ladders free from mud, dirt, grease, ice or snow.

• Clean the machine, especially threaded connections of any traces of oil or fuel before carrying out any maintenance or repairs. Never use aggressive detergents. Use lint free cleaning rags.

• E xamine all fuel, lubricant and hydraulic fluid lines and connectors for leaks, loose connections chafe marks or damage after cleaning.

• Repair or replace defective parts immediately.

• Whenever possible, avoid servicing or maintenance when the engine is running unless the drums or tires are adequately blocked, the articulation lock bar is in the locked position and the parking brake is applied.

1-005

SAFETY

• Never fill the fuel tank with the engine running, while near an open flame or while smoking.

Always clean up any spilled fuel.

• Ensure safe operation, optimum performance of the machine and its warranty by using only genuine SAKAI replacement parts.

• Use only the specified fluids and lubricants. Substitute only products known to be equivalent from reputable manufacturers.

• Disconnect the battery cables when working on the electrical system or when welding on the compactor.

• Be sure the battery area is well ventilated (clear of fumes) should it be necessary to connect a jumper cable or battery charger. Fumes can ignite from a spark and may explode.

• Be sure battery charger is OFF when making connections if charging is required.

• Use only original fuses with the specified rating. Switch off the machine immediately if trouble occurs in the electrical system.

• Work on the electrical system may only be carried out by a qualified electrician or by a specially trained person according to electrical engineering principles.

• Inspect the electrical equipment of the machine at regular intervals. Defects such as loose connections or burnt or scorched wires must be repaired or replaced immediately.

• Do not weld, flame cut or perform grinding on the machine unless expressly authorized, as there may be a risk of fire or explosion. Disconnect the battery when welding on the machine.

• Clean the machine and its surrounding from dust or other flammable substances and make sure the area is adequately ventilated before beginning welding, flame cutting 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 even after the engine has stopped.

• Do not disconnect hydraulic hoses or fittings until the pressure has been properly relieved.

• Wait until the systems and fluid have cooled down before disconnecting.

• Never use your hands to check for leaks when inspecting a hydraulic system. Use a piece of cardboard and always wear gloves and safety glasses.

• Get immediate medical attention if fluid has been injected under your skin. Fluid penetration from a pin hole leak can cause severe injury or death.

• E nsure that hydraulic lines and hoses are routed and fitted properly. Ensure that no connections are interchanged. All fittings, lengths and specifications of hoses must comply with the technical requirements.

1-006

SAFETY

• Observe all product safety regulations when handling fuel, oils, grease, engine coolant and other chemical substances. Be careful especially when these items are hot as there is a risk of burning or scalding.

• Operate internal combustion engines and fuel operated heating systems only in adequately ventilated premises. Before starting the engine in an enclosed area, make sure there is sufficient ventilation.

1-11. Transporting the Machine • Use only suitable and approved trailers and haul vehicles and lifting equipment of sufficient capacity.

• Entrust to experienced personnel the fastening and lifting of loads and instructing of crane operators.

• Only experienced persons familiar with the operation of the machine may load and unload the machine.

• Use ramps or a loading dock when loading or unloading the machine. Ramps must be the proper strength, low angle and the proper height and width.

• Block the drums or tires (front and rear) of the hauling vehicle when loading and unloading the compactor. Ensure that the haul vehicle is on level ground and approach the loading ramps squarely to make 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 down properly using the appropriate tackle.

• Know the overall height of the compactor and hauling vehicle. Observe height and weight regulations and be sure you can pass safely at overhead obstructions.

• Obey all traffic regulations and be sure that the proper clearance flags, lights and warning signs including “Slow Moving Vehicle” emblem are displayed when traveling on public roads.

• Know the approximate stopping distance at any given speed.

• Drive Safely. Never turn corners at excessive speeds.

1-007

SPECIFICATIONS

SPECIFICATIONS

1. SPECIFICATION DATA

838

00

838

∅13

00

∅13

280

838

838

2210

3080

1860

1860

1-1. SW770

1700

1800 675

1800 3600

1700 675

4950

0431-99007-0-10253-A

Model Weight

Operating weight Front axle Rear axle Overall length Overall width Overall height

Dimensions

Frame Frame Steering wheel ROPS

Wheelbase Compaction width Minimum height above ground Curb clearance Speed Forward/reverse Low amplitude Frequency High amplitude Low amplitude Vibration Centrifugal performance force High amplitude Low amplitude Amplitude High amplitude Minimum turning radius Gradability *1

10,800 kg 5,200 kg 5,600 kg 4,950 mm 1,860 mm 2,210 mm 3,080 mm 3,600 mm 1,700 mm 280 mm 838 mm 0 to 12 km/h 50 Hz 50 Hz 68 kN 132 kN 0.33 mm 0.65 mm 6.3 m 28 %

SW770 ( 23,810 lbs. ) ( 11,465 lbs. ) ( 12,345 lbs. ) ( 195 in. ) ( 73 in. ) ( 87 in. ) ( 121 in. ) ( 142 in. ) ( 67 in. ) ( 11 in. ) ( 32.5 in. ) ( 0 to 7.5 mph )

( ( ( ( ( (

*1: The gradability is the calculated value. It may vary based on the ground surface conditions.

2-001

15,285 lbs.

29,675 lbs.

0.013 in.

0.026 in.

249 in.

16 °

) ) ) ) ) )

SPECIFICATIONS Name Model Number of cylinders - Bore × Stroke Displacement Rated speed Rated output Performance

Max. torque Fuel consumption

Engine

Fuel injection system

ISUZU 4JJ1XDIA diesel engine (EPA Tier 3) with turbocharger Water-cooled, 4-cycle, 4-cylinder in-line, overhead camshaft, direct-injection type, with turbocharger 4-95.4 mm × 104.9 mm (4-3.756 in. × 4.130 in.)

2.999 L ( 183 cu.in ) 2,200 min-1

( 2,200 rpm

)

92 kW

(

123 HP

)

420 N·m

(

310 lbf·ft

)

at 1,800 min

206 g/kW·h ( 0.339 lb/HP·h ) at rated speed with silencer and air cleaner, without cooling fan Full electronic control

Fuel injection pump

Common rail HP3 TYPE

Lubrication system

Full forced pressure feed type

Oil filter

Full flow paper element

Oil cooler

Pressurized water forced circulation type

Air cleaner

Dry type

Cooling system

Centrifugal pump forced feeding system (pressure type)

Cooling fan Electrical system Transmission Power line

Vibrating system Braking device

Inhaling type Alternator

24 V 50 A

Starter

24 V 4.0 kW

Battery

12 V 80 Ah × 2 pcs. (24 V)

Type

Hydrostatic transmission

Speeds

Reverser Final drive

Planetary gear

Transmission

Hydrostatic transmission

Vibrator

Eccentric shaft type

Service brake

Hydrostatic and mechanical, multi-wet disc type

Parking brake

Mechanical, multi-wet disc type Hydraulic type (Articulated type)

Use

Front drum

Others

Vibration and driving × 1

Rear drum

Vibration and driving × 1

Dimension (width × dia.)

Front drum

1,700 mm × 1,300 mm (67 in. × 51 in.)

Rear drum

1,700 mm × 1,300 mm (67 in. × 51 in.)

Suspension system

Front drum

Rubber damper type

Rear drum

Rubber damper type

Water spray system

Fluid capacity

2 speed shifts Switching the direction of flow delivered from the variable pump

Steering system

Drums

-1

Pressurized type

Cooling water

15 L

(

Fuel tank

193 L

Engine oil pan

14 L

Vibrator case Wheel motor gear case Hydraulic oil tank

50.3 L

Sprinkler tank

1,000 L

Instruments and lights

4.0 gal.

)

(

51 gal.

)

(

3.7 gal.

)

20 L × 2

(

5.3 gal. × 2 )

2.0 L × 2

(

0.5 gal. × 2 )

(

13 gal.

)

(

264 gal.

)

1 set

2-002

SPECIFICATIONS

838

00

838

∅13

00

∅13

280

838

838

2210

3080

1860

1860

1-2. SW770HF

1700

1800

1800

675

3600

1700 675

4950

0431-99004-0-10230-A

Model Weight

Operating weight Front axle Rear axle Overall length Overall width Overall height

Dimensions

Speed

Frame Frame Steering wheel ROPS

Wheelbase Compaction width Minimum height above ground Curb clearance Forward/reverse Low amplitude Frequency High amplitude

Vibration performance

Centrifugal force

Low amplitude High amplitude

Amplitude Minimum turning radius Gradability *1

Low amplitude High amplitude

1 2 3 1 2 1 2 3 1 2

10,800 kg 5,200 kg 5,600 kg 4,950 mm 1,860 mm 2,210 mm 3,080 mm 3,600 mm 1,700 mm 280 mm 838 mm 0 to 14 km/h 42 Hz 50 Hz 67 Hz 42 Hz 50 Hz 47 kN 68 kN 120 kN 92 kN 132 kN 0.33 mm 0.65 mm 6.3 m 38 %

SW770HF ( 23,810 lbs. ) ( 11,465 lbs. ) ( 12,345 lbs. ) ( 195 in. ) ( 73 in. ) ( 87 in. ) ( 121 in. ) ( 142 in. ) ( 67 in. ) ( 11 in. ) ( 32.5 in. ) ( 0 to 8.7 mph )

( ( ( ( ( ( ( ( (

*1: The gradability is the calculated value. It may vary based on the ground surface conditions.

2-003

10,565 lbs.

15,285 lbs.

26,975 lbs.

20,680 lbs.

29,675 lbs.

0.013 in.

0.026 in.

249 in.

21 °

) ) ) ) ) ) ) ) )

SPECIFICATIONS Name Model Number of cylinders - Bore × Stroke Displacement Rated speed Rated output Performance

Max. torque Fuel consumption

Engine

Fuel injection system

ISUZU 4JJ1XDIA diesel engine (EPA Tier 3) with turbocharger Water-cooled, 4-cycle, 4-cylinder in-line, overhead camshaft, direct-injection type, with turbocharger 4-95.4 mm × 104.9 mm (4-3.756 in. × 4.130 in.)

2.999 L ( 183 cu.in ) 2,200 min-1

( 2,200 rpm

)

92 kW

(

123 HP

)

420 N·m

(

310 lbf·ft

)

at 1,800 min

206 g/kW·h ( 0.339 lb/HP·h ) at rated speed with silencer and air cleaner, without cooling fan Full electronic control

Fuel injection pump

Common rail HP3 TYPE

Lubrication system

Full forced pressure feed type

Oil filter

Full flow paper element

Oil cooler

Pressurized water forced circulation type

Air cleaner

Dry type

Cooling system

Centrifugal pump forced feeding system (pressure type)

Cooling fan Electrical system Transmission Power line

Vibrating system Braking device

Inhaling type Alternator

24 V 50 A

Starter

24 V 4.0 kW

Battery

12 V 80 Ah × 2 pcs. (24 V)

Type

Hydrostatic transmission

Speeds

Reverser

2 speed shifts Switching the direction of flow delivered from the variable pump

Final drive

Planetary gear

Transmission

Hydrostatic transmission

Vibrator

Eccentric shaft type

Service brake

Hydrostatic and mechanical, multi-wet disc type

Parking brake

Mechanical, multi-wet disc type

Steering system

Hydraulic type (Articulated type) Use

Drums

Front drum

Vibration and driving × 1

Rear drum

Vibration and driving × 1

Dimension (width × dia.)

Front drum

1,700 mm × 1,300 mm (67 in. × 51 in.)

Rear drum

1,700 mm × 1,300 mm (67 in. × 51 in.)

Suspension system

Front drum

Rubber damper type

Rear drum

Rubber damper type

Water spray system

Fluid capacity

Others

-1

Pressurized type

Cooling water

15 L

(

Fuel tank

193 L

Engine oil pan

14 L

Vibrator case Wheel motor gear case Hydraulic oil tank

50.3 L

Sprinkler tank

1,000 L

Instruments and lights

4.0 gal.

)

(

51 gal.

)

(

3.7 gal.

)

20 L × 2

(

5.3 gal. × 2 )

2.0 L × 2

(

0.5 gal. × 2 )

(

13 gal.

)

(

264 gal.

)

1 set

2-004

SPECIFICATIONS

838

00

838

∅13

00

∅13

280

838

838

2210

3080

1860

1860

1-3. SW770ND

1700

1800 675

1800 3600

1700 675

4950

0431-99015-0-10579-A

Model Weight

Operating weight Front axle Rear axle Overall length Overall width Overall height

Dimensions

Frame Frame Steering wheel ROPS

Wheelbase Compaction width Minimum height above ground Curb clearance Speed Forward/reverse Vibration Frequency Oscillation Vibration Vibration Centrifugal performance force Oscillation Vibration Amplitude Oscillation Minimum turning radius Gradability *1

11,320 kg 5,460 kg 5,860 kg 4,950 mm 1,860 mm 2,210 mm 3,080 mm 3,600 mm 1,700 mm 280 mm 838 mm 0 to 12 km/h 50 Hz 50 Hz 155 kN 162 kN 0.65 mm 0.70 mm 6.3 m 26 %

SW770ND ( 24,955 lbs. ) ( 12,035 lbs. ) ( 12,920 lbs. ) ( 195 in. ) ( 73 in. ) ( 87 in. ) ( 121 in. ) ( 142 in. ) ( 67 in. ) ( 11 in. ) ( 32.5 in. ) ( 0 to 7.5 mph )

( ( ( ( ( (

*1: The gradability is the calculated value. It may vary based on the ground surface conditions.

2-005

34,845 lbs.

36,420 lbs.

0.026 in.

0.028 in.

249 in.

15 °

) ) ) ) ) )

SPECIFICATIONS Name Model Number of cylinders - Bore × Stroke Displacement Rated speed Rated output Performance

Max. torque Fuel consumption

Engine

Fuel injection system

ISUZU 4JJ1XDIA diesel engine (EPA Tier 3) with turbocharger Water-cooled, 4-cycle, 4-cylinder in-line, overhead camshaft, direct-injection type, with turbocharger 4-95.4 mm × 104.9 mm (4-3.756 in. × 4.130 in.)

2.999 L ( 183 cu.in ) 2,200 min-1

( 2,200 rpm

)

92 kW

(

123 HP

)

420 N·m

(

310 lbf·ft

)

at 1,800 min

206 g/kW·h ( 0.339 lb/HP·h ) at rated speed with silencer and air cleaner, without cooling fan Full electronic control

Fuel injection pump

Common rail HP3 TYPE

Lubrication system

Full forced pressure feed type

Oil filter

Full flow paper element

Oil cooler

Pressurized water forced circulation type

Air cleaner

Dry type

Cooling system

Centrifugal pump forced feeding system (pressure type)

Cooling fan Electrical system Transmission Power line

Vibrating system Braking device

Inhaling type Alternator

24 V 50 A

Starter

24 V 4.0 kW

Battery

12 V 80 Ah × 2 pcs. (24 V)

Type

Hydrostatic transmission

Speeds

Reverser

2 speed shifts Switching the direction of flow delivered from the variable pump

Final drive

Planetary gear

Transmission

Hydrostatic transmission

Vibrator

Twin eccentric shaft type

Service brake

Hydrostatic and mechanical, multi-wet disc type

Parking brake

Mechanical, multi-wet disc type

Steering system

Hydraulic type (Articulated type) Use

Drums

Front drum

Vibration and driving × 1

Rear drum

Vibration and driving × 1

Dimension (width × dia.)

Front drum

1,700 mm × 1,300 mm (67 in. × 51 in.)

Rear drum

1,700 mm × 1,300 mm (67 in. × 51 in.)

Suspension system

Front drum

Rubber damper type

Rear drum

Rubber damper type

Water spray system

Fluid capacity

Others

-1

Pressurized type

Cooling water

15 L

(

Fuel tank

193 L

Engine oil pan

14 L

Vibrator case

45 L × 2

(

12 gal. × 2 )

Wheel motor gear case

2.0 L × 2

(

0.5 gal. × 2 )

Hydraulic oil tank

50.3 L

(

13 gal.

)

Sprinkler tank

1,000 L

(

264 gal.

)

Instruments and lights

4.0 gal.

)

(

51 gal.

)

(

3.7 gal.

)

1 set

2-006

SPECIFICATIONS

2. TIGHTENING TORQUE CHART

Metric fine screw

Metric coarse screw

N·m

2-007

(lbf·ft)

Strength Classification

Nominal Dia.

Pitch

5 6

0.8 1.0

4.9 7.8

(3.6) (5.8)

5.9 9.8

(4.4) (7.2)

7.8 13

(5.8) (9.6)

7.8 13

(5.8) (9.6)

8

1.25

17

(13)

23

(17)

31

(23)

31

(23)

10

1.5

39

(29)

49

(36)

59

(44)

59

(44)

12

1.75

69

(51)

78

(58)

108

(80)

108

(80)

14

2.0

98

(72)

127

(94)

167

(123)

167

(123)

16

2.0

157

(116)

196

(145)

265

(195)

265

(195)

18

2.5

196

(145)

245

(181)

343

(253)

343

(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)

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

(289)

392

(289)

20

1.5

343

(253)

441

(325)

588

(434)

588

(434)

22

1.5

490

(361)

588

(434)

785

(579)

785

(579)

24

2.0

588

(434)

735

(542)

981

(724)

981

(724)

27

2.0

834

(615)

1030

(760)

1422

(1049)

1422

(1049)

30

2.0

1177

(868)

1422

(1049)

1961

(1446)

1961

(1446)

6.8

8.8

10.9

12.9

ENGINE REMOVAL AND INSTALLATION

ENGINE REMOVAL AND INSTALLATION

1. PRECAUTIONS FOR REMOVAL AND installation • When removing or installing the engine, observe the general precautions described below.

1) Precautions for removal work • Coolant that contains antifreeze should be treated as a chemical, and must not be drained carelessly on the ground.

• To prevent dust from getting into disconnected hoses and tubes, cover them with a plug or similar means.

• When draining oil, use a receptacle with sufficient capacity to receive it.

• Before proceeding with the work, look for matchmarks that show the installation location. For reassembly, place matchmarks in the required locations to prevent errors. Then remove.

• When disconnecting wiring connectors, hold the connector components so that unreasonable force is not applied to the wires.

• Label wires and hoses to ensure correct installation location.

• Confirm the number and thickness of shims prior to storage.

• When lifting parts, use lifting equipment of sufficient capacity.

• When separating parts by using pull bolts, tighten the bolts alternately.

• Before removing a unit, clean its surrounding area. Then after removal, cover it to prevent dust and other 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 lock plates with new parts.

• Properly bend split cotter pins and lock plates.

• When applying an adhesive, first clean and remove oil/grease from the surfaces properly. Then apply two or three drops to the threaded areas.

• When applying a liquid gasket, first clean and remove oil/grease from the application surface properly, and confirm that the surface is free of dust and damage. Then apply the product evenly.

• Clean parts well. Repair scratches, dents, burrs, rust, etc.

• Apply gear oil to rotating and sliding components.

• Apply grease to the surfaces of press-fit parts.

• After installing snap rings, confirm that they are properly seated in the grooves.

• Connect wiring connectors securely after cleaning off adhering oil, dust and water.

• Use lifting bolts that are not fatigued or deformed. Screw them in fully.

• When tightening a split flange, tighten screws alternately to prevent uneven tightening.

• Before installing hydraulic parts, confirm that they are free of damage and dust, etc.

3) Precautions when work is completed • If coolant has been drained, securely retighten the drain cock and fill with coolant (mixing in longlife 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.

3-001

ENGINE REMOVAL AND INSTALLATION

2. ENGINE REMOVAL Time of procedures: • To remove engine takes about 3.5 hour × 2 people • To install the engine takes about 6 hours × 2 people Tools and equipment you need: • Box (10 mm, 12 mm, 13 mm, 17 mm, 19 mm, 24 mm) • Ratchet – big and small • Nippers • Screw Driver – “Phillips” big and small, “flat“ big • 10mm Box driver • Spanner (10 mm, 13 mm, 14 mm, 17 mm, 19 mm – 2 units, 36 mm, 41 mm) • Wrench (22-24, 17-19) mm • Handle bar • Pail can – Tank for hydraulic oil • Wire • Jack • Cap for hydraulic hose (41, 3/4* 36, 1/2* 27)

3-002

ENGINE REMOVAL AND INSTALLATION

2-1. Left and Right Side Cover Removal • Uninstall left and right side cover.

(7 bolts, 17 box); 2 people

• Uninstall 2 small and 1 big cover under radiator. (17 box)

• Uninstall left cover. (17 box)

• Remove engine coolant. Open up valve.

(Capacity 12 L. Proportion 50:50)

Right open

3-003

ENGINE REMOVAL AND INSTALLATION

2-2. Radiator Removal (Step 1) • Remove coolant tank with hose.

Remove cleaner hose. (10 box)

• Uninstall hoses connected to radiator except oil hose.

Intake hose 10 box + screw driver Coolant hose 10 box + screw driver

CAC hose

3-004

ENGINE REMOVAL AND INSTALLATION

2-2. Radiator Removal (Step 2)

Uninstall CAC hose.

Uninstall hose connected to upper part of radiator.

Oil cooler hose uninstall. (36 spanner)

Install the cap.

3-005

ENGINE REMOVAL AND INSTALLATION

2-2. Radiator Removal (Step 3) (NOTICE) • Oil cooler hose is connected with oil tank. Please use vacuum effect or put cap for oil hose to avoid oil leakage from the hose.

2100-12020-1, 4 bolts

2100-12020-1, 4 bolts

• Remove plate. 5 bolts. (17 box)

Move radiator to make a space to remove oil cooling hose. 36 spanner.

Put a cap to protect hose and radiator oil input and remove the radiator. (2 people)

3-006

ENGINE REMOVAL AND INSTALLATION

2-3. Fan and Air Cleaner Removal Unscrew 4 bolts. (12 mm box).

Correct position of fan.

Priority – order of fan elements

Remove clamp of air cleaner.

(17 mm spanner) Unscrew hose clamp. (13 mm box)

Use “flat” screw driver.

Keep this configuration of hose and air cleaner.

3-007

ENGINE REMOVAL AND INSTALLATION

2-4. Battery Relay; Bracket Removal

Unscrew 2 earth cables. (13 box)

Unscrew battery cable “positive”.

(14 spanner)

Remove battery relay with bracket.

(17 box)

Put electric wires in a safe position.

Prepare isolation.

3-008

ENGINE REMOVAL AND INSTALLATION

2-5. Engine Hoses Removal

Turbo charger hose keep in this position.

Pay attention on air sensor.

Remove from circle A in ③ photo.

CAC hose clamp. (10 box)

CAC hose clamp. (10 box)

Lower hose clamp. (10 box)

3-009

ENGINE REMOVAL AND INSTALLATION

2-6. Support Frame Removal

Keep free hose.

Unscrew 2 front bolts.

(24 box; torque 265 N·m (194 lbf·f))

Be careful on water sensor temperature.

Be careful. Washers inside.

Unscrew back side 4 bolts.

(24 box. Torque 265 N·m (194 lbf·f))

Push up a frame to unload the front frame. Use Jack.

• Lift up a little bit upper frame and take out bolts and remove the frame.

3-010

ENGINE REMOVAL AND INSTALLATION

2-7. Hydraulic Hose Removal

Disconnect vibration pressure oil hose and put cap.

(36 Spanner)

Remove 2 clamp hose brackets.

Remove pipe frame above the engine.

4 bolts. (19 box)

Need two people for this operation.

Lift up hydr. and elect. hoses and remove carefully pipe frame from below.

3-011

ENGINE REMOVAL AND INSTALLATION

2-8. Exhaust System Removal

Unscrew 4 bolts. (17 box)

Make loose of the clamp and remove exhaust pipe.

Remove clamp. (17 box and wrench)

Unscrew 3 nuts of exhaust pipe and rotate the pipe remove it from the machine.

3-012

ENGINE REMOVAL AND INSTALLATION

2-9. Main Hydraulic Pump Removal Remove carefully cables.

(10 box, spanner, 19 spanner × 2).

Unscrew and push aside electric harness.

• Unscrew main hydr. pump. (use 24 – 22 wrench. 24 box and handle bar) Do it with two people.

Fix pump and hoses by ropes.

Use wood block and put under the pump as a base.

Remove cable bracket from the engine.

3-013

ENGINE REMOVAL AND INSTALLATION

2-10. Bolts and Hoses Removal (NOTICE) • Remove below bolts and hoses before removing engine.

Engine oil drain hose. (U bolt. 13 box)

Pay attention on hose.

Unscrew hose clamp. (13 box, 3 clamps.)

Engine earth cables. (19 box)

Starter cable. (13 spanner) 2 bolts are on the other side.

Engines 4 bolts.

(24 box. Torque 265 N·m (194 lbf·f)

3-014

ENGINE REMOVAL AND INSTALLATION

2-11. Hoses Removal Cut hose clamp

Engine electric harness - disconnect

Unscrew oil tank hose. (41 spanner)

Use vacuum effect if possible.

(Connect flowing high pressure air to the oil tank to avoid leakage of hydraulic hose during unscrew the hose from oil cooler).

Keep engines harness and hoses in a good condition

Keep tight all of the wires, harness and hoses.

Use ropes.

3-015

ENGINE REMOVAL AND INSTALLATION

2-12. Engine Removal (Step 1)

Use crane. Fix 2 ropes in special lifting points.

Hydraulic Pump must be separate.

• Pay attention during lifting up the engine.

Pay attention on all cables, harness and hoses.

After you will lift up the engine, please remove steering hydraulic hoses.

3-016

ENGINE REMOVAL AND INSTALLATION

2-12. Engine Removal (Step 2)

Be careful to not hit engine to front bracket frame.

• Keep fuel hose clean. Protect against dust.

• Keep clean other hoses.

• Protect engine intake system.

3. ENGINE INSTALLATION Installation process of the engine is exactly opposite order of removing process.

3-017

SYSTEM CIRCUIT DIAGRAMS

SYSTEM CIRCUIT DIAGRAMS

1. Hydraulic circuit diagrams 3/8" M18×1.5

1/2" 1/2" 1/2"

1/4" M14×1.5

G

Lo→Ｈi 1.0MPa

R1 T2

PS1

G1

MB1

a

WIRING HARNESS (SOL.D)

PS2

SAE 3/4

WIRING HARNESS b (SOL.C)

3/4 -16UNF

1 1/16 -12UN

1 1/16 -12UN

5/8"

1700

MB2

SAE 3/4 54.8 /25.5 cc/rev

33.0ＭＰa

46.0 cc/rev

1.6MPa SAE 3/4

32.0 cc/rev

9/16 -18UNF

∅1.6

30.0MPa

∅1.4

32.5ＭＰa

33.0ＭＰa

3/8" 1/4" M14×1.5

G

R2 T3 X3 7/8 9/16 -14UNF -18UNF

MA1

7/16 -20UNF

Lo→Ｈi 1.0MPa

1 1/16 -12UN

1 1/16 -12UN

34.5ＭＰa

7/87/16 14UNF -20UNF

X4

MA2

1700

SAE 3/4

SAE 3/4 54.8 /25.5 cc/rev

1/2" SAE 3/4

9/16 -18UNF

G1/4

3/8"

G1/4

3/8"

Rc3/8

REAR

i=43.80 1.6MPa

1/4"

1/4"

1/2" Rc3/8

1/4"

M18×1.5

1.9MPa

2.4MPa

1/4"

1/2" G1/4

∅1.5

M

3/4"

G1/4 L

G3/8 G3/8 N

1/2" 1 1/16 -12UN

G1/2

1 1/16 -12UN

G3/8

5/8"

BETA5μm=2

3/8"

1 1/16 -12UN 1 1/16 -12UN

∅70X∅35-380 st

9/6 -18UNF

WIRING a HARNESS (SOL.A)

3/4 -16UNF

G3/4

MP

3/8"

15.0Mpa

400

3/8"

5/8"

(A1)(A1)

3/4 -16UNF

3/4 -16UNF

1/2"

3/4 -16UNF

1 1/16 -12UN

31.5MPa

REAR

23.5 cc/rev

1 1/16 -12UN

9/6 -18UNF

3/4 -16UNF

3/8"

3/8"

3/4 -16UNF

3/4 -16UNF

3/8"

3/4"

J1

∅70X∅35-380 st

1 1/16 -12UN

FRONT

23.5 cc/rev

1 1/16 -12UN

5/8"

G1/2

3/4"

0.35MPa G3/4

7/8 -14UNF

G1

WIRING HARNESS b (SOL.B)

G3/8

23.7 cc/rev

i=1:1

(B1)(B1)

G3/4

3/4 -16UNF

3/4 -16UNF

5/8"

G1/2

3/8"

G1/2

1/2"

5/8"

cc/rev

1 1/16 -12UN

3/4 -16UNF

3/8"

G1/2

150mesh

3/4"

1/2"

1/2"

7/8 -14UNF

1"

ENGINE (ISUZU 4JJ1 92.0kW/2200rpm) HIGH IDLE 2475rpm

FRONT

i=43.80

34.5ＭＰa

∅1300

3/8"

∅1300

1-1. SW770, 770ND

0431-99005-0-10249-A

4-001

SYSTEM CIRCUIT DIAGRAMS

1-2. SW770HF 3/8" M18×1.5

1/2" 1/2" 1/2"

1/4" M14×1.5

G

PS1

G1

MB1

a

b

WIRING HARNESS (SOL.C)

PS2

1 1/16 -12UN

3/4 -16UNF

WIRING HARNESS (SOL.D)

Lo→Ｈi 1.0MPa

1700

MB2

SAE 3/4 54.8 /25.5 cc/rev

43.0ＭＰa

1.6MPa SAE 3/4

46.0 cc/rev

9/16 -18UNF

1.9MPa

2.5MPa

32.0ＭＰa

∅1.6

40.0MPa 43.0ＭＰa

3/8" 1/4" M14×1.5

G

7/16 -20UNF

MH

7/16 -20UNF

Lo→Ｈi 1.0MPa

1 1/16 -12UN

1 1/16 -12UN

35.0ＭＰa

1 1/16 -12UN

R2 T3 X3 7/8 9/16 -14UNF -18UNF

MA1

X4

MA2

1700

1 1/16 -12UN

SAE 3/4 54.8 /25.5 cc/rev

1/2" SAE 3/4

9/16 -18UNF

G1/4

3/8"

G1/4

3/8"

Rc3/8

REAR

i=43.80 1.6MPa

1/4"

1/4"

1/2" Rc3/8

1/4"

M18×1.5

56.0 cc/rev

1/4"

1/2" G1/4

∅1.5

M

3/4"

G1/4 L

G3/8 G3/8 N

1/2" 1 1/16 -12UN

G1/2

1 1/16 -12UN

G3/8

5/8"

BETA5μm=2

3/8"

1 1/16 -12UN 1 1/16 -12UN

∅70X∅35-380 st

9/16 -18UNF

WIRING a HARNESS (SOL.A)

3/4 -16UNF

3/8"

5/8"

5/8"

1 1/16 -12UN

(B1)(B1)

G3/4

3/4 -16UNF

G1/2

3/8"

3/8"

5/8"

3/8"

WIRING HARNESS b (SOL.B)

G3/8

3/4"

J1

∅70X∅35-380 st

FRONT

23.5 cc/rev

5/8"

3/4"

0.35MPa G3/4 G1/2

3/8"

7/8 -14UNF

1 1/16 -12UN

1 1/16 -12UN

G1/2

G1

i=1:1

3/4 -16UNF

9/16 -18UNF

3/4 -16UNF

23.7 cc/rev

MP

3/4 -16UNF

3/4 -16UNF

400 cc/rev

3/4 -16UNF

G3/4

3/8"

15.0Mpa

1/2"

(A1)(A1)

3/4 -16UNF

3/4 -16UNF

1/2"

REAR

23.5 cc/rev

1 1/16 -12UN

31.5MPa

1"

1 1/16 -12UN

3/4 -16UNF

3/8"

G1/2

1/2"

1/2"

7/8 -14UNF

150mesh

3/4"

ENGINE (ISUZU 4JJ1 92.0kW/2200rpm) HIGH IDLE 2475rpm

FRONT

i=43.80

35.0ＭＰa

∅1300

R1 T2

1 1/16 -12UN

1 1/16 -12UN

5/8"

∅1300

3/8"

0431-99002-0-10228-A

4-002

SYSTEM CIRCUIT DIAGRAMS

2. electrical circuit diagrams 1-1. SW770, 770ND

LIGHT L-H SW.

GR

49 G

GY 49 G

Hi

1 42 1.25WG

2

F01 F02 F03 F04 F05 F06 F07 F08

ENGINE 4JJ1X

116 L 117 1.25Y 118 1.25R 119 1.25L 120 1.25G 121 1.25P 122 1.25O 123 YG 124 RW 125 RB

128 GB 129 WL 130 WB 131 WR

1 3

5 16 LgR

1

2 B

2

R

142 GW

19 LW

143 LW

18 L

144 L

27 1.25RG

2 B

SOL.A(F) VIB.BLOCK SOL.B(R) SOL.C(L) VIB.PUMP SOL.D(H)

TURN SIGNAL LAMP(R)(21W) BACK-UP LAMP(21W)

17 G

2 3

COM

OPTION 14 RL

51 RY

GR

LICENSE LAMP (12W×2)

16

19 LW

1

2

4

3 18 L 5

17 G NO

R

BACK BUZZER

2 1.25B

VIB.L-H CHANGE SWITCH

NC

FLOOD LAMP (55W)

RY

2 B

27 1.25RG

FLOOD LAMP (55W)

RY

6

VIB. F-R LEVER SWITCH

73 LY

WATER MODE CHANGE RELAY

2

10

9

6

5

4

3

2

2 B

9

8

7

6

5

4

3

HORN

HORN SWITCH

52 BY 5

COMBINATION METER

1

51 RY

R

40 GR

G

45 GY

GR

14 RL

RY

BACK-UP LAMP(21W) TURN SIGNAL LAMP(L)(21W) STOP LAMP(21W) TAIL LAMP(5W)

2

1

L

B

R

E

5

3 34 BW

2

1

2B

21 WY

ACC

81 BR

2

INTERLOCK RELAY(A)

INTERLOCK RELAY(B)

C

E110 TACHO E103 METER E111 SENSOR

15 RB

77 RW

15 RB

78 RY

BR

ECM

1 5R

F.L.65A

91 5WY

BATTERY RELAY

75 WL

GLOW PLUG

28 5G 2

1

15 RB

(E) 2 B

-

+

12V 95D31R

F.L.65A

32 5WR

-

12V 95D31R BATTERY

(M+)

75 WL

F.L.65A 43 5R

AV60 B (HEB 60)

+

(B)

54 L 4

77 RW

89 GW

THERMO UNIT

5 58 1.25LY

78 RY 25 RB

23 YB

23 YB

R

THROTTLE POSITION SENSOR

163 R 164 B 165 W 166 X

2 B

FUSE 30A

32 1.25WR

32 WR

FUSE 10A

2 B 1

15 RB

2 B

3

V40 OS-MAINER V21 OS-MAINER V5 PS-+B V2 PS-+B V10 OS-GLOWR V24 IS-IGKEY V6 OS-DIAG V7 OS-BOOST V11 OS-GLOWL V17 OS-OILPL V42 SP-5V1 V41 SG-5VRT1 V63 IA-ACCEL1 V64 IA-ACCEL2 V20 SG-SLD1 V1 PG-POWER V3 PG-POWER V4 PG-POWER V43 PG-SIGN V62 PG-SIGN

62 LW 3

5 63 BY

59 BR

ECM IS MDMAP0 V49 IS-MDMAP1 V50 IS-MDMAP1 V51 IS-DIAG V52 CC-KW2000 V38 CC-CAN-H V18 CC-CAN-L V37 SP-5V2 V61 SG-5VRT2 V60 IA-BARO V71 IA-IAT V72

IS-MEMCL V32 PG-CASE V81

94 RL

96 RW

2 95 RY 3

94 RL 96 RW

95 RY 5

80 L 134 BrW

135 LgR

135 LgR

87 Lg 83 Br

74 G 2

79 G

a BAROMETRIC b PRESSURE SENSOR c

3 15 RB

2 B

134 BrW

86 LW

FUEL PUMP IDLE RELAY

95 RY

80 L

85 WG

2

FUEL PUMP RELAY

5 6 THROTTLE SWITCH

79 G

2 B

2 B 1

2

MAIN RELAY

+V B GND W OUT

HYD.FILTER SWITCH

F.L.65A

32 5WR

61 WL

54 L

62 LW

TEMP. 50-103℃ SET TEMP.CURVE SEL. 1 2 OPNE OPNE

STARTER MOTOR

(M-) 36 WG

36 WG

59 1.25BR

BOOST LAMP

98 WL

FUEL UNIT

AV60 B (HEB 60)

E

3

3

64 BrR

2 B

5

LAMP CHECK RELAY

GLOW RELAY

2 B

122 PULS/REV SET REV RATIO SEL. 1 2 3 4 OPNE GND GND OPNE

B

2B

32 5WR

B

1.25BR

COMBI.METER SET

C

68 5Y

1 35 R

64 BrR

33 R

B Y YR YW BrW GR GW G W GY RB GB OG LgY WB OW

39 GB

2

72 5WB

STARTER SWITCH

59

E92 E93 E94

2B 1

DELAY RELAY

ALTERNATOR

57 5R

3 75 WL

65 WG

2B

35 R

3 24 BrR

ENG.CHECK LAMP

15 RB

32 WR 5

E

65 WG 2 2B

98 WL 98 2WL

2 B

R P O WR GL LR YL LW Br LB L

76 G

C

1

25 3 10 15 15 1 20 15 30 20 A A A A A A A A A A 10

68 5Y

7

B

72 5WB

8

67 BW

2 B

R

65 WG

S

92 5WY

50 P 1

HORN RELAY

E121 E116 E119 E118 E120 E117 E83 E105 E113 E89 E97

SAFETY RELAY

2LB

4

SPEED CHANGE SOL.VALVE SOL

93 O

5 53 GY

41 YL

OVER HEAT LAMP

127 GW

11 GW

31 5WR

41 YL 3

E100 E87 E82 E90 E101 E84 V80 V67 V79 V74 E91

NO USE

126 GY

3

71 LW

81 BR

25 RB

115 BR

56 Lg

74 G

8

26 YL

2 6

14 RL

114 BY

55 LY

C D 19 LW 18 L

16 1 LgR

4 73 LY

33 R

9 WR 1

2

20 Y

113 LY

141 GR

LgR

68 5Y

E98

40 GR

112 WB

4

7 LR

65 WG

SPEED CHANGE SWITCH

84 BY

111 RB

WATER MODE CHANGE SWITCH

42 2WG

3

5

27 RG

110 B

2

WATER SPRAY TIMER

73 LY

6

1

2

2 B

G04 G06

30 GW 1

PARKING BRAKE SWITCH

14 RL

109 R

2

4

3 5

LB

5

2B

22 LR

O/H SW.(OEM) W/T SENS.(OEM)

E108 E107 E109 E95

15 2RB

108 W

8

74 G 1

2

51 RY

TAIL LAMP(5W) STOP LAMP(21W)

2 B

13 YB

G03

45 GY

3 107 X

5 38 YR 3

1

LB

12 GR

VIB.CONT-AUTO CHANGE SWITCH

61 WL

106 R

PARKING BRAKE RELAY

I 60 LR

Diode unit

7 LR

57 2R

105 W

66 GR 3

3 11 GW 5

8

PEDAL BRAKE RELAY

B

4

57 2R

104 B

G01 G02

SCV-LOW

EGR SENSOR VCC EGR SENSOR W EGR SENSOR V EGR SENSOR U EGR SENSOR GND EGR MOTOR W EGR MOTOR V EGR MOTOR U

103 R

W

B Br BrW G GB GL GR GW GY L LB LR LW LgY O OG OW P R RB W WB WR Y YL YR YW

E01 E02 E05 E06 E07 E08

FT SENSOR SCV-HI

102 X

NO COM

R

9 WR

9 1.25WR

3

NC

2

GND WATER SPRAY LAMP CHECK HYD.PRESSURE REV RATIO SEL.2 TURN SIGNAL(R) PARKING BRAKE HYD.FILTER GLOW VIBRATING LIQUIT SPRAY TURN SIGNAL(L) FLOOD LAMP REV RATIO SEL.4 REV PULSE INPUT・1 REV RATIO SEL.3 TEMP.CURVE SEL.2 KEY SW.(ACC) 24V(+) REV RATIO SEL.1 ELEC.CHG.WARNING TEMP.CURVE SEL.1 LIGHTING REV PULSE INPUT・2 POSITION LIGHT FUEL METER TEMP.METER

INJ-COM1 INJ-COM2 INJ-CYL#1 INJ-CYL#2 INJ-CYL#3 INJ-CYL#4

W

37 WB

Y

D14 D07 D09 D10 D11 D15 D16

W R

1

2

66 GR

2 B

PC GND ENG.W/T ENG.O/P VCC ENG.O/P OUT ENG.O/P GND BT SENSOR BP VOUT

B

COM NO NC

B

LIGHTING SWITCH 27 1.25RG

D03 D02 D01 D04 D17 D08 D05 D18 D19 D06 D12 D13

W B

R

6

FLOOD LAMP SWITCH

NE SLD NE OUT NE GND NE VCC BP GND BP VCC G OUT G GND G VCC G&PC SLD PC VCC PC OUT

R

4 42 2WG

COM

1

46 BrB

G

A B C D E F G H I

VIB.F-R CHANGE SWITCH

3 30 GW

5

2B

B

12 GR

9 WR

41 YL

2 B

NO COM

66 GR

NC

A

2 B

P

GR

39 GB

2 B

84 BY

GH

F

(B)

6

HOLDING RELAY

92 WY

14 RL

2 B

NC

NO

PEDAL BRAKE SWITCH

92 1.25WY

Y

VIB.AUTO SWITCH

30 GW

40 GR

BACKUP SWITCH

92 WY

G

44 1.25Lg

3 5

FORWARD

L B E

2 1 42 2WG

14 RL

TURN SIGNAL LAMP(L) (25W) SIDE MARKER LAMP (5W)

FLASHER UNIT

WATER SPRAY RELAY(B)

15 2RB

2 B

REVERSE

9 WR

48 RW

40 GR

7

16 LgR

R

G

21 WY

47 RB

39 GB

9 WR

Lo W

INTERLOCK SWITCH

5

2

E

WATER PUMP (B)

15A FUSE HOLDER

RY

45 GY

20 Y

2 B

P

6 2W

60 2LR

2 B

92 WY

2 B

HEAD LAMP 75/70W

2

4 6

5 60 1.25LR

1

98 2WL

48 1.25RW 3

15A FUSE HOLDER

2

70 BrR

57 R

48 RW

70 BrR

2 WATER SPRAY SWITCH (PUMP B)

67 BW

R Hi

2 B

3 2WR

55 2LY

2 B 1

57 R

47 1.25RB 1

56 Lg 1

46 BrB

SOL

5 55 1.25LY

BrW

8 1.25LB 3

52 BY

47 RB

SERVO SOL.VALVE

29 YW

Lo W

TURN SIGNAL SWITCH

5

WATER PUMP (A)

2 B

6

8 1.25LB 3

5 BrW

2 WATER SPRAY SWITCH (PUMP A)

46 BrB

SOL

2 B

46 BrB

4 49 G

WATER SPRAY RELAY(A)

56 Lg 1

26 YL

3 5

40 GR

2 B

BRAKE SOL.VALVE

1 49 G

STOP

2

30 GW

39 GB

41 YL

14 RL

51 RY

39 GB

Y

89 GW

HEAD LAMP 75/70W

G

44 1.25Lg

TURN SIGNAL LAMP(R) (25W) SIDE MARKER LAMP (5W)

HAZARD SWITCH

14 RL

2 B

1 7

TERMINAL FOR TOOL 14 (TECH2) 5 6

1

79 G

2 B

2 1 DIAGNOSIS SWITCH

4

INTAKE AIR TEMP. SENSOR

133 BW

132 2B

TERMINAL FOR MEMORY CLEAR

0431-99006-0-10250-B

4-003

SYSTEM CIRCUIT DIAGRAMS

1-2. SW770HF

G04 G06 F01 F02 F03 F04 F05 F06 F07 F08

ENGINE 4JJ1X

116 L 117 1.25Y 118 1.25R 119 1.25L 120 1.25G 121 1.25P 122 1.25O 123 YG 124 RW 125 RB

NO USE

127 GW 128 GB 129 WL 130 WB 131 WR

8

7

6

5

4

3

2

COMBINATION METER

2 B

B

R

5

3 34 BW

2

1

2B

ACC

81 BR

2

INTERLOCK RELAY(A)

C BR

E110 E103 TACHO METER E111 SENSOR

15 RB

77 RW

15 RB

78 RY

ECM

TEMP. 50-103℃ SET TEMP.CURVE SEL. 1 2 OPNE OPNE

2B

26

43 37

14 RL

SOL.D(L) VIB.PUMP SOL.C(H) SOL.B(R) VIB.BLOCK SOL.A(F)

44

160 W

3 51

39

50

18

24

17

52

7

2 28

51 RY

154 O

LICENSE LAMP (12W×2)

R

BACK BUZZER

155 LW 156 B 27 1.25RG

157 Lg

FLOOD LAMP (55W)

RY

2 B

H B D

51 RY

R

157 Lg

40 GR

G

156 B

45 GY

GR

155 LW

14 RL

RY

BACK-UP LAMP(21W)

154 O

C

TURN SIGNAL LAMP(L)(21W) STOP LAMP(21W) TAIL LAMP(5W) 2 B

9 WR

A F

2 B

G

STD /OPT SEL.

GR

2 1.25B

8 20

167 Y 169 YR

144 L

OPTION

40

22

FLOOD LAMP (55W)

RY

143 LW

2 B

RC2-2/21

32

DIAGNOSTIC CONNECTOR

3 5

E

2

B

2B 5

158 LB

C

68 5Y

1 35 R

AV60 B (HEB 60)

E

3

LAMP CHECK RELAY

STARTER MOTOR

F.L.65A

1 5R

F.L.65A

91 5WY

BATTERY RELAY (M-)

36 WG

75 WL

(B)

GLOW PLUG

28 5G 2

(E)

1 43 5R

15 RB

F.L.65A

-

+

12V 95D31R

F.L.65A

32 5WR

-

12V 95D31R BATTERY

(M+)

2 B

160 W

VIB.ERROR LAMP

AV60 B (HEB 60)

+

75 WL 32 5WR

54 L 4

77 RW

THERMO UNIT

5 58 1.25LY

78 RY 25 RB

23 YB

23 YB

R

THROTTLE POSITION SENSOR

163 R 164 B 165 W 166 X

2 B

FUSE 30A

32 1.25WR

32 WR

FUSE 10A

2B 1

15 RB

2 B

3

V40 OS-MAINER V21 OS-MAINER V5 PS-+B V2 PS-+B V10 OS-GLOWR V24 IS-IGKEY V6 OS-DIAG V7 OS-BOOST V11 OS-GLOWL V17 OS-OILPL V42 SP-5V1 V41 SG-5VRT1 V63 IA-ACCEL1 V64 IA-ACCEL2 V20 SG-SLD1 V1 PG-POWER V3 PG-POWER V4 PG-POWER V43 PG-SIGN V62 PG-SIGN

62 LW 3

5 63 BY

59 BR

ECM IS MDMAP0 V49 IS-MDMAP1 V50 IS-MDMAP1 V51 IS-DIAG V52 CC-KW2000 V38 CC-CAN-H V18 CC-CAN-L V37 SP-5V2 V61 SG-5VRT2 V60 IA-BARO V71 IA-IAT V72

IS-MEMCL V32 PG-CASE V81

94 RL

96 RW

2 95 RY 3

94 RL 96 RW

95 RY 5

80 L

134 BrW

134 BrW

87 Lg 83 Br

74 G 2

79 G

86 LW

3 15 RB

2 B

80 L

135 LgR

a BAROMETRIC b PRESSURE SENSOR c

FUEL PUMP IDLE RELAY

95 RY

79 G

85 WG

2

FUEL PUMP RELAY

5 6 THROTTLE SWITCH

135 LgR

2 B

2 B 1

2

MAIN RELAY

+V B GND W OUT

HYD.FILTER SWITCH

2

45

191 YG

2 B 1

64 BrR

61 WL

54 L

89 GW

FUEL UNIT

TURN SIGNAL LAMP(R)(21W) BACK-UP LAMP(21W)

DELAY RELAY

36 WG

59 1.25BR

BOOST LAMP

62 LW

2B

171 B

6

3

64 BrR

122 PULS/REV SET REV RATIO SEL. 1 2 3 4 OPNE GND GND OPNE

R

GLOW RELAY

98 WL

COMBI.METER SET

170 RW

6

169 YR

3 75 WL

65 WG

2 B

33 R

2 B

E92 E93 E94

4

3 18 L 5

170 RW 4

32 5WR

B

1.25BR

15 RB

32 WR 5

E

STARTER SWITCH

59

39 GB

167 Y

AUTO /MANU SEL.

ALTERNATOR

57 5R

51 RY

TAIL LAMP(5W) STOP LAMP(21W)

72 5WB

L

E

168 P

2

17 G NO

VIB.F-R LEVER SWITCH

65 WG 2

1

135 LgR

1

NC

33

25

134 BrW

19 LW

11

34

140 G

VIB.L-H CHANGE SWITCH

30

48

140 G

VIB. FREQUENCY SELECT 168 P 1 SWITCH

16 LgR

C

18 L

35 R

3 24 BrR

INTERLOCK RELAY(B)

B Y YR YW BrW GR GW G W GY RB GB OG LgY WB OW

R P O WR GL LR YL LW Br LB L

76 G

COM 9

1

98 WL 98 2WL

21 WY

17 G

2 3

73 LY

72 5WB

68 5Y

67 BW 2

65 WG

8 2LB

3

B

G

27 1.25RG

142 GW

31

10

31 5WR

2B

9

1

OVER HEAT LAMP 126 GY

4

ENG.CHECK LAMP

E121 E116 E119 E118 E120 E117 E83 E105 E113 E89 E97

5

R

61 WL

115 BR

6

10

25 RB

114 BY

7

HORN SWITCH

14 RL

113 LY

2

WATER MODE CHANGE RELAY

25 3 10 15 15 1 20 15 30 20 A A A A A A A A A A

2B

20 Y

112 WB

8

52 BY 5

40 GR

111 RB

2

9

HORN

50 P 1

HORN RELAY

10

1

92 5WY

5 53 GY

41 YL

84 BY

110 B

2B

B Br BrW G GB GL GR GW GY L LB LR LW LgY O OG OW P R RB W WB WR Y YL YR YW

109 R

41 YL 3

E100 E87 E82 E90 E101 E84 V80 V67 V79 V74 E91

1

2 B

33 R

93 O

5 16 LgR

68 5Y

9 WR 1

2

SPEED CHANGE SOL.VALVE SOL

71 LW

81 BR 42 2WG

4

19 LW

4 73 LY

3

S

9 1.25WR

26 YL

56 Lg

74 G

2 B

O/H SW.(OEM) W/T SENS.(OEM)

3 2 6

A B C D E F G H I

WR

SAFETY RELAY

22 LR

G03

EGR SENSOR VCC EGR SENSOR W EGR SENSOR V EGR SENSOR U EGR SENSOR GND EGR MOTOR W EGR MOTOR V EGR MOTOR U

108 W

G01 G02

SCV-LOW

E98

15 2RB

FT SENSOR SCV-HI

30 GW 1

5

SPEED CHANGE SWITCH

1

2

16 LgR

WR

73 LY

WATER MODE CHANGE SWITCH

2B

3 107 X

2

4

3 5

Diode unit

9

7 LR

GND WATER SPRAY LAMP CHECK HYD.PRESSURE REV RATIO SEL.2 TURN SIGNAL(R) PARKING BRAKE HYD.FILTER GLOW VIBRATING LIQUIT SPRAY TURN SIGNAL(L) FLOOD LAMP REV RATIO SEL.4 REV PULSE INPUT・1 REV RATIO SEL.3 TEMP.CURVE SEL.2 KEY SW.(ACC) 24V(+) REV RATIO SEL.1 ELEC.CHG.WARNING TEMP.CURVE SEL.1 LIGHTING REV PULSE INPUT・2 POSITION LIGHT FUEL METER TEMP.METER

E01 E02 E05 E06 E07 E08

106 R

1

2

4

1 3

7 LR

6

5

74 G

PARKING BRAKE SWITCH

89 GW

INJ-COM1 INJ-COM2 INJ-CYL#1 INJ-CYL#2 INJ-CYL#3 INJ-CYL#4

105 W

E108 E107 E109 E95

Y

D14 D07 D09 D10 D11 D15 D16

104 B

45 GY

8 LB

1

41 YL

2

103 R

5 38 YR 3

37 WB

1 42 1.25WG

102 X

66 GR 3

92 WY

66 GR

8 LB

PARKING BRAKE RELAY

158 LB

3

PEDAL BRAKE RELAY

R W B

6

2 B

PC GND ENG.W/T ENG.O/P VCC ENG.O/P OUT ENG.O/P GND BT SENSOR BP VOUT

NC NO COM

92 1.25WY

27 1.25RG

D03 D02 D01 D04 D17 D08 D05 D18 D19 D06 D12 D13

W R

LIGHTING SWITCH

FLOOD LAMP SWITCH

NE SLD NE OUT NE GND NE VCC BP GND BP VCC G OUT G GND G VCC G&PC SLD PC VCC PC OUT

B

COM NO NC

B

1

2

30 GW

2 B

W B

R

46 BrB

15 2RB

Y

44 1.25Lg

R

W

VIB.F-R CHANGE SWITCH

3 30 GW

5

2B

137 RY

40 GR 14 RL

2B

COM

9 WR

G

4 42 2WG

NO COM

27 RG

TURN SIGNAL LAMP(L) (25W) SIDE MARKER LAMP (5W)

1 42 2WG

3 5

NC

66 GR

NC

98 2WL

14 RL

2

NO

2

WATER SPRAY TIMER

11 GW

141 GR

29 15

1 27

12 GR

18 L

VIB.CONT-AUTO CHANGE SWITCH

6

HOLDING RELAY

57 R

2 B

L B E

4

3 11 GW 5

41 42

137 RY

C D 19 LW

B

12 GR

2

136 RB

I 60 LR 55 LY

A

2 B

P

GR

39 GB

2 B

84 BY

GH

F

(B)

1

9 WR

92 WY

49 G

Hi

FLASHER UNIT

PEDAL BRAKE SWITCH

16 LgR

48 RW

GY

9 WR

VIB.AUTO SWITCH

21 WY

R

49 G

BACKUP SWITCH

9 WR

47 RB

GR

WATER SPRAY RELAY(B)

FORWARD

14 RL

HEAD LAMP 75/70W

Lo W

40 GR

REVERSE

7

G

39 GB

2

E

WATER PUMP (B)

15A FUSE HOLDER

RY

45 GY

20 Y

2 B

P

6 2W

60 2LR

2 B 1

67 BW

2 B

INTERLOCK SWITCH

5

4 6

5 60 1.25LR

136 RB

48 1.25RW 3

2 WATER SPRAY SWITCH (PUMP B)

57 R

48 RW

SOL

2 B

15A FUSE HOLDER

2

70 BrR

52 BY

R Hi

2

70 BrR

29 YW

47 1.25RB 1

56 Lg 1

46 BrB

1 8 1.25LB 3

3 2WR

55 2LY

2 B

26 YL

47 RB

SERVO SOL.VALVE

5 55 1.25LY

BrW

46 BrB

LIGHT L-H SW.

Lo W

TURN SIGNAL SWITCH

5

92 WY

6

8 1.25LB 3

5 BrW

2 WATER SPRAY SWITCH (PUMP A)

46 BrB

SOL

2 B

WATER PUMP (A)

57 2R

3 5 4 49 G

40 GR

2 B

WATER SPRAY RELAY(A)

56 Lg 1

65 WG

BRAKE SOL.VALVE

57 2R

1 49 G

STOP

2

30 GW

39 GB

41 YL

14 RL

51 RY

39 GB

Y

13 YB

HEAD LAMP 75/70W

G

44 1.25Lg

TURN SIGNAL LAMP(R) (25W) SIDE MARKER LAMP (5W)

HAZARD SWITCH

14 RL

2 B

1 7

TERMINAL FOR TOOL 14 (TECH2) 5 6

1

79 G

2 B

2 1 DIAGNOSIS SWITCH

4

INTAKE AIR TEMP. SENSOR

133 BW

132 2B

TERMINAL FOR MEMORY CLEAR

0431-99003-0-10229-A

4-004

HYDRAULIC PUMP AND MOTORS LOCATION

HYDRAULIC PUMP AND MOTORS LOCATION

1. Location (1/5)

15°

Valve block assembly

D

TO FRONT DRUM TO

D

BE BF

TO

SECTION X-X Valve block assembly

TO TO

TO

TO

PA1/PB1 PA/PB

1

TO

2 3 Hydraulic pump

TO

TO

Rear propulsion motor and gear box

8

SEE STEERING HYD SYS

Front propulsion motor and gear box

(NO.13) (NO.8) (NO.16) (NO.1) (NO.14) (NO.18)

(NO.13) (NO.8) (NO.16) (NO.1)

(NO.15) (NO.3) (NO.17) (NO.2)

(NO.15) (NO.3) (NO.17) (NO.2)

FD4-BE

(NO.13)

FDB-PB

(NO.15)

FDX-BF

(NO.16)

FDA-PA

(NO.17)

FDL-BT1

(NO.14)

SECTION D-D X

(NO.14) (NO.18)

(NO.3) (NO.2)

(NO.3) (NO.2)

(NO.1) (NO.8)

(NO.8) (NO.1) (NO.18)

Hydraulic pump

13 14

CONNECT HOSES AS FOLLOWS. NO. 1

15

16

17

X

18 0431-36807-0-10362-D

5-001

HYDRAULIC PUMP AND MOTORS LOCATION

2. Location (2/5) Valve block assembly

1 BVP BVB

BVA

Valve block assembly

3

4

TO (NO.4) SEE STEERING HYD SYS

TO (NO.7)

TO (NO.1)

5

6

TO (NO.6)

7

(NO.4) (NO.5) (NO.4) (NO.6) (NO.3) (NO.7) (NO.15)

(NO.5) (NO.4) (NO.6) (NO.3) (NO.7) (NO.15)

(NO.3)

(NO.1)

(NO.4) (NO.3) (NO.15)

15

CONNECT HOSES AS FOLLOWS.

Front vibrator motor

Rear vibrator motor

VIB. LOW MOTOR FVA:HIGH PRESSURE VIB.HIGH MOTOR FVB:HIGH PRESSURE

VIB. LOW MOTOR RVA:HIGH PRESSURE VIB.HIGH MOTOR RVB:HIGH PRESSURE

0431-49803-0-10363-D

5-002

HYDRAULIC PUMP AND MOTORS LOCATION

3. Location (3/5)

1

TANK

TOP

TO

SVA

SVP

DR

OIL COOLER

FROM FROM

BOTTOM

FROM

FROM Hydraulic oil tank

9 ROUT-DR

Valve block assembly

RIN-BA BA

14

BA-PT1

39 BC1-OUT

15

BH1-PT 40

SVP-PX2

OUT PT1

PX1

16

PX2

PT

37

38

PA1

CONNECT HOSES AS FOLLOWS. NO. 1

17 SVP-PX2

PT1

PB1

PA1-VALVE PA1-VALVE Hydraulic pump

20

ROUT-TANK

0431-36802-0-10079-C

5-003

HYDRAULIC PUMP AND MOTORS LOCATION

4. location (4/5) Hydraulic pump

TANK 1

Valve block assembly

12 13

7

PB2

8

TO

TO PA2

Hydraulic pump

CONNECT HOSES AS FOLLOWS.

0431-49801-0-10081-C

5-004

HYDRAULIC PUMP AND MOTORS LOCATION

5. Location (5/5)

P-PT2

R-R3 1

2

L2-R1 7

IN R3 R1

R2 NO.2 NO.6

SECTION A-A

L1

L2

L3

5

6

IN-T

L-L3

3

L1-R2

TO TANK Hydraulic tank

C TO

8

TO

TO

FROM TANK

CONNECT HOSES AS FOLLOWS.

FROM

Steering Charge pump

0431-32803-0-10078-B

5-005