SW654 SHOP MANUAL
3498-6559A-0
Introduction This manual provides important information to familiarize you with safe operating and maintenance procedures for your SAKAI roller. Even though you may be familiar with similar equipment you must read and understand this manual before operating or servicing this unit. Safety is everyone’s business and it is one of your primary concerns. Knowing the guidelines presented in this manual will help provide for your safety, for the safety of those around you and for the proper operation and maintenance of the machine. Improper operation is dangerous and can result in injury or death. Sakai Heavy Industries cannot foresee all possible circumstances or varying conditions to which the operator, serviceman or machine may be exposed to that might lead to a potential hazard. Therefore, the warnings and cautions listed in this manual and those placed on the machine are not intended to be all inclusive and liability for personal injury or damage to equipment or property cannot be assumed. All information, specifications and illustrations in this publication are based on the product information available at the time that the publication was written. The contents may change without prior notice due to modifications of the model.
0 SW654 ○
CONTENTS 1. SAFETY 1. GENERAL SAFETY 1-1. Understanding the Safety Symbols and Words 1-001 1-2. General 1-001 1-3. Qualifications of Operators and Maintenance Personnel 1-002 1-4. Safety Practices and Policies 1-002 1-5. Pre Start Inspection 1-003 1-6. Safety Instructions 1-003 1-7. Starting 1-004 1-8. Operating 1-004 1-9. Stopping 1-004 1-10. Maintenance 1-005 1-11. Transporting the Machine 1-007
2. SPECIFICATIONS 1. SPECIFICATION DATA 1-1. SW654 2-001 1-2. SW654ND 2-003 1-3. Common Specifications 2-005 2. TABLE OF STANDARD VALUES 2-1. Engine 2-006 2-2. Propulsion 2-006 2-3. Hydraulic System 2-006 2-4. Steering 2-007 2-5. Brakes 2-007 2-6. Capacities 2-007 3. FUEL AND LUBRICANTS SPECIFICATION 3-1. Rating 2-008 3-2. Recommended Lubricants 2-008 4. TIGHTENING TORQUE CHART 2-009
3. ENGINE AND CONTROLS 1. ENGINE 1-1. Engine Mount 3-001 1-2. Engine Exterior 3-002
0-001
0 SW654 ○
2. FUEL SYSTEM 3-003 3. CONTROL SYSTEM 3-1. Throttle Control 3-005 3-2. Forward-reverse Control 3-006 4. PUMP MOUNT 4-1. Pump Mount 3-009 4-1-1. Installation of pump 3-010
4. HYDRAULIC SYSTEMS 1. SYSTEM CIRCUIT DIAGRAM 1-1. Graphic Symbols for Hydraulic Circuits 4-001 1-2. Hydraulic Circuit Diagram 4-003 1-2-1. Hydraulic circuit diagram (SW654) 4-003 1-2-2. Hydraulic circuit diagram (SW654ND) 4-004 2. PROPULSION HYDRAULIC SYSTEM 2-1. Propulsion Hydraulic Piping 4-005 2-1-1. Propulsion hydraulic piping (1) 4-005 2-1-2. Propulsion hydraulic piping (2) 4-006 2-2. Hydraulic Component Specifications 4-007 2-2-1. Hydraulic pump assembly (propulsion + vibrator + steering • charge + load) 4-007 2-2-2. Propulsion hydraulic motor 4-009 2-2-3. Servo bypass solenoid valve 4-010 2-2-4. Valve block 4-011 3. VIBRATOR HYDRAULIC SYSTEM 3-1. Vibrator Hydraulic Piping 4-012 3-2. Hydraulic Component Specifications 4-013 3-2-1. Vibrator hydraulic motor 4-013 3-2-2. Valve assembly 4-014 4. STEERING SYSTEM 4-1. Steering Hydraulic Piping 4-015 4-2. Steering Wheel 4-016 4-3. Hydraulic Component Specifications 4-017 4-3-1. Orbitrol 4-017 4-3-2. Load solenoid valve 4-018
0-002
0 SW654 ○
5. ELECTRICAL SYSTEM 1. Precautions for work 1-1. Wire Numbers, Wire Sizes, Wire Colors and Connectors Shown in Electrical Circuit Diagram, Wiring Harness Layout and Wiring Harnesses 5-001 2. SYSTEM CIRCUIT DIAGRAM 2-1. Electrical Circuit Diagram 5-003 3. ELECTRICAL COMPONENTS 3-1. Wiring Harness Layout (1) 5-004 3-2. Wiring Harness Layout (2) 5-005 3-3. Wiring Harness Layout (3) 5-006 4. WIRING HARNESSES 4-1. Main Harness 5-007 4-2. Fuse • Relay Harness (1) 5-009 4-3. Fuse • Relay Harness (2) 5-011 4-4. ECU Harness 5-013 4-5. Control Panel Harness 5-015 4-6. Battery Relay Harness 5-017 4-7. Stater Switch Harness 5-019 4-8. Engine Harness 5-020 4-9. Head Lamp Harness 5-021 4-10. Member (F) Harness 5-022 4-11. Combination Lamp (F) Harness 5-023 4-12. Member (R) Harness 5-024 4-13. Combination Lamp (R) Harness 5-025 4-14. Dashboard Harness 5-026 4-15. F-R Lever Vibration Switch (L) Harness 5-027 4-16. F-R Lever Vibration Switch (R) Harness 5-028 4-17. Hydraulic Oil Filter Switch Harness 5-029 4-18. Fuel Gauge Unit Harness 5-030 4-19. Water Spray Pump Harness 5-031 4-20. Cord 5-032 5. ELECTRICAL COMPONENT SPECIFICATIONS 5-1. Fuse Box (1) 5-033 5-2. Fuse Box (2) 5-034 5-3. Combination Meter 5-035
0-003
0 SW654 ○
6. VIBRATORY DRUM 1. PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY 6-001 2. VIBRATORY DRUM 2-1. Removal and Installation of Vibratory Drum 6-003 2-1-1. Removal of vibratory drum 6-003 2-1-2. Installation of vibratory drum 6-007 3. VIBRATORY DRUM ASSEMBLY (SW654) 3-1. Vibratory Drum Assembly 6-008 3-2. Disassembly and Reassembly of Vibratory Drum 6-009 3-2-1. Disassembly of vibratory drum 6-009 3-2-2. Reassembly of vibratory drum 6-018 4. VIBRATORY DRUM ASSEMBLY (SW654ND) 4-1. Vibratory Drum Assembly 6-036 4-2. Disassembly and Reassembly of Vibratory Drum 6-037 4-2-1. Disassembly of vibratory drum 6-037 4-2-2. Reassembly of vibratory drum 6-047
7. BRAKE 1. BRAKE PEDAL 7-001 2. BRAKE SYSTEM 7-002
8. WATER SPRAY SYSTEM 1. WATER SPRAY PIPING 1-1. Water Spray Piping (1) 8-001 1-2. Water Spray Piping (2) 8-002
9. INSPECTION AND ADJUSTMENT 1. INSPECTION AND ADJUSTMENT 1-1. Safety Precautions for Inspection and Adjustment 9-001 1-2. Preparation for Inspection and Adjustment 9-001 1-3. Precautions for Inspection and Adjustment 9-001 1-4. Warm-up 9-001 1-5. Inspection and Adjustment of Engine Related Items 9-001 2. MEASUREMENT AND ADJUSTMENT OF PROPULSION CIRCUIT PRESSURE 2-1. Measurement 9-002 2-2. Adjustment 9-003
0-004
0 SW654 ○
2-2-1. If pressures on both forward and reverse sides deviate from maximum circuit pressure range by same value 9-003 2-2-2. If pressure on either forward or reverse side deviates from maximum circuit pressure range 9-004 3. MEASUREMENT AND ADJUSTMENT OF PROPULSION/ VIBRATOR CHARGE CIRCUIT PRESSURE 9-005 3-1. Measurement 9-005 3-2. Adjustment 9-006 4. MEASUREMENT OF MACHINE HIGH/LOW SPEED CHANGE CIRCUIT PRESSURE 9-007 4-1. Measurement 9-007 5. MEASUREMENT OF PROPULSION SERVO CIRCUIT PRESSURE 5-1. Measurement 9-008 6. MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE 9-009 6-1. Measurement 9-009 7. MEASUREMENT AND ADJUSTMENT OF VIBRATOR CIRCUIT PRESSURE 7-1. Measurement 9-010 7-2. Adjustment 9-011 7-2-1. If pressures on both Low amplitude/Oscillation and High amplitude/ Normal sides deviate from maximum circuit pressure range by same value 9-011 7-2-2. If pressure on either Low amplitude/Oscillation or High amplitude/ Normal side deviates from maximum circuit pressure range 9-012 8. MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE 8-1. Measurement 9-013 8-2. Inspection 9-014 9. MEASUREMENT OF HYDRAULIC PUMP CASE PRESSURE 9-1. Measurement of Propulsion Pump Case Pressure 9-015 9-2. Measurement of Vibrator Pump Case Pressure 9-016 10. MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE 10-1. Measurement 9-017 11. MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE 11-1. Measurement 9-018 12. ADJUSTMENT OF THROTTLE LEVER 12-1. Adjustment of Potentiometer 9-019 12-2. Adjustment of Operating Force 9-021
0-005
0 SW654 ○
13. ADJUSTMENT OF F-R LEVER AND SHIFT LEVER 13-1. Adjustment of Linkage 9-022 13-2. Adjustment of Operating Force 9-024 13-2-1. Adjustment of F-R lever 9-024 13-2-2. Adjustment of shift lever 9-025 14. MOVABLE WEIGHT ADJUSTMENT (SW654ND) 9-026 14-1. Adjustment 9-026
10. TROUBLESHOOTING 1. TROUBLESHOOTING 1-1. Safety Precautions for Troubleshooting 10-001 1-2. Important Information for Troubleshooting 10-001 1-3. Before Starting 10-002 2. ELECTRICAL SYSTEM TROUBLESHOOTING 2-1. When Performing Electrical System Fault Diagnosis 10-003 2-1-1. Precautions to take during electrical circuit fault diagnosis 10-003 2-1-2. Inspection procedures using a tester 10-004 2-1-3. Inspection of electrical system 10-009 2-2. Engine Diagnosis Trouble Code 10-011 2-2-1. Description of diagnostic trouble code (DTC) 10-011 2-2-2. 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) 1/3 10-019 2-3-1. Engine will not start (Starter motor does not run) 2/3 10-021 2-3-1. Engine will not start (Starter motor does not run) 3/3 10-023 2-3-2. Engine will not start (But starter motor runs) 10-025 2-3-3. No charging 10-025 2-3-4. Glow heater is not heated (Engine starting performance is bad in cold weather) 10-027 2-3-5. Starter motor runs even when F-R lever is not at “N” 10-027 2-3-6. Engine speed does not change when operating throttle lever 10-029 2-4. Propulsion System 10-031 2-4-1. Machine moves neither forward nor backward 10-031 2-4-2. Machine speed cannot be changed 10-033 2-4-3. Brake cannot be released 10-035 2-4-4. Brake does not work 10-037 2-5. Vibration 10-039 2-5-1. No vibration occurs 1/2 10-039 2-5-1. No vibration occurs 2/2 10-041 0-006
0 SW654 ○
2-5-2. Amplitude does not change (Remains either low or high) : SW654 10-041 2-5-3. Vibration does not change (Remains normal or oscillation vibration) : SW654ND 10-043 2-5-4. Vibration mode cannot be switched (F-R lever vibration switch does not work) 10-045 2-5-5. Vibratory drum cannot be switched 10-047 2-6. Water Spray 10-049 2-6-1. Continuous water spray does not operate 1/2 10-049 2-6-1. Continuous water spray does not operate 2/2 10-051 2-6-2. Continuous water spray works, but auto water spray does not operate 10-053 2-6-3. Continuous water spray works, but intermittent water spray does not operate 10-055 2-7. Lighting 10-057 2-7-1. Head lamp, side marker lamp and tail lamp do not light 10-057 2-7-2. Flood lamp does not light 10-059 2-7-3. High-beam of head lamp does not light 10-059 2-7-4. Turn signal lamp does not blink 10-061 2-7-5. Hazard lamp does not light (Turn signal blinks) 10-063 2-7-6. Backup lamp does not light 10-063 2-7-7. Stop lamp does not light 10-065 2-7-8. Illumination of combination meter does not light 10-067 2-7-9. Combination meter warning lamp or indicator lamp is abnormal 10-067 2-7-10. Tachometer reading is abnormal 10-069 2-7-11. Hour meter is abnormal 10-069 2-7-12. Temperature meter is abnormal 10-071 2-7-13. Fuel meter is abnormal 10-071 2-7-14. Hydraulic oil filter warning lamp remains ON 10-073 2-7-15. Charge warning lamp remains ON 10-073 2-7-16. Vibration indicator lamp does not light 10-075 2-7-17. Water spray indicator lamp does not light 10-077 2-7-18. Flood lamp indicator lamp does not light 10-079 2-7-19. Side marker lamp indicator lamp does not light 10-079 2-7-20. Parking brake indicator lamp does not light 10-081 2-7-21. Turn signal indicator lamp does not light 10-083 2-7-22. Horn does not sound 10-085 2-7-23. Backup buzzer does not sound 10-085
0-007
0 SW654 ○
3. HYDRAULIC SYSTEM TROUBLESHOOTING 3-1. When Performing Hydraulic System Troubleshooting 10-086 3-2. Propulsion System 10-087 3-2-1. Machine moves neither forward nor backward 1/2 10-087 3-2-1. Machine moves neither forward nor backward 2/2 10-088 3-2-2. Machine moves in one direction only (forward or backward) 10-088 3-2-3. Slow machine speed or small drive force 1/2 10-088 3-2-3. Slow machine speed or small drive force 2/2 10-089 3-2-4. Machine speed cannot be switched 10-089 3-2-5. Machine does not stop completely with F-R lever in “N” 10-089 3-2-6. Propulsion system is overheating 10-090 3-2-7. Abnormal noise from propulsion system 10-090 3-3. Vibrator System 10-091 3-3-1. No vibration 1/2 10-091 3-3-1. No vibration 2/2 10-092 3-3-2. Vibrator frequency is too low 10-092 3-3-3. Vibration mode does not switch 10-093 3-3-4. Vibratory drum does not changeover vibrating 10-093 3-3-5. Vibrator does not stop 10-093 3-3-6. Vibrator system is overheating 10-093 3-3-7. Abnormal noise from vibrator system 10-094 3-4. Steering System 10-095 3-4-1. Steering wheel is hard to turn 10-095 3-4-2. Steering response is slow 10-095 3-4-3. Steering wheel backlash or play is large 10-096 3-4-4. Steering system is overheating 10-096 3-4-5. Abnormal noise from steering system 10-096
0-008
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 • Work 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. • Define 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. • Never 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. • Never 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. • Be 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. • Operate 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. • Obey 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. • Park behind a safe barrier, use proper flags, and warning devices, especially when parking in areas of heavy traffic. 1-004
SAFETY
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. • Immediately 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. • Use 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. • Examine 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. • 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. 1-005
SAFETY
• 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. • Ensure 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. • 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.
1-006
SAFETY
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
1480
67
1615 10
705
705 610
3100 4300
275
67
705
705
2060
70
10
2840
70
1615
1-1. SW654
590
67
1480
67
0559-99086-0-11166-0
Model & Type
Model Type Operating weight
without ballast with ballast
Maximum weight Weight
Dimensions
2-001
with ROPS without ROPS Load on front axle with operating weight Load on rear axle with operating weight Overall length Overall width with ROPS Overall height without ROPS Wheelbase Compaction width Front drum width × dia. × thickness Rear drum width × dia. × thickness Ground clearance Right Kerb clearance Left Right Side clearance Left Leveling blade width Shipping weight
SAKAI SW654 with ROPS VIBRATORY TANDEM ROLLER 7,070 kg ( 15,585 lbs. ) N/A kg ( N/A lbs. ) 7,430 kg ( 16,380 lbs. ) 6,600 kg ( 14,550 lbs. ) 6,320 kg ( 13,935 lbs. ) 3,360 kg ( 7,405 lbs. ) 3,710 kg ( 8,180 lbs. ) 4,300 mm ( 169 in. ) 1,615 mm ( 64 in. ) 2,840 mm ( 112 in. ) 2,060 mm ( 81 in. ) 3,100 mm ( 122 in. ) 1,480 mm ( 58 in. ) 1,480 mm × 1,070 mm × 17 mm (58 in. × 42 in. × 0.7 in.) 1,480 mm × 1,070 mm × 17 mm (58 in. × 42 in. × 0.7 in.) 275 mm ( 11 in. ) 705 mm ( 28 in. ) 705 mm ( 28 in. ) 67 mm ( 2.5 in. ) 67 mm ( 2.5 in. ) N/A mm ( N/A in. )
SPECIFICATIONS Centrifugal Low amplitude force High amplitude Low amplitude Front Frequency High amplitude Low amplitude Amplitude High amplitude Vibrator system Centrifugal Low amplitude force High amplitude Low amplitude Rear Frequency High amplitude Low amplitude Amplitude High amplitude Static linear Front drum Operating weight pressure Rear drum Operating weight Low Operating amplitude Front drum weight Linear High Dynamic pressure amplitude linear Performance Low pressure Operating amplitude Rear drum weight High amplitude Number of speed shift 1st 2nd Low 3rd Traveling 4th Speed speed range 1st 2nd High 3rd 4th Gradeability (without vibration) Machine clearance radius inside Machine clearance radius outside Turning radius Turning radius inside compacted surface Turning radius outside compacted surface Steering / Oscillating angle
62 kN 69 kN 67 Hz 50 Hz 0.27 mm 0.53 mm 62 kN 69 kN 67 Hz 50 Hz 0.27 mm 0.53 mm 223 N/cm 246 N/cm
( ( ( ( ( ( ( ( ( ( ( ( ( (
13,940 lbf ) 15,510 lbf ) 4,000 vpm ) 3,000 vpm ) 0.011 in. ) 0.021 in. ) 13,940 lbf ) 15,510 lbf ) 4,000 vpm ) 3,000 vpm ) 0.011 in. ) 0.021 in. ) 125 lbf./in. ) 140 lbf./in. )
642 N/cm
(
365 lbf./in. )
689 N/cm
(
395 lbf./in. )
665 N/cm
(
380 lbf./in. )
712 N/cm
(
405 lbf./in. )
8 speed ( 0 to 1.2 mile/h ) 0 to 2 km/h ( 0 to 2.5 mile/h ) 0 to 4 km/h ( 0 to 3.7 mile/h ) 0 to 6 km/h ( 0 to 4.4 mile/h ) 0 to 7 km/h ( 0 to 2.5 mile/h ) 0 to 4 km/h ( 0 to 4.4 mile/h ) 0 to 7 km/h ( 0 to 6.8 mile/h ) 0 to 11 km/h ( 0 to 8.1 mile/h ) 0 to 13 km/h 34 % ( 18 ° ) 3.6 m ( 142 in. ) 5.5 m ( 217 in. ) 3.7 m ( 146 in. ) 5.2 m ( 205 in. ) ± 39 ° / ± 9 °
2-002
SPECIFICATIONS
1480
67
1615 10
705
705 610
3100 4300
275
67
705
705
2060
70
10
2840
70
1615
1-2. SW654ND
590
67
1480
67
0559-99086-0-11166-0
Model & Type
Model Type Operating weight
without ballast with ballast
Maximum weight Weight
Dimensions
2-003
with ROPS without ROPS Load on front axle with operating weight Load on rear axle with operating weight Overall length Overall width with ROPS Overall height without ROPS Wheelbase Compaction width Front drum width × dia. × thickness Rear drum width × dia. × thickness Ground clearance Right Kerb clearance Left Right Side clearance Left Leveling blade width Shipping weight
SAKAI SW654ND with ROPS VIBRATORY TANDEM ROLLER 7,370 kg ( 16,250 lbs. ) N/A kg ( N/A lbs. ) 7,730 kg ( 17,040 lbs. ) 6,960 kg ( 15,345 lbs. ) 6,620 kg ( 14,595 lbs. ) 3,510 kg ( 7,740 lbs. ) 3,860 kg ( 8,510 lbs. ) 4,300 mm ( 169 in. ) 1,615 mm ( 64 in. ) 2,840 mm ( 112 in. ) 2,060 mm ( 81 in. ) 3,100 mm ( 122 in. ) 1,480 mm ( 58 in. ) 1,480 mm × 1,070 mm × 17 mm (58 in. × 42 in. × 0.7 in.) 1,480 mm × 1,070 mm × 17 mm (58 in. × 42 in. × 0.7 in.) 275 mm ( 11 in. ) 705 mm ( 28 in. ) 705 mm ( 28 in. ) 67 mm ( 2.5 in. ) 67 mm ( 2.5 in. ) N/A mm ( N/A in. )
SPECIFICATIONS Centrifugal Normal force Oscillation Normal Frequency Front Oscillation Normal Amplitude Oscillation Vibrator system Centrifugal Normal force Oscillation Normal Rear Frequency Oscillation Normal Amplitude Oscillation Static linear Front drum Operating weight pressure Rear drum Operating weight Linear Operating Front drum Normal Dynamic pressure weight linear Performance Operating pressure Rear drum Normal weight Number of speed shift 1st 2nd Low 3rd Traveling 4th Speed speed range 1st 2nd High 3rd 4th Gradeability (without vibration) Machine clearance radius inside Machine clearance radius outside Turning radius Turning radius inside compacted surface Turning radius outside compacted surface Steering / Oscillating angle
68 kN 124 kN 49 Hz 49 Hz 0.52 mm 0.75 mm 68 kN 124 kN 49 Hz 49 Hz 0.52 mm 0.75 mm 233 N/cm 256 N/cm
( ( ( ( ( ( ( ( ( ( ( ( ( (
15,285 lbf ) 27,875 lbf ) 2,940 vpm ) 2,940 vpm ) 0.020 in. ) 0.030 in. ) 15,285 lbf ) 27,875 lbf ) 2,940 vpm ) 2,940 vpm ) 0.020 in. ) 0.030 in. ) 135 lbf./in. ) 145 lbf./in. )
692 N/cm
(
395 lbf./in. )
715 N/cm
(
410 lbf./in. )
8 speed ( 0 to 1.2 mile/h ) 0 to 2 km/h ( 0 to 2.5 mile/h ) 0 to 4 km/h ( 0 to 3.7 mile/h ) 0 to 6 km/h ( 0 to 4.4 mile/h ) 0 to 7 km/h ( 0 to 2.5 mile/h ) 0 to 4 km/h ( 0 to 4.4 mile/h ) 0 to 7 km/h ( 0 to 6.8 mile/h ) 0 to 11 km/h ( 0 to 8.1 mile/h ) 0 to 13 km/h 33 % ( 18 ° ) 3.6 m ( 142 in. ) 5.5 m ( 217 in. ) 3.7 m ( 146 in. ) 5.2 m ( 205 in. ) ± 39 ° / ± 9 °
2-004
SPECIFICATIONS
1-3. Common Specifications Model Type Bore × Stroke Displacement Rated speed Rated output Performance
Max. torque Fuel consumption rate
Engine
Fuel system
Lubrication system Air intake system Cooling system Electrical system
Fuel consumption Fuel Fuel injection pump Fuel injection time regulator Lubrication type Oil filter type Oil cooler type
Drive system
Vibration system
Steering system
Drum and tyres
Sprinkler system Others
2-005
Full forced pressure feed Full flow plastic fiber element Integrated water cooled Dry
Cooling type Cooling fan type Alternator Starter Battery
Pressurized water forced circulation Exhale 12 V 90 A 12 V 3.0 kW 12 V (72 Ah, CCA750A) × 1 pcs. (12 V) 311 kg (686 lbs.) Hydrostatic 8 speed shifts Switching the direction of flow delivered from the variable pump N/A N/A Planetary gear Planetary gear Hydraulic Single eccentric shaft Twin eccentric shaft Dynamic braking through hydrostatic drive system (F-N-R lever)
Type Speeds
Reverser Differential type
Front Rear Front Final drive Rear Power transmission type SW654 Vibrator type SW654ND Service brake
Brake system
Electric speed control
Air cleaner type
Dry weight Transmission
KUBOTA V3307-CR-T-EF05 (Diesel, EPA-Tier 4) 4-cycle, water-cooled, 4-cylinder in-line, overhead valve, direct injection type, with turbocharger 94 mm × 120 mm (3.7 in. × 4.72 in.) 3.331 L ( 203.3 cu.in. ) 2,200 min-1 54.6 kW ( 73 HP ) 261 N·m ( 193 lbf·ft ) -1 at 1,500 min 227 g/kW·h ( 0.373 lb/HP·h ) at 2,200 min-1 15 L/h with full load ( 3.9 gal. with full load) Diesel (ASTM D975-2D) High pressure commonrail
Secondary brake (Emergency brake) Parking brake Power transmission type Steering type Front Use Rear Front Suspension system Rear Water spray type Liquid spray type ECO mode
Hydrostatic + spring applied hydraulically released type (Brake pedal) Spring applied hydraulically released type (Panel button) Hydraulic Articulated Steel drum / Vibrate and drive / 1pc. Steel drum / Vibrate and drive / 1pc. Rubber isolation Rubber isolation Pressurized N/A Standerd
SPECIFICATIONS
2. TABLE OF STANDARD VALUES 2-1. Engine Item Engine model Rated output Max. rpm under no load Min. rpm under no load Cylinder head tightening torque Intake manifold tightening torque Exhaust manifold tightening torque
Standard value KUBOTA V3307-CR-TE4B 53.8 kW 72 HP ( 2,400 ± 50 min-1 1,000 ± 50 min-1 187 to 196 N·m ( 138 to 145 lbf·ft 18 to 20 N·m 13 to 15 lbf·ft ( 30 to 34 N·m 22 to 25 lbf·ft (
Fan belt tension
10 to 12 mm
Valve clearance (intake) Valve clearance (exhaust) Standard value Compression pressure Allowable limit
(
0.13 to 0.17 mm 0.13 to 0.17 mm 3.92 MPa 2.90 MPa
Remarks )
) ) )
0.39 to 0.47 in.
)
( 0.005 to 0.007 in. ( 0.005 to 0.007 in. ( 568 psi ( 421 psi
) ) ) )
When midpoint of belt pressed at 98 N (22 lbf)
250 min-1 250 min-1
2-2. Propulsion Item Low Travel speed (Forward/reverse) High
1st 2nd 3rd 4th 1st 2nd 3rd 4th
Standard value 0 to 2 km/h ( 0 to 1.2 mile/h ) 0 to 4 km/h ( 0 to 2.5 mile/h ) 0 to 6 km/h ( 0 to 3.7 mile/h ) 0 to 7 km/h ( 0 to 4.4 mile/h ) 0 to 4 km/h ( 0 to 2.5 mile/h ) 0 to 7 km/h ( 0 to 4.4 mile/h ) 0 to 11 km/h ( 0 to 6.8 mile/h ) 0 to 13 km/h ( 0 to 8.1 mile/h )
Remarks
2-3. Hydraulic System
Propulsion
Vibration
Item High pressure relief valve setting Cut off valve setting Charge relief valve setting Pump Case pressure Motor (F) Motor (R) Motor (F) Brake release pressure Motor (R) Motor (F) Drainage Motor (R) High pressure relief valve setting Cut off valve setting Charge relief valve setting Pump Case pressure Motor Drainage
Steering oil pressure
Standard value Remarks 33.0 ± 1.0 MPa ( 4,785 ± 145 psi ) Differential pressure 30.0 ± 1.0 MPa ( 4,350 ± 145 psi ) Differential pressure 2.4 ± 0.2 MPa ( 348 ± 29 psi ) 0.4 MPa ( 58.0 psi ) or less 0.4 MPa ( 58.0 psi ) or less 0.4 MPa ( 58.0 psi ) or less More than 1.8 MPa ( 261 psi ) More than 1.8 MPa ( 261 psi ) 5.2 L/min ( 1.4 gal./min ) , 4th 5.2 L/min ( 1.4 gal./min ) 34.5 ± 1.0 MPa ( 5,003 ± 145 psi ) Differential pressure 32.5 ± 1.0 MPa ( 4,713 ± 145 psi ) — 0.4 MPa ( 58.0 psi ) or less 0.2 MPa ( 29.0 psi ) or less
SW654
9.4 L/min (
2.5
gal./min )
SW654ND
6.9 L/min (
1.8
gal./min )
18.1 ± 1.0 MPa ( 2,625 ± 145 psi
)
(orbitroll relief pressure + charge relief pressure)
2-006
SPECIFICATIONS
2-4. Steering Item
Standard value 5 to 10 mm ( 0.2 to 0.4 in. )
Play in steering wheel 0.5 mm (
0.02 in. ) or less
Remarks Steering wheel circumference Steering column shaft direction
2-5. Brakes Clearance between brake pedal and floorboard (as released)
112 mm (4.4 in.) Note 1: See dimensions
Clearance between brake pedal and floorboard (when pressed down)
52 mm (2.0 in.) Note 2: See dimensions
Remarks
Note 1
Standard value
Note 2
Item
SW652-1-02001
Propulsion motor inner brake wear limit Thickness of disc assembly (15 discs)
19.9 mm (0.78 in.) Note 3: See dimensions Note 3 SW652-1-02002
2-6. Capacities Item Engine oil pan Fuel tank Coolant Gear box Hydraulic oil tank Vibrator case Water spray tank
2-007
SW654 SW654ND
Standard value 11.2 L ( 3.0 gal. ) 120 L ( 32 gal. ) 9L ( 2.4 gal. ) 1.2 L × 2 ( 0.3 gal. × 2 ) 44 L ( 11.6 gal. ) 4.0 L × 2 ( 1.1 gal. × 2 ) 10.4 L × 2 ( 2.7 gal. × 2 ) 300 L × 2 ( 79 gal. × 2 )
Remarks
SPECIFICATIONS
3. FUEL AND LUBRICANTS SPECIFICATION 3-1. Rating Lubricant
Ambient temp. and applicable viscosity rating
Service classification
-15 to 30°C (5 to 86°F) Cold
0 to 40°C (32 to 104°F) Moderate
15 to 55°C (59 to 131°F) Tropical
Applicable Standards
Engine oil
API-CH-4 or JASO DH-2
SAE10W-30
SAE10W-30
SAE10W-30
—
Gear oil
API grade GL5
SAE80W-90
SAE90
SAE140
MIL-L-2105
Hydraulic oil
Wear resisting
ISO-VG32 Over VI 140
ISO-VG46 Over VI 140
ISO-VG68 Over VI 110
ISO-3448
Grease
Lithium type extreme-pressure grease
Fuel
Diesel oil
NLGI-2 ASTM-D975-2D
3-2. Recommended Lubricants Lubricant
Engine oil API CJ-4
JASO DH-2
Gear oil API GL 5
Hydraulic oil ISO-VG 46
Grease (NLGI-2)
CHEVRON
DELO 400 LE
DELO 400 LE
RPM Universal Gear Lubricants
Rando HDZ 46
Multifak EP 2
BP
—
—
BP Energear HYPO-U
Bartran HV 46
BP Energrease LS-EP 2
CASTROL
Tection Extra
TECTION J-MAX 2
EXP Gear OILS
Castrol Hyspin AWH 46
Castrol Spheerol EPL 2
EXXON MOBIL
Mobil Delvac 1 ESP
—
Mobilube HD
Mobil DTE 10 Excel 46
Mobilux EP 2
SHELL
Shell Rimula R4 L
Shell Rimula R4 L
Shell Spirax S2 A 90
Shell Tellus S2V 46
Shell Alvania Greases EP 2
Oil company
2-008
SPECIFICATIONS
4. TIGHTENING TORQUE CHART
Metric fine screw
Metric coarse screw
N·m
2-009
Nominal Dia.
Pitch
5 6 8 10 12 14 16 18 20 22 24 27 30 10 12 14 16 18 20 22 24 27 30
0.8 1.0 1.25 1.5 1.75 2.0 2.0 2.5 2.5 2.5 3.0 3.0 3.5 1.25 1.25 1.5 1.5 1.5 1.5 1.5 2.0 2.0 2.0
6.8 4.9 7.8 17 39 69 98 157 196 294 441 539 785 1079 39 69 108 167 245 343 490 588 834 1177
(3.6) (5.8) (13) (29) (51) (72) (116) (145) (217) (325) (398) (579) (796) (29) (51) (80) (123) (181) (253) (361) (434) (615) (868)
Strength Classification 8.8 10.9 5.9 (4.4) 7.8 (5.8) 9.8 (7.2) 13 (9.6) 23 (17) 31 (23) 49 (36) 59 (44) 78 (58) 108 (80) 127 (94) 167 (123) 196 (145) 265 (195) 245 (181) 343 (253) 392 (289) 539 (398) 539 (398) 686 (506) 637 (470) 883 (651) 981 (724) 1324 (977) 1324 (977) 1765 (1302) 49 (36) 69 (51) 88 (65) 118 (87) 137 (101) 186 (137) 206 (152) 284 (209) 294 (217) 392 (289) 441 (325) 588 (434) 588 (434) 785 (579) 735 (542) 981 (724) 1030 (760) 1422 (1049) 1422 (1049) 1961 (1446)
(lbf·ft)
12.9 7.8 13 31 59 108 167 265 343 539 686 883 1324 1765 69 118 186 284 392 588 785 981 1422 1961
(5.8) (9.6) (23) (44) (80) (123) (195) (253) (398) (506) (651) (977) (1302) (51) (87) (137) (209) (289) (434) (579) (724) (1049) (1446)
ENGINE AND CONTROLS
ENGINE AND CONTROLS
1. ENGINE 1-1. Engine Mount 1
3
2
A
B
6 7 8
4
(1) (2) (3) (4) (5) (6) (7) (8)
10 11
15 16 17
18
19
20
5 14
C
9
VIEW A
Bracket Bracket Engine Bracket Bracket Bolt : M12×50 Bracket Bolt : M12×60
13
DETAIL B
12
23
22
21
DETAIL C 0559-01805-0-10853-A
(9) Bolt : M16×160 (10) Plate (11) Bolt : M14× 40 P=1.5 (12) Damper (13) Nut (upper) : M16 (14) Nut (lower) : M16 (15) Bolt : M12× 50 (16) Bracket
(17) Bolt : M12× 60 (18) Bolt : M16×160 (19) Plate (20) Damper (21) Bolt : M12×35 P=1.25 (22) Nut (upper) : M16 (23) Nut (lower) : M16
N•m
(6) Bolt M12×50 (11) Bolt M14×45 P=1.5 (13) Nut (upper) M16 (14) Nut (lower) M16
: 108 N·m ( 80 lbf·ft ) : 186 N·m ( 137 lbf·ft ) : 100 N·m ( 74 lbf·ft ) : 265 N·m ( 195 lbf·ft )
(15) Bolt M12×50 : 108 N·m ( 80 lbf·ft ) (21) Bolt M12×35 P=1.25 : 118 N·m ( 87 lbf·ft ) (22) Nut (upper) M16 : 100 N·m ( 74 lbf·ft ) (23) Nut (lower) M16 : 265 N·m ( 195 lbf·ft ) 3-001
ENGINE AND CONTROLS
1-2. Engine Exterior Water temperature sensor Boost sensor
Throttle sensor
CR fuel pressure sensor
EGR valve
Intake air temperature sensor
Oil level gauge
Exhaust temperature sensor
Oil pressure warning switch
Alternator Exhaust port
Crankshaft position sensor
Differential pressure sensor
Exhaust temperature sensor
Cooling water outlet
Oil filter cartridge Oil drain plug
Starter motor
VIEW A Fan belt
Intake port
Thermo unit
Turbocharger
DPF
A
Cooling water inlet Flywheel
Fan drive pulley
* The actual equipment may differ from that shown above.
Camshaft position sensor
Oil pan SW654-03001
3-002
ENGINE AND CONTROLS
2. FUEL SYSTEM 1
2
3
4
5
6
7
A
8
3-003
0559-02803-0-10908-A
ENGINE AND CONTROLS
IN
9
OUT
VENT
10
IN
Supply pump Common rail Engine
OUT
Engine (return)
Engine (suction) Engine side Vehicle side Main filter
Check valve Check valve
Pre-filter Fuel pump OUT
IN 13
14
OUT
12
IN 11
Separator Fuel tank (suction)
Fuel tank (return) Fuel tank
Fuel system diagram
15
B
20
21
18
19
16
18
17
12
14
B DETAIL A
13
SECTION B-B 0559-02803-0-10908-A
(1) Fuel tank (2) Fuel gauge unit (3) Fuel tank (return) (4) Fuel tank (suction) (5) Engine (suction) (6) Engine (return) (7) Fuel supply port (8) Drain plug (9) Fuel pump (10) Hose (Pre-filter OUT → Main filter IN) (11) Hose (Separator OUT → Fuel pump IN)
(12) Hose (Engine (return) → Check valve) (13) Hose (Main filter OUT → Engine (suction)) (14) Hose (Fuel pump OUT → Pre-filter IN) (15) Pre-filter (16) Separator (17) Hose (Fuel tank (suction) → Separator IN) (18) Hose (Check valve → Fuel tank (return)) (19) Main filter (20) Check valve (21) Check valve
3-004
ENGINE AND CONTROLS
3. CONTROL SYSTEM 3-1. Throttle Control
12 11 10 9 8
A A IDOL 1
6
7
SECTION A-A 2
3
4
FULL 5
0559-12805-0-10846-A
(1) Lock nut (2) Stopper bolt (FULL) (3) Lock nut (4) Stopper bolt (IDOL) (5) Throttle lever (6) Screw * : Lithium-based grease
3-005
: M6 : M6×60 : M6 : M6×60 : M4×12
(7) Potentiometer (8) Nut : M16 (9) Disc spring (Do not apply grease) (10) Washer (Apply grease*) (11) Bush (Apply grease*) (12) Washer (Apply grease*)
ENGINE AND CONTROLS
3-2. Forward-reverse Control F
N
1
1
2
3
4
R
A
B
A
B
1ST 2ND 3RD 4TH 5 6
F N R F R
R F
VIEW A-A
VIEW B-B 0559-12804-0-10827-0
(1) F-R lever (L) (2) Lever subassembly (3) Shaft subassembly
(4) F-R lever (R) (5) Control cable (F-R) (6) Control cable (shift)
3-006
ENGINE AND CONTROLS 2) Lever subassembly 1
2
A
A
3
B
B
4
13
5
12
11
23
10
9
8
7
6
14
22
15
24
3 4
21 20
16
19
17
18
SECTION A-A
13 1
2 25
SECTION B-B 0559-12003-0-11017-0
(1) Shift lever (2) Base (3) Plate (4) Rod end (Apply grease*) : M6 (5) Lock nut : M6 (6) Rod end (Apply grease*) : M6 (7) Lock nut : M6 (8) Control cable (F-R) (9) Control cable (shift) (10) Lock nut : M6 (11) Rod end (Apply grease*) : M6 (12) Lock nut : M6 (13) Rod end (Apply grease*) : M6 * : Lithium-based grease 3-007
(14) Bolt : M12×30 (15) Lock nut : M12 (16) Spring (Fill grease*) (17) Steel ball (18) Washer (Apply grease*) (19) Bush (Apply grease*) (20) Washer (MC nylon) (21) Bush (Apply grease*) (22) Disc spring (Do not apply grease) (23) Nut : M20 (24) Washer (MC nylon) (25) Washer (MC nylon)
ENGINE AND CONTROLS 3) Shaft subassembly 1
D
2
3
4
A
B C
A
B
SECTION A-A
C
D 7 8
9
10
11
6
5
SECTION B-B SECTION C-C
12
13
E
E
15
14
25 24
16
23
17
22
18 19
21
SECTION D-D
20
SECTION E-E 0559-12004-0-11020-A
(1) Arm (2) Arm (3) Arm (4) Shaft (5) F-R lever switch (6) Vibration AUTO switch (7) Backup buzzer switch (8) Rod end (Apply grease*) : M6 (Left-hand thread) (9) Nut : M6 (Left-hand thread) (10) Rod : M6 (11) Nut : M6 (12) Rod end (Apply grease*) : M6 (13) Spring (Fill grease*)
(14) Steel ball (15) Friction plate (16) Holder (17) Disc spring (Fill grease*) (18) Lock nut (19) Bolt (20) Lock nut (21) Bolt (22) Washer (Apply grease*) (23) Bush (Apply grease*) (24) Washer (Apply grease*) (25) Bush (Apply grease*)
: M12 : M12×30 : M12 : M12×30
* : Lithium-based grease 3-008
ENGINE AND CONTROLS
4. PUMP MOUNT 4-1. Pump Mount 1
2
3
A
7
a
A
6
5
4
8
SECTION A-A (1) Bolt : M10×25 P=1.25 (2) Bolt : M10×30 P=1.25 (3) Pump (4) Bolt : M14×40 N•m
(1) Bolt M10×25 P=1.25 : 69 N·m ( 51 lbf·ft ) (2) Bolt M10×30 P=1.25 : 49 N·m ( 36 lbf·ft ) (8) Bolt M12×35 : 86 N·m ( 63 lbf·ft )
3-009
(5) (6) (7) (8)
0559-36811-0-10839-B
Housing Flange Hub Bolt : M12×35
ENGINE AND CONTROLS
4-1-1. Installation of pump • When the pump assembly has been removed from the engine for repair or replacement, reinstall it in accordance with the following procedure. ① Apply adequate amount of grease to pump (3) and hub (7) splines. ② Set hub (7) to pump (3) and the specified dimension. ★ Specified dimension a: 2 mm (0.08 in.) ③ Secure hub (7) with bolt (8). N•m
(8) Bolt M12×35 : 86 N·m (63 lbf·ft)
④ Secure flange (6) to engine flywheel with eight bolts (2), spring washers and washers. N•m
(2) Bolt M10×30 P=1.25 : 49 N·m (36 lbf·ft)
⑤ Secure housing (5) to flywheel housing with twelve bolts (1). N•m
(1) Bolt M10×25 P=1.25 : 69 N·m (51 lbf·ft)
⑥ Engage hub (7) of pump subassembly with flange (6). ⑦ Secure pump subassembly to housing (5) with two bolts (4) and washers. (NOTICE) • Bolts (2) is treated with thread-locking fluid. Use new thread-locking fluid treated bolts for installation.
3-010
HYDRAULIC SYSTEMS
HYDRAULIC SYSTEMS
1. SYSTEM CIRCUIT DIAGRAM 1-1. Graphic Symbols for Hydraulic Circuits Basic Symbols DESCRIPTION Lines:
Pump, Motors and Cylinders SYMBOL
DESCRIPTION Hydraulic pumps:
Main working
Fixed displacement
Pilot control
Unidirectional
Drain or bleed
Bidirectional
Lines, joining
Variable displacement Unidirectional
Not connected Component outline Arrow indicates direction of flow. Line with fixed restriction (orifice). Test port, pressure measurement. Temperature measurement gauge Pressure measurement gauge Reservoir (vented)
Bidirectional Variable displacement pressure compensated Unidirectional Hydraulic Motor: Unidirectional Bidirectional Double acting hydraulic cylinder Differential cylinder
Filter or strainer Heat exchanger, lines indicate flow of coolant. Quick disconnect: Connected with mechanically opened checks. Disconnected. Sloping arrow through a symbol at 45° indicates that a component can be adjusted or varied.
4-001
Electric motor
SYMBOL
HYDRAULIC SYSTEMS
Valves DESCRIPTION
Methods of Operation SYMBOL
DESCRIPTION
Check valve
Spring
Manual shut off (On-Off)
Manual
SYMBOL
Pressure compensated Pressure relief Reversing motor Flow control, adjustable Valve symbols: The basic valve symbol one or more squares with lines representing flow paths and flow conditions between ports. Multiple squares indicate a valve with as many distinct positions there are squares 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 component.
Pilot pressure: Internal supply Remote supply Solenoid: Single winding Two windings operating in opposite directions. Pilot directional valve is actuated by the solenoid.
Valves with infinite positioning between certain limits are symbolized with lines parallel to the squares.
4-002
HYDRAULIC SYSTEMS
1-2. Hydraulic Circuit Diagram Forward (3/8")
TV2 TMA
(1/2")
(3/8")
(1/2")
(1/4") FDL
Vibrator pump PG1
b
PB1 PB
a
PG2
Vibration:Low (42cc/rev)
(1/2")
Propulsion pump
FDB
Steering charge pump PB2 B3
Drum (F)
Lo Hi 3.0 MPa
B4 45.0/23.0 cc/rev
1.8
i=35.00
0.7 33.0 MPa
34.5 MPa
46.0 cc/rev
FDA
42.0/31.0 cc/rev 22.4 cc/rev
ENGINE 1.9 MPa
30.0MPa
54.6kW/2200min -1 (74.2PS) Maximum no-load rotational speed 2400min -1 KUBOTA V3307-CR-TE4B 3331cc
1.6
Load pump
22.4 cc/rev
32.5MPa
1.4
33.0 MPa
1.8 MPa
1480
Propulsion motor (F) FD4
(1/4") (3/8") (1/4")
(1/2")
RDL
TFX
0.7
FDX
(5/8")
1070
1-2-1. Hydraulic circuit diagram (SW654)
RDX
34.5 MPa
TRX
2.4 MPa
RDA X2
PA1
PA PT1
PT3
PA2
PT4
S3
3.0 MPa
S4
45.0/23.0 cc/rev
i=35.00
(1/2") BV2 (1/4")
(1/2")
(3/8") TV1 TMB
BV1
Bypass valve
(1/4")
1.8 MPa
RDB
Reverse
1070
Drum (R)
Lo Hi PT2 X1
1480
Propulsion motor (R) RD4
Vibration:High (31cc/rev) (1") (1")
(1/4")
Suction filter
Servo bypass solenoid valve
150mesh
(1/2")
(1/4")
TP2 TBT
1.0
OUT FO FS BETA5μm=2
(1/2")
(1/4")
(1/2")
IN
(1/2")
TF4
BT5
TT5
R
(3/8")
230 cc/rev
L P
(3/8")
SR2
T
SRR
(3/8")
AVL
Pipe assembly 2
RVA LP
SLL
BB1
(5/8")
31.5 MPa
30-260 st
1.3 MPa
AVT
T8
a
BAA
Valve assembly
APT
(3/4")
BT
R
B A
B A
F
B
F
Vibration:Low Vibration:High
FVA 23.5 cc/rev
FVB
(1/4")
Pipe assembly 1
IN CS OUT CO
B
A R
(5/8")
0.3 MPa
(3/8")
TFL TT3
FVL
Vibrator motor (F)
(3/8") T6
(3/4") T4
A TRB TFA
(5/8")
BA1
AOS
Oil cooler
(3/8")
1
Load solenoid valve (5/8")
(5/8")
BP 1.8
(3/4")
Steering cylinder (R)
RVL
RVB
b
12.7 MPa
(3/8") SRL SR1
23.5 cc/rev
(5/8")
BCP BBB
60X
AFL
AT7
Vibrator motor (R)
TBC
LT
Orbitrol
APL (1/2")
TBB
30-260 st
SLR (3/8")
Valve block
BPB
Steering cylinder (L) 60X
BB
BT3
BC1
(1/2")
Hydraulic oil filter
15.7 MPa
(1/4")
BT1
TR4
VSP
T1 T2
TB1
VSA
(3/8")
T5
T7
T3
0559-99094-0-11221-0
4-003
HYDRAULIC SYSTEMS
1-2-2. Hydraulic circuit diagram (SW654ND) (3/8")
TV2 TMA
(1/2")
(3/8")
(1/2")
(1/4") FDL
(1/2")
Propulsion pump
PG1
b
PB1 PB
Vibration :Oscillation (31cc/rev)
Vibrator pump a
FDB
Steering charge pump PB2 B3
PG2
Drum (F)
Lo Hi 3.0 MPa
B4 45.0/23.0 cc/rev
1.8
i=35.00
0.7 33.0 MPa
34.5 MPa
46.0 cc/rev
FDA
31.0 cc/rev 22.4 cc/rev
ENGINE 1.9 MPa
30.0MPa
54.6kW/2200min -1 (74.2PS) Maximum no-load rotational speed 2400min -1 KUBOTA V3307-CR-TE4B 3331cc
1.6
Load pump
22.4 cc/rev
32.5MPa
1.4
33.0 MPa
1.8 MPa
1480
Propulsion motor (F) FD4
(1/4") (3/8") (1/4")
(1/2")
RDL
TFX
0.7
FDX
(5/8")
1070
Forward
RDX
34.5 MPa
TRX
2.4 MPa
RDA X2
PA1
PA PT1
PT3
PA2
PT4
S3
3.0 MPa
S4
45.0/23.0 cc/rev
i=35.00
(1/2") BV2 (1/4")
(1/2")
(3/8") TV1 TMB
BV1
Bypass valve
(1/4")
1.8 MPa
RDB
Reverse
1070
Drum (R)
Lo Hi PT2 X1
1480
Propulsion motor (R) RD4
Vibration:Normal (31cc/rev) (1") (1")
(1/4")
Suction filter
Servo bypass solenoid valve
150mesh
(1/2")
(1/4")
TP2 TBT
1.0
TF4 BC1
(1/4")
(1/2")
IN
OUT FO FS BETA5μm=2
(1/2")
BT5
TT5
R
(3/8")
230 cc/rev
L P
(3/8")
SR2
T
SRR
(3/8")
AVL
Pipe assembly 2
RVA LP
SLL
BB1
(5/8")
31.5 MPa
30-260 st
1.3 MPa
AVT
T8
a
BAA
Valve assembly
APT
(3/4")
BT
R
B A
B A
B
F
Vibration :Oscillation
B
F
Vibration :Normal
FVA 23.5 cc/rev
FVB
(1/4")
Pipe assembly 1
IN CS OUT CO
A R
(5/8")
0.3 MPa
(3/8")
TFL TT3
FVL
Vibrator motor (F)
(3/8") T6
(3/4") T4
A TRB TFA
(5/8")
BA1
AOS
Oil cooler
(3/8")
1
Load solenoid valve (5/8")
(5/8")
BP 1.8
(3/4")
Steering cylinder (R)
RVL
RVB
b
12.7 MPa
(3/8") SRL SR1
23.5 cc/rev
(5/8")
BCP BBB
60X
AFL
AT7
Vibrator motor (R)
TBC
LT
Orbitrol
APL (1/2")
TBB
30-260 st
SLR (3/8")
Valve block
BPB
Steering cylinder (L) 60X
BB
BT3
(1/2")
Hydraulic oil filter (1/2")
15.7 MPa
(1/4")
BT1
TR4
VSP
T1 T2
TB1
VSA
(3/8")
T5
T7
T3
0559-99095-0-11222-0
4-004
HYDRAULIC SYSTEMS
2. PROPULSION HYDRAULIC SYSTEM Hose (PT1
2-1. Propulsion Hydraulic Piping 2-1-1. Propulsion hydraulic piping (1)
APT)
SOT
PT1 Bypass valve
PA1
BV2
Hydraulic oil tank
BT1
Hose (TV2
Hose (CO SOT)
BV2) PB1
PT1
Hose (AT7 T7)
Servo bypass solenoid valve
PT3
Hose (PT3 AVT) AT7
A
VSA Pipe assembly 2
PT2 Hose (PT2
TP2 PT4 Pump assembly
TP2)
VSP
DETAIL C PB1
A
TV2
B Oil cooler
Hose (VSA X1)
X1 Hose (AOS
X2
Hose (X2 VSP)
T3
CS)
TV1 PA1 PT2
BV1
C
CS
Hose (TT3 T3)
TV2
VIEW B Hose (TB1 BT1)
TP2 PT4 Valve block BT1 BT5
CO Hose (TT5 T5)
Hose (CO SOT)
Hose (SOT
T4)
TT3 AOS
AVT
SECTION A-A
APT
The letters and numbers in the figure such as “TV1” and “BV1” show each port. ; ” symbols show the hose connection and the direction of the flow of the oil. Arrow “
Hose (TV1
Hose (BT3 T6
BV1)
T5
T4 Pipe assembly 1
TV1
Hose (TT3 T3)
TT3
Hose (AT7 T7)
T6)
TB1 TT5
BT3
DETAIL VALVE BLOCK
T7
0559-36812-0-10885-B
4-005
HYDRAULIC SYSTEMS
2-1-2. Propulsion hydraulic piping (2)
F
RDA
D
RDB
Propulsion motor (R)
Propulsion pump PB
Hose:FB
F Hose:RA
RDX
F
F
E
Hose:FA RDL
RD4
TMA
VIEW D B
Hose:RD Hose:RS
A
Propulsion motor (F)
FDA
Hose:FB Hose:FB
Hose:FD
Hose:FD
Hose:FA
Hose:FBR
SECTION B-B
Hose:FBR
Hose:FA
SECTION C-C
BB
AFL Hose:RD
Pipe assembly 2
TFX
APL
BPB
DETAIL VALVE BLOCK
SECTION G-G Hose:RS
Pump assembly
Hose:FBR (TF4 FD4)
FDL
BC1
Hose:RBR
A
Hose:FB (PB FDB) Hose:FD (FDL AFL)
BC1
TRX
SECTION A-A
Hose:FS (TFX FDX) Hose:FA (PA FDA)
TFX
VIEW E
Hose:FD
Hose:FA
Hose:FBR
TR4
TF4
Hose (TBB BPB) Hose:FS
Hose:FS
Hose:FS
Hose:RA
SECTION F-F Hose:FB
BB
TF4
Hose:RB
Hose:RBR TBB
FDB
Hose:RB
PA
C
C
B A
TMB
G A
A
A B
FDX
B
FD4
The letters and numbers in the figure such as “PB” and “FDB” show each port. ; ” symbols show the hose connection and the direction of the flow of the oil. Arrow “
G H
Hose:RBR (TR4 RD4)
Hose:FBR
Hose:RS (TRX RDX) Hose:RA (TMA RDA) Hose:RB (TMB RDB) Hose:RD (RDL APL)
Hose:FS
Hose (TBB
Valve block
BPB)
VIEW H 0559-36813-0-10891-B
4-006
HYDRAULIC SYSTEMS
2-2. Hydraulic Component Specifications 2-2-1. Hydraulic pump assembly (propulsion + vibrator + steering • charge + load) 1
2-2
1-2
1-1
2-1
2-15
1-5
1-17
1-6 1-3 1-7
1-2, 1-1, 2-1, 1-4 1-5 2-3 2-4 2-2 2-5 3-1 3
1-8
2-7
4-1 4
1-3
1-4
VIEW A 1-10, 2-9
1-9, 2-8 1-9 (Back to 1-10) 1-11
2
2-6
1-12 2-8 (Back to 2-9) 2-10 2-11
1-12, 2-11
A
1-14, 1-16, 2-13 2-14
1-17, 2-15
1-9
1-12
1-16
1-14
1-15
1-7 1-2 1-1
b
1-13
2-14
a
2-13 2-12
3-2
2-11 2-5 2-1
3-2
4-2
2-13 2-2
3-1
4-1
2-8
4-2
34.5 MPa
33 MPa
30 MPa
1.9 MPa
1.6
1.4
32.5 MPa
34.5 MPa
33 MPa 2.4MPa
1-10 1-16 1-6
1-8
1-14 1-4 1-5 1-3
2-9 2-14
Hydraulic circuit diagram
4-007
SW654-04001
HYDRAULIC SYSTEMS (1) Propulsion pump (1-1) Port B (Forward) (1-2) Port B1 (Forward) (1-3) Drain port (1-4) Port A1 (Reverse) (1-5) Port A (Reverse) (1-6) Servo pressure gauge port (1-7) High pressure gauge port (For port B) (1-8) Servo pressure gauge port (1-9) Control pressure port (1-10) Drain port or Filler port (1-11) High pressure relief valve (For port B) (1-12) Charge pressure gauge port (1-13) High pressure relief valve (For port A) (1-14) High pressure gauge port (For port A) (1-15) Charge relief valve (1-16) Drain port (1-17) Cut off valve Specifications • Displacement • High pressure relief valve pressure setting • Charge relief valve pressure setting • Cut off valve pressure setting
[PB] : 1 1/16-12UN [PB1] : 1 1/16-12UN [PT1] : 9/16-18UNF [PA1] : 1 1/16-12UN [PA] : 1 1/16-12UN [X1] : 7/16-20UNF : 7/16-20UNF [X2] : 7/16-20UNF : 9/16-18UNF : 7/ 8-14UNF [PG1] :
3/ 4-16UNF
:
7/16-20UNF
[PT2] :
7/ 8-14UNF
: 46 cm3/rev ( 2.8 cu.in./rev : 33.0 MPa ( 4,785 psi : 2.4 MPa ( 348 psi : 30.0 MPa ( 4,350 psi
) ) ) )
(2) Vibrator pump (2-1) Port B2 (Low amplitude/Oscillation) [PB2] : SAE 3/4” (2-2) Port A2 (High amplitude/Normal) [PA2] : SAE 3/4” (2-3) Servo pressure gauge port : 7/16-20UNF (2-4) Solenoid valve a (High amplitude/Normal) (2-5) High pressure gauge port (For port B) : 7/16-20UNF (2-6) Solenoid valve b (Low amplitude/Oscillation) (2-7) Servo pressure gauge port : 7/16-20UNF (2-8) Control pressure port : 9/16-18UNF (2-9) Drain port or Filler port [PT3] : 7/ 8-14UNF (2-10) High pressure relief valve (For port B) (2-11) Charge pressure gauge port [PG2] : 3/ 4-16UNF (2-12) High pressure relief valve (For port A) (2-13) High pressure gauge port (For port A) : 7/16-20UNF (2-14) Drain port [PT4] : 7/ 8-14UNF (2-15) Cut off valve Specifications • Displacement SW654 (Low amplitude) : 42.0 cm3/rev ( 2.6 cu.in./rev 3 (High amplitude) : 31.0 cm /rev ( 1.9 cu.in./rev SW654ND : 31.0 cm3/rev ( 1.9 cu.in./rev • High pressure relief valve pressure setting : 34.5 MPa ( 5,003 psi • Cut off valve pressure setting : 32.5 MPa ( 4,713 psi
) ) ) ) )
(3) Steering • charge pump (3-1) Suction port (3-2) Discharge port (4) Load pump (4-1) Suction port (4-2) Discharge port Specifications • Displacement
[S3] : SAE 3/4” [B3] : SAE 3/4” [S4] : SAE 3/4” [B4] : SAE 3/4”
• Allowable pump case pressure • Pump assembly weight
: 22.4 cm3/rev (
1.4 cu.in./rev )
: 0.4 MPa ( 58.0 psi ) or less : 66 kg ( 146 lbs. ) 4-008
HYDRAULIC SYSTEMS
2-2-2. Propulsion hydraulic motor 1
2
3
4
5
VIEW A 6
A
7
8
1 6
Flow of oil
2
2
5 Counterclockwise rotation Propulsion motor (F) : Forward Propulsion motor (R) : Reverse
5
2 Clockwise rotation
i=35.00
5
Propulsion motor (F) : Reverse Propulsion motor (R) : Forward
7
Motor ciruit diagram
(1) Drain port (2) Port B (3) Motor (4) Reduction gear
SW652-1-04002
[FDL] [RDL] : 7/ 8-14UNF [FDB] [RDB] : 1 1/16-12UNF
(5) Port A (6) Pilot pressure port (7) Brake release port (8) Drain port
[FDA] [RDA] : 1 1/16-12UNF [FDX] [RDX] : 7/16-20UNF [FD4] [RD4] : G1/4 : 7/ 8-14UNF
Motor specifications • Displacement (max) : 45.0 cm3/rev ( 2.8 cu.in./rev ) (min) : 23.0 cm3/rev ( 1.4 cu.in./rev ) • Maximum working pressure : 30.0 MPa ( 4,350 psi ) • Allowable motor case pressure : 0.4 MPa ( 58.0 psi ) or less • Brake release pressure : More than 1.8 MPa ( 261 psi ) • Speed change pressure : 2.4 MPa ( 348 psi ) Reduction gear specifications • Reduction ratio : 1/35.000 • Weight
4-009
:
60 kg
(
132 lbs.
)
HYDRAULIC SYSTEMS
2-2-3. Servo bypass solenoid valve 1
2 8
3 4 6
7
5
7
8 6 Hydraulic circuit diagram
(＋)
(−)
Connection diagram K-40026
(1) Solenoid (2) O-ring (1B P14) (3) Spool (K) (4) Body (5) Spring (6) Port T : G1/4 (7) Port A [VSA] : G1/4 (8) Port P [VSP] : G1/4 Specifications • Rated flow • Rated pressure • Weight
: 30 L/min ( 7.9 gal./min : 4.9 MPa ( 711 psi : 0.5 MPa ( 72.5 psi : 1.5 kg ( 3.3 lbs.
) ) (7, 8) ) (6) )
4-010
HYDRAULIC SYSTEMS
2-2-4. Valve block 1
5
2 11
3
6
A 10
4
7 9 3
8
10 13
12 1 2
7 14
12
4
Hydraulic circuit diagram
13 14
VIEW A SW654-04002
(1) (2) (3) (4) (5) (6) (7)
Port T1 [BT1] : G3/8 Port T2 : G3/8 Port B [BB] : G3/8 Port T5 [BT5] : G3/8 Hand pump Rotary valve Port T3 [BT3] : G1/8
(8) Parking brake solenoid valve (9) Speed change solenoid valve (10) Port C1 [BC1] : G3/8 (11) Block (12) Port P [BPB] : G3/8 (13) Port C2 : G3/8 (14) Port T4 : G1/8
Specifications • Maximum flow : 11 L/min ( 2.9 gal./min ) • Maximum working pressure : 21 MPa ( 3,045 psi ) • Hand pump displacement : 5.7 mL/stroke ( 0.0015 gal./stroke ) • Weight : 4 kg ( 8.8 lbs. )
4-011
HYDRAULIC SYSTEMS
3. VIBRATOR HYDRAULIC SYSTEM 3-1. Vibrator Hydraulic Piping FVA
Vibrator pump Hose (PB2
Pipe assembly 1
FVB
Propulsion pump
PB2
BBB)
PG1 Hose (TBC
BCP)
BCP BBB
TFL Pipe assembly 2 Hose (PA2
TBC
Valve assembly
PA2
BAA)
VIEW B
B
BAA BT
Hose (BT TBT) AVL
Hose (BB1
PG1
Valve assembly
TBT
TBC
RVB
Hose (PB2 Hose (FVL Hose (BA1 Hose (TFA
BBB)
Hose (BB1
C
FVB)
Hose (RVL Hose (TRB
A
TFL)
BAA)
BB1 BA1
FVB)
AVL) RVB)
BP TFA Hose (TFA
TRB
FVA)
RVA) Valve assembly
FVA)
RVB)
BT
A Hose (TFA
FVL
Hose (TRB
VIEW C
TFA
D
Vibrator motor (F)
RVA)
Valve assembly
RVA
Hose (BA1 Hose (PA2
SECTION A-A
TBT
RVL
Vibrator motor (R)
Hose (BT TBT) FVA)
TRB
VIEW D
Hose (TRB
The letters and numbers in the figure such as “TFA” and “FVA” show each port. ; ” symbols show the hose connection and the direction of the flow of the oil. Arrow “
RVB)
0559-49805-0-10838-B
4-012
HYDRAULIC SYSTEMS
3-2. Hydraulic Component Specifications 3-2-1. Vibrator hydraulic motor
1
2
4
2
3
3
4 1 Hydraulic circuit diagram Flow of oil (Low amplitude/Oscillation) 2 3 Clockwise rotation 3 2 Counterclockwise rotation (High amplitude/Normal) SW652-1-04005
(1) Drain port (2) Port A (3) Port B (4) Drain port
: 3/ 4-16UNF [FVA][RVA] : 1 1/16-12UN [FVB][RVB] : 1 1/16-12UN [FVL][RVL] : 3/ 4-16UNF
Specifications • Displacement • Working pressure • Allowable motor case pressure • Weight
: 23.5 cm3/rev : 28 MPa : 0.2 MPa : 12 kg
( 1.43 cu.in./rev ) ( 4,060 psi ) ( 29 psi ) ( 26 lbs )
4-013
HYDRAULIC SYSTEMS
3-2-2. Valve assembly 4
5
6 12
1
2
11 3 7
10
13
8 9 3
2
1 14
14 16
5
18 10
4 (+) 1.8 1
(-)
R2
7
6
13
12
18
17
16
Connection diagram
15
Hydraulic circuit diagram SW654-04004
(1) (2) (3) (4) (5) (6) (7) (8) (9)
Port B Port CP Port A Solenoid valve b Port MP Port B1 Port A1 Port Port
Specifications • Rated flow • Rated pressure
[BBB] : 1 1/16-12UN [BCP] : 9/16-18UNF [BAA] : 1 1/16-12UN :
7/16-20UNF
[TFA] : G3/4 [TRB] : G3/4
(10) Solenoid valve a (11) Flushing valve (12) Port (13) Port (14) Relief valve (R1) (15) Block (16) Port P (17) Body (18) Port T
: 100 L/min ( 26.4 gal./min : 35 MPa ( 5,075 psi : 0.5 MPa ( 72.5 psi • Relief valve pressure setting : 31.5 MPa ( 4,568 psi : 1.3 MPa ( 189 psi • Weight : 26 kg ( 57.3 lbs.
4-014
[BB1] : G3/4 [BA1] : G3/4
[BP]
: 1 1/16-12UN
[B3]
:
) ) (1 to 3, 5, 16) ) (18) ) (14) ) (R2) )
9/16-18UNF
HYDRAULIC SYSTEMS
4. STEERING SYSTEM
Hydraulic oil filter
4-1. Steering Hydraulic Piping Hose (FO SFG)
FS
Hose (STF
Hose (STF
FS)
FS)
Hose (T STF)
Hose (STF
Hose (T STF) Hose (SFG
SFG
STF
STF
STF
PG2)
T1
T2
E
T8
FO
Load solenoid valve
FS)
Hose (B4 LP)
Hose (LT T8)
Hose (B3 P)
Hose (FO SFG)
S3 LT
S4
SFG
LP
DETAIL A
Coupling : Charge pressure gauge port Hose (R
Hose (L SRL)
SRR)
Hose (SR2
Hose (B4 LP)
Load pump
SLR) PG2
Hose (SFG
Vibrator pump
DETAIL E
PG2)
Steering charge pump
Hose Hose (T2 S4) (T1 S3)
Hose (SR1
SLL)
SECTION B-B Orbitrol
C
L T Hose (T STF) P
SECTION D-D
Steering cylinder (L)
Steering cylinder (R)
C
PG2
R
B3 B4
SECTION C-C
D
D
Hose (T STF)
A B
F
B
T8
STF SFG
Hydraulic oil tank
Suction filter SR1
SRL
SRR
SR2
The letters and numbers in the figure such as “R” and “SRR” show each port. ; ” symbols show the hose connection and the direction of the flow of the oil. Arrow “
SLL
SLR
Hydraulic oil tank
VIEW F 0559-32804-0-10870-B
4-015
HYDRAULIC SYSTEMS
4-2. Steering Wheel 1
2
3
4
5
0559-32802-0-20493-0
(1) Nut (2) Steering wheel (3) Column shaft
: M12 P=1.25
(4) Bolt (5) Orbitrol
: M10×30
N•m
(1) Nut M12 P=1.25 (4) Bolt M10×30
: 54 to 64 N·m ( 40 to 47 lbf·ft ) : 49 N·m ( 36 lbf·ft )
4-016
HYDRAULIC SYSTEMS
4-3. Hydraulic Component Specifications 4-3-1. Orbitrol
1
2
5
4 1 3
3
4 2
Hydraulic circuit diagram GW751-04016
(1) Port L (2) Port R (3) Port P (4) Port T (5) Relief valve
[L] : 3/4-16UNF [R] : 3/4-16UNF [P] : 3/4-16UNF [T] : 3/4-16UNF
Specifications • Displacement : 230 cm3/rev ( 14.0 cu.in./rev ) • Maximum pressure : 17.2 MPa ( 2,494 psi ) • Relief valve pressure setting : 15.7 MPa ( 2,277 psi ) • Weight : 7.7 kg ( 17.0 lbs. )
4-017
HYDRAULIC SYSTEMS
4-3-2. Load solenoid valve
4
3 1 5 Hydraulic circuit diagram 2
4
5
1
3
SW654-04003
(1) Port B : G3/4 (2) Load solenoid valve (3) Port A : G3/4 (4) Port T [LT] : G3/4 (5) Port P [LP] : G3/4 Specifications • Maximum flow : 75 L/min • Maximum pressure : 21.0 MPa • Relief valve pressure setting : 12.7 MPa • Weight : 1.30 kg
( 19.8 gal./min ( 3,045 psi ( 1,842 psi ( 2.9 lbs.
) ) ) )
4-018
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
1. Precautions for work 1-1. Wire Numbers, Wire Sizes, Wire Colors and Connectors Shown in Electrical Circuit Diagram, Wiring Harness Layout and Wiring Harnesses • Codes used in electrical circuit diagrams give the following information. • The wire size is AVS 0.85 unless otherwise specified. 26 Lg
7 5G
24 1.25 BR R2
26 Lg
B BR
4 5BY
Wire color AVS wire size Wire number
24 1.25BR
ACC
28 LgW
R1
C
STARTER SWITCH
Fuel sensor (BrR),(GL)
Wire color Reference page
J
(P.5-005)
Mark S
Starter relay harness
Type of terminal
(P.5-017)
58X-2F
3LY Marking "C"
C
* * 9 Brw
38 LY
38
63 GB
* * 63 9 GB Brw
SWP-4㧲
SWP-4M
LY
120
Marking
770
50
2BrW
AVS Size
70
Wire color (Indicated inconnectors in case of wires)
Length between
200
38
Reference page
Corrugate Ǟ70
58X-2M 9
9 38 2BrW 3LY
Wire number
Marking
C Corrugate Ǟ13
CB104
GB,100
Corrugate Ǟ10
63
Wire number Protection between
Type of terminal
• The pin or socket layout of mating connectors are symmetrical, either vertically or horizontally. When the connector valves are connected, the pin and socket that have the same number are connected. Wire number Terminal type
Wire number
BR,70
2Lg,70
1.25LgW,70
4
LA305
(B)
24
LA105
(BR)
26
LA205
(C)
28
LA105
(ACC)
BW,150
Starter switch
5BY,70
Switch terminal number
WG,150
RY,150
RW,150
94
(1)
93
(3)
30
(4)
97
(5)
Throttle switch
Switch terminal number
5-001
ELECTRICAL SYSTEM • Wire color code chart B
Black
W White R
Red
G
Green
Y
Yellow
Br Brown L
Blue
Lg Light green
O
Orange
Gy Gray (Gr)
Sb Sky blue P
Pink
Pu Purple
5-002
Black/ White stripe White/ WR Red stripe Red RW /White stripe Green/ GW White stripe Yellow/ YR Red stripe Brown/ BrW White stripe Blue/ LW White stripe Light green/ LgR Red stripe BW
Black/ Yellow stripe White/ WB Black stripe Red/ RB Black stripe Green/ GR Red stripe Yellow/ YB Black stripe Brown/ BrR Red stripe Blue/ LR Red stripe Light green/ LgY Yellow stripe BY
Yellow/ Orange/ OW Orange stripe White stripe Blue/ Orange/ LO OB Orange stripe Black stripe Green/ Orange/ GO OG Orange stripe Green stripe Gray/ Gray/ GyR GrW Red stripe White stripe Gray/ Gray/ GyL GrY Blue stripe Yellow stripe Gray/ GrB Black stripe Pink/ Pink/ PB PG Black stripe Green stripe Pink/ PL Blue stripe YO
Black/ Black/ BG Red stripe Green stripe White/ White/ WL WY Blue stripe Yellow stripe Red/ Red/ RY RG Yellow stripe Green stripe Green/ Green/ GY GB Yellow stripe Black stripe Yellow/ Yellow/ YG YL Green stripe Blue stripe Brown/ Brown/ BrY BrB Yellow stripe Black stripe Blue/ Blue/ LY LB Yellow stripe Black stripe Light green/ Light green/ LgB LgW Black stripe White stripe BR
Black/ Blue stripe White/ WG Green stripe Red/ RL Blue stripe Green/ GL Blue stripe Yellow/ YW White stripe Brown/ BrG Green stripe Blue/ LG Green stripe Light green/ LgL Blue stripe BL
BrL
Brown/ Blue stripe
ELECTRICAL SYSTEM
L04 2RW
R
L07 GR
GR(L)
L08 G
GY
L06 LY
2
3 4
5
6
7
BACKUP BUZZER COMBINATION LAMP (R,L) BACKUP LAMP (L) 21W L09 WR R TAIL LAMP L01 BY RY (L) 5W L10 GY GR STOP LAMP L08 G G (L) 21W TURN SIGNAL N B LAMP (L) 21W
L05 2RG
6
V16 Br E67 WR V36 BrW E66 LR E78 0.5R E54 0.5W E33 GrR
INJ2-COM(3) B03 INJ3-COM(2) B04 INJ4-COM(1) B05 SHIELD GND B06 INJ1-DRV(9) B08 INJ2-DRV(8) B09 INJ3-DRV(7) B10 INJ4-DRV(6) B11 SHIELD GND B12 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
E14 1.25B E18 1.25W E18 1.25B E14 1.25G N B E15 1.25R E20 1.25R E19 1.25G E16 1.25W N B E43 RW E57 BW E63 RB E57 BW E44 RY E57 BW E45 WY V65 B V71 RG
AIR FLOW (+)(4) AIR FLOW VO(3) AIR FLOW GND(2) AIR FLOW POW.(1)
AIR FLOW SENSOR
V45 0.5BY V49 0.5GY E69 0.5LY N 0.5B V01 0.5WB
2 6
A B
C D
E F G H
K04 PG
I
F
B C
G
N B
N B
D I
H
PARKING SERVO BYPASS BRAKE SOLENOID SOLENOID
W03 GrY
G08 OW
W06 LgB
P15 RY
L14 P
5
3 P15 RY
2
1
B
W06 LgB
4
W01 2LW
3
5
N
1
2
W03 GrY
W05 2W
WATER SPRAY PUMP (F)
1
2
W10 Gr 1
3 2
W10 Gr 1
W12 2YB
W12 2YB
W11 GY 3
5
N B
1
2
LIQUID SPRAY PUMP (OPTION)
3
P12 2WY
W04 2LR
P13 2WG
P15 2RY
W01 2LW
P16 WB
P17 WL
P18 RL
P20 1.25WL
P14 YR
P21 YL
P23 2R
P23 2R
2
N 2B
P
N 2B
W12 YB R
LIQUID SPRAY SOLENOID (OPTION)
N B W11 GY
LIQUID SPRAY SWITCH (OPTION)
P07 3WL
W05 2W
P09 5WR
E73 G-SIG
FUSE BOX (1)
W02 2WR
1
FUSE BOX (2)
V65 A-GND11
N 2B
P
4
LIQUID SPRAY RELAY (OPTION)
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
16_16M
15_16M
14_16M
13_16M
12_16M
11_16M
P
W02 2WR
N B
9_16M
8_16M
10_16M
V07 GL
7_16M
2
B
ROTATORY LAMP ROTATORY LAMP (OPTION) SWITCH(OPTION)
Z03 YW
K03 WY
6_16M
5_16M
4_16M
3_16M
3
WATER SPRAY SWITCH (R)
P21 YL
V06 YG
K10 LR
L12 LB
K03 WY
K08 GB
1_16M
12_12F
11_12F
9_12F
10_12F
8_12F
2_16M
V34 BrY
K09 P
V29 OIL-SW
N B
E58 A-GND5
7_12F
E72/E75 NE(12)-GND
N
2
WATER SPRAY PUMP (R)
3
COMBINATION METER
V48 INTAKE THROTTLE
W04 2LR
5
1
WATER SPRAY SWITCH (F)
E76 A-GND2 E52 NE(12)-SIG
4 3
WATER SPRAY RELAY (F)
P23 2R
E53 G-VCC
1
P20 1.25WL
N B
L05 RG
W10 Gr W09 GrW
WATER SPRAY MODE SELECT SWITCH
P12 2WY W03 GrY
G07 LW
2
WATER SPRAY RELAY (R)
K13 OG N B
5
3
W09 GrW
P12 2WY W06 LgB
A E
V50 A-VCC10
E48 FUEL TEMP E13 A-VCC1
K03 WY
E49/E68 PFUEL1/2
P11 LgR
E47 INTAKE AIR TEMP
B
E56 A-GND1 E67 BOOST SENSOR E66 COOLANT TEMP E78 A-GND6
RESISTOR IG-SW V13/V33 +BP V18/V58/V38/V78 +BF V01/V21
E33 A-VCC2
MAIN V03/V23
FUEL GAUGE UNIT
V13 LgR V01 WB
B
YG
V01 WB
LED
ECO LAMP
CAN2-L V17
E34 INJ COMMON
K11 Sb
CAN2-H V37
V17 RB
V17 RB
V37 RW
V37 RW
E18 INJ COMMON
V13 LgR
E38 INJ COMMON CAN1-L V16 CAN1-H V36
E20/E40 INJ DRVTWV4 E19/E39 INJ DRVTWV2
A-VCC11(+5V) V51
E16/E36 INJ DRVTWV3
APS1(SIG) V47 A-GND12 V46
E43 OUTLET DPF E57 A-GND3
APS2(SIG) V67
E63 OUTLET DOC
A-GND13 V66 TACHMETER PULSE V34 SPEED SENSOR V14
V16 Br
V16 Br
V36 BrW
V36 BrW N B
V51 0.5R V47 0.5W V46 0.5B V67 0.5W V66 0.5B
LOAD #12 SUB-ECU LAMP #13 GND #16 V45 A-GND10 V49 INTAKE TEMP E69 AFS-SIG
ECU
HYDRAULIC OIL FILTER SWITCH
BATTERY(+) #22 CAN-H #23 CAN-L #24 LOAD ON/OFF #35 INHIBIT SW.OUT #39 ACC #44
SUB ECU
5 2
+V2
V34 BrY
S12 GR S13 RY N B S22 R
2
N B
V01 3WB 4 5
3
P25 3BY
2
1
CAN-L
CAN-L
CAN-H
CAN-H
S23 GW
GND
N B
5
N B
1
2
G11 BW PARKING SW. V75 N-SW. V30 DPF SW. V56 OIL PRE.LAMP V06 HEATER LAMP V07 DPF REQUEST LAMP V28 DPF ACTIVE LAMP V26 OVERHEAT LAMP V27 STOP LAMP V08
4
V34 BrY
5
3 V75 BrR 1
4 3
V30 LB S24 LR
SPEED PULSE ON/OFF RELAY
WARNING LAMP V09 STOP-SW. V32 DPF INHIBIT SW. V74
ECU
V75 BrR
ST
B
R1
R2
ACC
BR
ON
E
V05 YB
OFF
V05 YB
STARTER V05
NO
COM
BR
E
P11 LgR
BATTERY RELAY
ECU P11 LgR V01 WB
V28 YR
N B
N B
P
FUEL PUMP
V26 YB V27 LgW
P02 5R V24 BR
V08 YL R
3
V01 WB G
LED
V74 Lg
E
STARTER MOTOR
V24 BR
HEATER RLY V24
STARTER SWITCH
V07 GL
G
ENGINE WARNING LAMP
V08 YL
R
G
LED
ENGINE STOP LAMP
B
E
B
S1(50)
V06 YG
V09 YW
R
B (30)
V12 YG
ST-SW V12
HT
V56 BrB
C
(X1)
(X2)
(X1)
(X2)
V26 YB
LED
V28 YR
LED
R
V27 LgW
LED
ENGINE OVER HEAT LAMP
DPF ACTIVE LAMP (GREEN)
DPF REQUEST LAMP (AMBER)
1
2
K01 5BY B
G
g
e
N
P02 5R
B AV60 B(HEB 60)
GLOW RELAY
V56 BrB
GLOW HEATER
DPF SWITCH
+ 12V 115D31R BATTERY
YG
SUB ECU LAMP
S23 GW S24 LR
P17 WL
L13 GrB
V01 WB 3
5
V74 Lg
1
2
V01 WB
S
STARTER RELAY
NEUTRAL RELAY
V30 LB
C
S22 R
4 3 24V
K02 3BW
K05 GY B
S22 3R
ECU MAIN RELAY
N B
L
ALTERNATOR
K06 RG
PARKING INTERLOCK RELAY
V13 LgR
POTENTIOMETER
2
5
V03 LgY
V14 O N B
3 1
V75 BrR
V01 3WB
GND2
N B
E45 DIFF SEN. SIG.
OUT1
OUT2
6 1
4
G11 BW
V13 LgR
ECU SUB (CAN) ECU (SERVICE (CAN) TOOL)
+V1 GND1
V50 0.5R
ECU
V71 A-VCC12(MAX10mA)
THERMO UNIT
G
V03 LgY
RESISTOR
E14 INJ COMMON
E44 INLET DOC
K10 LR
DPF METER
V40/V60 SIGNAL GND
E15/E35 INJ DRVTWV1
P24 15B
Y
N B
E54 G-GND
ENGINE KUBOTA V3307-CR-TE4B AIR FLOW (-)(5)
L15 GY
E77 A-GND4
V20/V39/V79/V80/V59 GND
INJ1-COM(4) B02
V75 BrR
5
P01 5BR
E56 LW
VIBRATOR SOLENOID
4
N B
65A
E47 GR
N B
G09 Br
AV60 B(HEB 60)
E49 0.5W
SPEED CHANGE SWITCH
DIODE UNIT
sol.a
N B
W07 LgY
AV60 B(HEB 60)
CAM SHAFT(2) A40 SENSOR BOOST(3) A41
E13 0.5B
sol.b
W07 LgY
WATER SPRAY CHANGE RELAY
P04 5W
RAIL PRESSURE(3) A39
E48 GB
P17 WL 1
3
G06 BR
VIBRATION SWITCH
HIGH (NORMAL)
6
65A
EGR VALVE(2) A36 COOLANT TEMP(1) A38
E73 0.5B
SPEED CHANGE SOLENOID
2
4
3 5
4
P03 5W
SENSOR BOOST(2) A33
V65 0.5B
3
K12 PL
LOW (OSCILLATION)
5
1
4
W08 Lg
P07 3WL
EGR VALVE(1) A31
V29 Lg
G07 LW
1
1 P12 WY
G06 BR
2 6
2
W07 LgY
2
P12 WY
3
1
W08 Lg
N B
G08 OW
P16 WB
B
N B
VIBRATORY DRUM SELECT SOLENOID
sol.a
3
2
W08 Lg
45A
INTAKE TEMP(2) A30
E58 GW
G02 GW
NC COM
P09 5WR
INTAKE TEMP(1) A29
E13 0.5B
6
R
FOOT BRAKE SWITCH
N B
L13 GrB
3
N B
4
WATER SPRAY TIMER
F-R LEVER VIBRATION SWITCH (L)
sol.b
G02 GW
G06 BR
Br
65A
RAIL PRESSURE(2) A28
E72 0.5R
W
W
P06 3WL
RAIL PRESSURE(1) A26
V48 0.5W
R
L10 GY
G05 W
P08 5WR
FUEL TEMP(1) A24
E52 0.5W
L11 O
4
G01 BrW
VIBRATORY DRUM SELECT SWITCH
P22 Y
B
G
NO
SUB POWER (120W)
4
HORN SWITCH HORN RELAY
E21 INTAKE THRO.(-)
W
G
F-R LEVER VIBRATION SWITCH (R) F
G01 BrW
P09 5WR
CAM SHAFT(1) A23
E53 0.5R
E09/E29 SCV(+)
N B
B
K13 OG
OIL SW(1) A21 INTAKE THRO.(4) A22
E76 P
HORN
R
P18 RL
BACKUP BUZZER SWITCH
N B
PARKING BRAKE SWITCH
P15 RY N
G
Z02 LB L09 WR
3 5
G04 YW
B
L06 LY
HAZARD SWITCH N B
E
W12 YB
FUEL TEMP(2) A20
V50 0.5R
L06 LY
K04 PG
CRANK SHAFT(1) A19
E77 WG
4
L05 RG
CRANK SHAFT(2) A18
E21 L
5
L
6_12F
INTAKE THRO.(3) A17
E09 Gr
1
L01 BY
CRANK SHAFT(3) A15
K07 2Y
E01 INTAKE THRO.(+)
FLASHER UNIT
L06 LY
2 6
5_12F
CAM SHAFT(3) A14
E01 WL
E10/E30 SCV(-)
3
L08 G
INTAKE THRO.(2) A12 COOLANT TEMP(2) A13
L08 G
N 2B E10 BR
L07 GR
4_12F
SENSOR BOOST(1) A09
N 2B
C2 (4)
L07 GR
SCV(2) A07 INTAKE THRO.(6) A08
C1 (1)
3_12F
EGR VALVE(4) A06
C2 (4)
L01 BY
INTAKE THRO.(5) A04
C1 (1)
7
4
1_12F
SCV(1) A03
C2 (4)
5
P14 YR
L12 LB
NO1 NC1 NO2 NC2 NO1 NC1 NO2 NC2 NO1 NC1 NO2 NC2 (2) (3) (5) (6) (2) (3) (5) (6) (2) (3) (5) (6)
C1 (1)
P15 2RY
1
2_12F
SHIELD GND A01 EGR VALVE(3) A02
C2 (4)
MIHAALU(R) (W)(OPTION)
2
L11 O
V13 LgR
C1 (1)
MIHAALU(F) (W)(OPTION)
FLOOD LAMP SWITCH MIHAALU(POWER) (R)(OPTION)
3 POSITION SWITCH CENTER RIGHT
P05 BW
C2 (4)
3 4
Z01 PB
L05 2RG C1 (1)
1
N B
1
2
P18 RL
L02 2Y
LIGHTING LO-HI SWITCH
B
G(R)
1
COM NO
W
P10 3BR
LEFT
TURN SIGNAL SWITCH
L03 2RB
P11 LgR
NO1 NC1 NO2 NC2 NO1 NC1 NO2 NC2 (2) (3) (5) (6) (2) (3) (5) (6)
COMBINATION LAMP (F,L) TURN SIGNAL L08 G G LAMP (L) 21W L01 BY Y SIDE MARKER LAMP (L) 5W N B
L16 W
Y
G11 BW
W
P19 LR
2 POSITION SWITCH LEFT RIGHT
L09 WR
B
V12 YG
16
N B
G10 YG
NC
Br
VIBRATION MODE CHANGE SWITCH
R
F-R LEVER SWITCH
FLOOD LAMP (L) 55W
B
N B
P10 3BR
12
15
L03 1.25RB
R
P13 2WG
G03 L
3
P25 3BY
11
14
W(Lo)
L05 1.25RG
1
V13 LgR
10
L04 1.25RW
7
G06 BR
2
G09 Br
P22 Y
9 13
HEAD LAMP (L) 60/55W
R(Hi)
5
6
LIGHTING SWITCH
FLOOD LAMP (R) 55W
B
N B
L02 2Y
P18 RL
B
P19 LR
8 12
8
R
W
S22 3R
7 11
7
L05 1.25RG
G09 Br
P05 BW
6 10
6
L03 1.25RB
3 4
P13 2WG
P04 5W
5 9
5
L04 1.25RW
W(Lo)
2
VIBRATION AUTO SWITCH
P04 5W
4
4
R(Hi)
1
L01 BY
R
K06 RG
3
3
HEAD LAMP (R) 60/55W
N B
G10 YG
K07 2Y
2
2
GROUND REV. PULSE INPUT 2 FUEL METER TEMPERATURE METER LAMP CHECK PARKING BRAKE HYD. OIL FILTER WARNING ENGINE OIL PRESS. WARNING CHARGE WARNING PREHEATING REV. RATIO SEL.1 (OPEN) REV. RATIO SEL.2 (GND) REV. RATIO SEL.3 (OPEN) REV. RATIO SEL.4 (OPEN) COOLANT TEMP. SEL.1 (OPEN) COOLANT TEMP. SEL.2 (OPEN)
L01 BY
V01 3WB
1
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Y
COMBINATION LAMP (R,R) TURN SIGNAL L07 GR G LAMP (R) 21W L10 GY GR STOP LAMP (R) 21W L01 BY GY TAIL LAMP L09 WR R (R) 5W BACKUP N B LAMP (R) 21W
K05 GY
BATTERY 12V (+) BATTERY 24V (+) STARTER SWITCH (ACC) REV. PULSE INPUT 1 COMBI. METER ILLUMI. TURN SIGNAL (R) TURN SIGNAL (L) SIDE MARKER LAMP FLOOD LAMP WATER SPRAY LIQUID SPRAY VIBRATOR COMBINATION METER SWP12M SWP16F
L07 GR
N/A 24 N/A 23 N/A 22 N/A 21 5A 20 5A 19 20A 18 5A 17 5A 16 15A 15 5A 14 20A 13
1 2 3 4 5 6 7 8 9 10 11 12
G
VALVE
2-1. Electrical Circuit Diagram
COMBINATION LAMP (F,R) TURN SIGNAL LAMP (R) 21W SIDE MARKER LAMP (R) 5W
G08 OW
2. SYSTEM CIRCUIT DIAGRAM
N B
K14 BrY S12 GR
LOAD RELAY
R
R
SOL LOAD SOLENOID
POWER REV.SIG GND OUT1
R
Z01 PB
W
Z02 LB
B
N B
Y
Z05 Br
MIHAALU (F) (OPTION)
POWER REV.SIG GND OUT1
R
Z01 PB
W
L09 WR
B
N B
Y
Z04 GY
MIHAALU (R) (OPTION)
0559-99084-0-11146-A
5-003
ELECTRICAL SYSTEM
3. ELECTRICAL COMPONENTS
Horn Hydraulic oil filter switch harness
3-1. Wiring Harness Layout (1) Mark F
Member (F) harness (P.5-022)
(P.5-029)
Combination lamp (F) harness (P.5-023)
Servo bypass solenoid
Hydraulic oil filter switch (LR)
Load solenoid
B
Mark H
(B),(BrY)
(B),(GY)
Fuel gauge unit harness (P.5-030)
Sub power
Fuel gauge (B),(P)
Combination lamp (R,R) Head lamp harness (P.5-021)
Head lamp (R)
C Mihaalu (option) MF
VIEW A
Flood lamp (R)
A
(B),(RG)
Load solenoid CB104
ECU(CAN)(service tool) Head lamp harness
Mihaalu(option) MR
B
R
BrY
R
ECU harness
(P.5-021)
CA104
(P.5-013)
DETAIL B
Combination lamp (R) harness (P.5-025)
Head lamp (L)
Flood lamp (L)
G
(B),(RG)
Backup buzzer (B),(W)
Water spray pump (R)
Water spray pump (F)
Water spray pump harness (P.5-031)
Mark W
Vibrator solenoid a RH Diode
Battery relay harness
Vibrator solenoid b LH
Water spray pump harness
J
K
(P.5-005)
H
(P.5-005)
(P.5-027)
F Ground
Mark FR
L
(P.5-005)
Parking brake solenoid PB
Member (R) harness (P.5-024)
Vibratory drum select solenoid b Upr
Diode
Main harness
CA104
Main harness
(P.5-007)
NO(G)
YW
COM(Br)
BR
NC(W)
W
(P.5-007)
Diode
CB104 CA104
VIEW E
Mark R
(B),(YW)
F-R lever vibration switch (L) harness
(P.5-005)
(P.5-031)
Rotatory lamp (option) Liguid spray solenoid (option)
(P.5-017)
Diode
Mark RR
Combination lamp (R,L)
D
DETAIL F
VIEW C
[58Y-2],[58X-3],[SWP-12]
Vibratory drum selector solenoid a Lwr
ECU harness (P.5-013)
VIEW G
E
Speed change solenoid SC
Main harness (P.5-007)
Fuse relay harness (1) (P.5-009)
[SWP-2],[SWP-2],[SWP-16] Fuel pump
[58Y-2],[58X-4],[58X-4], [SWP-6],[SWP-8],[SWP-14]
DETAIL D
0559-09821-0-10951-A
5-004
ELECTRICAL SYSTEM
3-2. Wiring Harness Layout (2)
Alternator ALT
Starter motor STA
(B),(RW)
Starter switch harness
(P.5-019)
ECU harness
Mark ST
Main harness
(P.5-007)
(P.5-013)
Main harness
(P.5-007)
Q Mark V Dashboard harness
ECU harness
(P.5-026)
(P.5-013)
Engine connector A
VIEW H Main harness
(P.5-007)
Engine harness
Mark ST
ECU harness
(P.5-013)
Starter switch harness
Foot brake switch
(P.5-019)
(P.5-020)
P
N M
F-R lever vibration switch (R) harness
R
(P.5-028)
Glow heater
(W)
Dashboard harness
(P.5-026)
NO(G)
W
COM(Br)
L
NC(W)
YW
CA104 CB104
Air flow sensor
DETAIL Q
Backup buzzer switch
Potentiometer
Vibration AUTO switch
Turn signal switch
(P)
Thermo unit
F-R lever switch
G(GR),GR(G),GY(LY)
Combination lamp (F,L)
B(B),G(G),Y(BY)
BR (LgR)
SECTION M-M
VIEW N
NO(W) NC(R) BW
B (W)
R1 (N/A)
COM(B) NO(W) NC(R) COM(B)
Main harness [58X-4F] To Control panel harness
RL Br
Main harness [58X-3F] To Control panel harness
R2 (N/A)
COM(B) NO(W) NC(R)
Main harness [SWP-12F] To Control panel harness
Combination lamp (F,R)
B(B),G(GR),Y(BY)
C (BR)
Starter switch Main harness Mark B To Control panel harness
Mark STA
ACC (LR)
Y WR LB
Main harness [SWP-14F] To Control panel harness
VIEW K
(YW)
VIEW J Main harness Mark A To Control panel harness
ECU harness
(P.5-013)
Mark ALT
VIEW P CB104
Engine connector C
Engine harness
COM:B(WB),NC:R(O),NO:W(GY)
M
Horn switch
Engine connector B
(P.5-020)
Combination lamp (F) harness
VIEW R
(P.5-023)
VIEW L 0559-09821-0-10952-A
5-005
ELECTRICAL SYSTEM
3-3. Wiring Harness Layout (3)
Lighting switch
Lighting Lo-Hi switch
2(WG),3(BY),5(WG),6(Y),7(B)
1(RB),2(Y),3(RW),7(B)
Hazard switch
ECO lamp
1(LY),2(GR),4(LY),5(G)
Combination meter
B(Sb),YG(LgR)
Parking brake switch
(P.5-035 )
Flood lamp switch
1(O),2(BrR),3(GrB),4(LB),5(B)
Water spray timer
2(RY),3(RG),5(YR),6(PB),7(B)
1(Gr),2(GrY)
Vibration mode change switch
S Speed change switch
1(Br),2(BR),3(L)
1(WL),2(PL)
T
Water spray switch (F)
U
WR
Vibratory drum select switch
W
1(RL),2(BrW),4(RL),5(GW)
DPF meter
Cord
DPF switch
(P.5-032)
T
U
1(WB),2(BrB)
ENGINE WARNING lamp
Water spray switch (R)
G(YW),R(WB)
1(Gr),2(LgB)
Control panel harness
DPF request lamp
ENGINE STOP lamp
(P.5-015)
X1(YR),X2(WB)
G(YL),R(WB)
Vibration switch
1(BR),2(OW),4(BR),5(LW)
DPF active lamp
ENGINE OVER HEAT lamp
Water spray mode select switch
X1(YB),X2(WB)
G(LgW),R(WB)
1(WY),2(LgY),3(Lg),4(WY),5(GrW)
Fuse relay harness (1),(2)
VIEW S
(P.5-009),(P.5-011)
Fuse relay box
Sub ECU lamp
(P.5-011),(P.5-033),(P.5-034)
B(RY),YG(WB)
Diode unit
Glow relay
Sub ECU
ECU
Starter relay STR ECU main relay MAI
Flasher unit
VIEW U-U
Fuse relay harness (1),(2) (P.5-009),(P.5-011)
Load relay
VIEW T-T
0559-09005-0-11209-0 0559-09822-0-11210-A
5-006
ELECTRICAL SYSTEM
DT06-2S
SWP-2M
SWP-2F
G08 N OW B
50
150 RH Corrugate
LH
50 Tape
300 Corrugate
50 Tape
K03 K08 20 WY GB
80 Tape
Marking tape 50 V06 V07 V08 V09 Tape (Color:white) YG GL YL YW V26 V27 V28 V56 YB LgW YR BrB 20 20 SWP-16F 200 P11 * * V37 Tape LgR * * 0.75RW Corrugate 500 * * * V17 Twist pair cable Corrugate * * * 0.75RB V17,V37 (AVSS 0.75mm2×2C)
58X-2F
Rotatory lamp (option)
5-007
Z03 CB104 N
CA104
* *
L05
B,50
50
100 Tape
R
SWP-8M
80 Tape
450 Corrugate 3B,50
58X-4F Water spray pump harness (P.5-031)
N
7123-2825 Fuel pump
LA208 Ground
50 Corrugate
50 Corrugate
Sub power SWP-6M
DT04-2P-E005
Fuel gauge unit harness (P.5-030) SWP-3F
P20 N 1.25WL B
K09 N P B
70
20
20 58Y-2F
Starter switch harness (P.5-019)
A
V17 RB V37 RW
SWP-16F
* *
* *
Servo bypass solenoid
Z04 Z05 GY Br SWP-2F Mihaalu (option)
20
SWP-2F N L13 B GrB
* *
420 Corrugate
SWP-2M Cap
B
SWP-6F
ECU harness (P.5-013)
Fuse relay harness (1) (P.5-009)
300 Corrugate
V01 WB N
20
Twist cable processing diagram
V34 V13 V01 BrY LgR WB L15 L14 L06 V75 20 GY P LY BrR SWP-14M W08 W06 W03 Lg LgB GrY W12 W11 W10 W09 YB GY Gr GrW
600 Corrugate
* *
70
P17 P16 P14 P05 20 WL WB YR BW P22 P21 P19 P18 Y YL LR RL
20
N 2B
70
20 Tape
W W02 W05 2WR 2W
70
58X-4M
G09 G08 G07 Br OW LW K13 K04 G11 OG PG BW
P10 P04 3BR 5W
Control panel harness (P.5-015)
Control panel harness (P.5-015)
P15 P13 20 2RY 2WG N P20 3B 1.25WL
20
V
2 wire twist cable
160 Tape
100 Corrugate
50
2RG
YW,50
50 Tape
* * * * N B
58X-3F
58X-4F
20
Member (R) harness (P.5-024)
L01 L07 L08 BY GR G L09 L10 L16 SWP-12F WR GY W Z01 * Z04 PB * GY
58X-4F
P12 P23 20 WY 2R W02 W05 2WR 2W
160 Tape
L13 P17 20 GrB WL
SWP-12F
20 Tape
50 Tape
N G08 100 B OW
SWP-14F
58Y-2M
50
ECU harness (P.5-013)
50
SWP-16F
20 P10 P04 3BR 5W
L06 L07 L08 LY GR G L14 P11 P19 P LgR LR
700 Corrugate
80 Corrugate
150 Corrugate
20
H
400 Corrugate
LR,50
500 Corrugate
PB
SC
N L13 B GrB DT06-2S Parking brake solenoid
N K12 B PL DT06-2S Speed change solenoid
58X-4F
Member (F) harness (P.5-022) 20
600 Corrugate
N L04 2B 2RW L15 L03 GY 2RB
F
20
Diode (solenoid b) DT04-2P-RT01
G07 N LW B
SWP-16F
80 Tape
L03 L04 2RB 2RW
200 Corrugate
Vibrator solenoid b (low/oscillation) DT06-2S
N G07 100 B LW
L05 2RG
80 Corrugate
DT06-2S
N G02 100 B GW
P23 N 2R 3B
20
Vibrator solenoid a (high/normal)
Twist pair cable V17,V37 (AVSS 0.75mm2×2C)
P13 P15 2WG 2RY
20
DT06-2S
150 Tape
L01 L06 L07 L08 BY LY GR G L09 L11 L13 L16 WR O GrB W * * Z01 Z03 * * PB YW
200 Corrugate
Diode (solenoid a) DT04-2P-RT01
Lwr
250 Corrugate
P05 P12 P14 BW WY YR P17 P18 P21 * WL RL YL * W03 W06 W08 GrY LgB Lg W09 W10 W11 W12 GrW Gr GY YB
200 Corrugate
DT06-2S
50
50 Tape
G01 G02G03 G06 BrW GW L BR G07 G08 G09 * LW OW Br * K03 K04 K08 K09 WY PG GB P K10 K12K13 * LR PL OG *
20
Diode (solenoid a) DT04-2P-RT01
G02 N GW B
Upr
V01 V06 V07 V08 WB YG GL YL V09 V13 V26 V27 YW LgR YB LgW V28 V34 V56 V75 YR BrY BrB BrR V17 V37 * * 0.75RB 0.75RW * *
100 Corrugate
DT06-2S
50
680 Corrugate
G03 G04 G05 G09 L YW W Br G11 L09 L10 L11 SWP-12F Dashboard harness BW WR GY O (P.5-026) P16 P18 P22 Z02 WB RL Y LB
ST
100 Corrugate
Vibratory drum select solenoid a (rear)
G01 N BrW B
N LA208 Ground
B
20
DT06-2S
N G01 100 B BrW
A
50
Vibratory drum select solenoid b (front)
(Color:white)
200 Corrugate
50
DT06-2S
Marking tape
620 Corrugate
Diode (solenoid b) DT04-2P-RT01
W,50
CB104 G05
200 Corrugate
(W/NC)
200 Corrugate
20 Tape
BR,50
(Br/COM) CA104 G06
3B,50
CB104 G04
(G/NO)
300 Corrugate
20 Tape
YW,50
220 Corrugate
F-R lever vibration switch harness (L) (P.5-027)
250
4-1. Main Harness
400 Corrugate
20
4. WIRING HARNESSES
Z01 Z05 PB Br * Z02 * LB
SWP-4F
L01 N BY B L07 L08 GR G
SWP-4F
K10 CB104
Combination lamp (F) harness (P.5-023)
Hydraulic oil filter switch harness (P.5-029)
1559-09096-0-11254-0
ELECTRICAL SYSTEM No.
SIZE, COLOR
CONTACT POINTS
G01
BrW
3
G02
GW
G03
No.
SIZE, COLOR
CONTACT POINTS
B , Upr × 2
P13
2WG
2
Control panel harness (4F), Fuse • relay harness (1)(4M)
3
B , Lwr × 2
P14
YR
2
Control panel harness (14F), Fuse • relay harness (1)(8M)
L
2
B, V
P15
2RY
2
Control panel harness (4F), Fuse • relay harness (1)(4M)
G04
YW
2
V , F-R lever vibration switch (L) harness-G/NO
P16
WB
2
V , Fuse • relay harness (1)(8M)
G05
W
2
V , F-R lever vibration switch (L) harness-W/NC
P17
WL
3
Control panel harness (14F), ECU harness, Fuse • relay harness (1)(8M)
G06
BR
2
B , F-R lever vibration switch (L) harness-Br/COM
P18
RL
3
V , Control panel harness (14F), Fuse • relay harness (1)(8M)
G07
LW
4
B , RH × 2, Fuse • relay harness (1)(6M)
P19
LR
2
ST , Fuse • relay harness (1)(8M)
G08
OW
4
B , LH × 2, Fuse • relay harness (1)(6M)
P20
1.25WL
2
Fuse • relay harness (1)(4M), Sub power
G09
Br
3
B , V , Fuse • relay harness (1)(6M)
P21
YL
2
Control panel harness (14F), Fuse • relay harness (1)(8M)
G11
BW
2
V , Fuse • relay harness (1)(6M)
P22
Y
2
V , Fuse • relay harness (1)(8M)
K03
WY
2
B , ECU harness
P23
2R
2
Control panel harness (4F), Fuse • relay harness (1)(4F)
K04
PG
2
B , Fuse • relay harness (1)(6M)
V01
WB
3
A , Fuel pump, Fuse • relay harness (1)(14M)
K08
GB
2
B , ECU harness
V06
YG
2
A , ECU harness
K09
P
2
B , Fuel gauge unit harness
V07
GL
2
A , ECU harness
K10
LR
2
B , Hydraulic oil filter switch harness
V08
YL
2
A , ECU harness
K12
PL
2
B , SC
V09
YW
2
A , ECU harness
K13
OG
2
B , Fuse • relay harness (1)(6M)
V13
LgR
2
A , Fuse • relay harness (1)(14M)
L01
BY
3
H , R , Control panel harness (12F)
V17
0.75RB
2
A , ECU harness
L03
2RB
2
F , Control panel harness (3F)
V26
YB
2
A , ECU harness
L04
2RW
2
F , Control panel harness (3F)
V27
LgW
2
A , ECU harness
L05
2RG
2
R , Control panel harness (3F)
V28
YR
2
A , ECU harness
L06
LY
3
ST , Control panel harness (12F), Fuse • relay harness (1)(14M)
V34
BrY
2
A , Fuse • relay harness (1)(14M)
L07
GR
4
H , R , ST , Control panel harness (12F)
V37
0.75RW
2
A , ECU harness
L08
G
4
H , R , ST , Control panel harness (12F)
V56
BrB
2
A , ECU harness
L09
WR
3
R , V , Control panel harness (12F)
V75
BrR
2
A , Fuse • relay harness (1)(14M)
L10
GY
2
R, V
W02
2WR
2
W , Fuse • relay harness (1)(4F)
L11
O
2
V , Control panel harness (12F)
W03
GrY
2
Control panel harness (14F), Fuse • relay harness (1)(14M)
L13
GrB
4
PB , Control panel harness (12F), ECU harness, Servo bypass solenoid
W05
2W
2
W , Fuse • relay harness (1)(4F)
L14
P
2
ST , Fuse • relay harness (1)(14M)
W06
LgB
2
Control panel harness (14F), Fuse • relay harness (1)(14M)
L15
GY
2
F , Fuse • relay harness (1)(14M)
W08
Lg
2
Control panel harness (14F), Fuse • relay harness (1)(14M)
L16
W
2
R , Control panel harness (12F)
W09
GrW
2
Control panel harness (14F), Fuse • relay harness (1)(14M)
W10
Gr
2
Control panel harness (14F), Fuse • relay harness (1)(14M)
23
F , H , LH × 2, Lwr × 2, PB , R × 2, RH × 2, SC , Upr × 2, W , Control panel harness (4F), Ground × 2, Fuel gauge unit harness, Fuel pump, Fuse • relay harness (1)(4M), Servo bypass solenoid, Sub power
W11
GY
2
Control panel harness (14F), Fuse • relay harness (1)(14M)
W12
YB
2
Control panel harness (14F), Fuse • relay harness (1)(14M)
N
B,2B,3B
CONNECTION
CONNECTION
P04
5W
2
ST , Fuse • relay harness (1)(2M)
Z01
PB
3
F , R , Control panel harness (12F)
P05
BW
2
Control panel harness (14F), Fuse • relay harness (1)(8M)
Z02
LB
2
F, V
P10
3BR
2
ST , Fuse • relay harness (1)(2M)
Z03
YW
2
R , Control panel harness (12F)
P11
LgR
2
ST , ECU harness
Z04
GY
2
R , Mihaalu (option)
P12
WY
2
Control panel harness (14F), Fuse • relay harness (1)(4F)
Z05
Br
2
F , Mihaalu (option) 5-008
ELECTRICAL SYSTEM
4-2. Fuse • Relay Harness (1) Fuse box (2)
20
80 Tape
100 Corrugate
140 Corrugate
460 Corrugate
100 Corrugate
20
* *
Marking tape
7123-9246
G B
K01 5BY P02 5R
N e 20 B V24 g BR
80 Tape
160 Corrugate
Glow relay
Main harness (P.5-007)
Starter relay
ECU main relay
TYCO : VCF4-1002
TYCO : VCF4-1002
K02 3BW V05 K05 YB GY P25 3BY
V01 3WB V03 S22 LgY R S22 3R
20
20
STR
MAI
200 Corrugate
160 Corrugate
20
20 Tape
20
160 Tape
20
20 Tape
P20 N 1.25WL 3B
SWP-8F
P05 P14 P16 P17 BW YR WB WL P18 P19 P21 P22 RL LR YL Y
SWP-6F
G07 G08 G09 LW OW Br G11 K04 K13 BW PG OG
SWP-14F
V01 V13 V34 WB LgR BrY V75 L06 L14 L15 BrR LY P GY W03 W06 W08 GrY LgB Lg W09 W10 W11 W12 GrW Gr GY YB
20
80 Tape
50 Tape
K01 K02 5BY 3BW
V01 S22 3WB R
V03 V05 V12 V13 LgY YB YG LgR V14 V24 V30 V34 O BR LB BrY V75 S13 P11 * BrR RY LgR *
K07 2Y 58Y-2F
58X-3F ECU harness (P.5-013)
5-009
30
58X-4F
P13 P15 2WG 2RY
950 Corrugate
130 Corrugate
58X-2M Cap
30
50 Tape
160 Tape
20
160 Tape
20
G08 * * W06 OW * * LgB G07 K13 * K04 W03 LW OG * PG GrY
20
W05 W02 2W 2WR
Liquid spray solenoid (option)
180 Corrugate
7319-3090
80 Tape
20 Tape
Diode unit
P23 P12 2R WY
20
20
58X-4M
P04 P10 5W 3BR
80 Tape
58Y-2F
20
80 Tape
120 Corrugate
L06 L 20 LY N P15 E B B RY
7123-2835
* *
58X-2F
150 Corrugate
(Color:white) Flasher unit
W12 N 2YB 2B
P04 P02 5W 5R
P09 P07 5WR 3WL
N P11 B LgR
58Y-2M
58Y-2F
SWP-2F
200 Corrugate
W11 P23 W12 GY 2R 2YB N * B *
3B,20
7123-2262
20
Liquid spray relay (option)
350 Corrugate
50 Tape
250 Corrugate
RY,50
CA104 S13
Relay box
300 Corrugate
Sub ECU lamp
Fuse box (1)
Fuse relay harness (2) (P.5-011)
30
WB,50
CB104 V01
Battery relay harness (P.5-017) N
LA208
Ground
SWP-12F
1559-09084-0-11187-0
ELECTRICAL SYSTEM
No.
SIZE, COLOR
CONTACT POINTS
G07
LW
2
G08
OW
G09
CONNECTION
CONNECTION
No.
SIZE, COLOR
CONTACT POINTS
Diode unit, Main harness (6F)
P18
RL
2
Main harness (8F)
Fuse 9
2
Diode unit, Main harness (6F)
P19
LR
2
Main harness (8F)
Fuse 15
Br
2
Main harness (6F)
Relay 5-5
P20
1.25WL
2
Main harness (4F)
Fuse 11
G11
BW
3
Main harness (6F)
Relay 1-3, 2-1
P21
YL
2
Main harness (8F)
Fuse 12
K01
5BY
2
ECU harness, Glow relay
P22
Y
2
Main harness (8F)
Fuse 15
K02
3BW
2
STR , ECU harness
P23
2R
3
Fuse 1
K04
PG
2
Diode unit, Main harness (6F)
Main harness (4M), Liguid spray relay (option)
K05
GY
2
STR
P25
3BY
2
STR
Fuse 13
K06
RG
2
S13
RY
2
ECU harness, Sub ECU lamp
K07
2Y
2
ECU harness
S22
R,3R
4
MAI × 2, ECU harness
Fuse 18
K13
OG
2
Diode unit, Main harness (6F)
V01
WB,3WB
5
MAI , ECU harness, Main harness (14F), Sub ECU lamp
Fuse 20
L06
LY
2
Flasher unit, Main harness (14F)
V03
LgY
2
MAI , ECU harness
L14
P
2
Main harness (14F)
Relay 4-2
V05
YB
2
STR , ECU harness
L15
GY
2
Main harness (14F)
Relay 4-5
V12
YG
2
ECU harness
Fuse 14
V13
LgR
3
ECU harness, Main harness (14F)
Fuse 16
14
Battery relay harness, Flasher unit, Glow relay, Ground, Main harness (4F), Liguid spray relay (option), Liguid spray solenoid (option)
V14
O
2
ECU harness
Relay 3-4
V24
BR
2
ECU harness, Glow relay
V30
LB
2
ECU harness
Relay 2-3
V34
BrY
3
ECU harness, Main harness (14F)
Relay 3-3
V75
BrR
4
ECU harness, Main harness (14F)
Relay 1-1, 3-1
N
B,2B,3B
(1)
(2)
Fuse 19 Fuse 19, Relay 1-5 Fuse 20
Relay 1-2, 2-2, 2-5, 3-2, 5-2, 6-2, 7-2
(1)
(2)
P02
5R
2
Battery relay harness, Glow relay
P04
5W
3
Battery relay harness, Main harness (2F)
Fuse 17
P05
BW
2
Main harness (8F)
Fuse 17
W01
2LW
2
P07
3WL
2
Battery relay harness
Fuse 1
W02
2WR
2
Main harness (4M)
Fuse 4
P09
5WR
3
Battery relay harness
Fuse 5, 10
W03
GrY
3
Diode unit, Main harness (14F)
Relay 7-1
P10
3BR
2
Main harness (2F)
Fuse 13
W04
2LR
2
P11
LgR
2
Battery relay harness, ECU harness
W05
2W
2
Main harness (4M)
Fuse 3
P12
WY,2WY
4
Main harness (4M)
Fuse 2, Relay 6-3, 7-3
W06
LgB
3
Diode unit, Main harness (14F)
Relay 6-1
P13
2WG
2
Main harness (4F)
Fuse 5
W08
Lg
2
Main harness (14F)
Relay 5-4
P14
YR
2
Main harness (8F)
Fuse 10
W09
GrW
2
Main harness (14F)
Relay 5-1
P15
RY,2RY
5
Flasher unit, Main harness (4F)
Fuse 6, Relay 4-1, 4-3
W10
Gr
2
Main harness (14F)
Relay 5-3
P16
WB
2
Main harness (8F)
Fuse 7
2
Main harness (8F)
Fuse 8
GY
2
P17
WL
W11 W12
YB,2YB
3
Fuse 4, Relay 7-5
Fuse 3, Relay 6-5
Main harness (14F), Liguid spray relay (option) Main harness (14F), Liguid spray relay (option), Liguid spray solenoid (option)
5-010
ELECTRICAL SYSTEM
4-3. Fuse • Relay Harness (2)
20A
5A
RL 9
Fuse box (1) (P.5-033)
(5WR) (5WR) 5A 15A P20 P21
YR 10
1.25WL 11
YL 12
P04 5W 5A P05
P04 5W 20A S22
K05
V01
*
*
*
*
Fuse 12
UNI F630 P21
GY 5A K06
3WB 5A K07
* N/A *
* N/A *
* N/A *
* N/A *
Fuse 11
UNI F630 P20
3BR 13
YG 14
Y 15
LgR
BW 17
3R 18
RG 19
2Y 20
* 21
* 22
* 23
* 24
Fuse 10
Speed pulse ON/OFF relay
G11 BW K06 RG
V30 LB N B
V34 BrY
N B
* V75 * BrR 1
N B
* G11 * BW 2
5A
Fuse box (2) (P.5-034)
Neutral relay
* * N V14 V75 B O BrR 3
Horn relay
L14 P
P15 RY L15 GY
* P15 * RY 4 Relay box
UNI F630 P14 UNI F630 P09
5A
Water spray change relay
Water spray relay (R)
Water spray relay (F)
W10 Gr G09 Br N W08 W09 B Lg GrW 5
P12 2WY W04 2LR
P12 2WY W01 2LW N * W03 B * GrY 7
N B
* W06 * LgB 6
Fuse 9
UNI F630 P18
Fuse 8
UNI F630 P17
Fuse 7
UNI F630 P16
Fuse 6 Fuse box (1)
UNI F630 P15 UNI F630 P13
Fuse 5
UNI F630 P09 UNI F630 W01 Fuse 4
UNI F630 W02 UNI F630 W04 Fuse 3
UNI F630 W05 4 NC
Fuse 2
3 3 COM
5 NO
1(coil)
2(coil)
supply
ground
Fuse 20
UNI F630
UNI F630
UNI F630
UNI F630
Fuse 19
UNI F630
Fuse 18
UNI F630
Fuse 17
UNI F630
Fuse 16
UNI F630
Fuse 15
UNI F630
Fuse 14
UNI F630
B,200
2LR,200 GrW,160
Gr,160
P19 LR 5A V13
Parking interlock relay
LgB,200
B,160
P19 LR 15A P22
15A
UNI F630
15A
P25 3BY 5A V12
20A
2LW,200
2WY,200
P25 3BY 20A P10
16
UNI F630
(P09)
P09 5WR 5A P14
15A
K07
2Y,160
WL 8
V01
3WB,160
WB 7
K06
RG,160
2RY 6
K05
GY,160
2WG 5
S22
3R,140
2LW 4
P05
BW,140
2LR 3
(5WR) (5WR) 15A 15A P17 P18
P04
5W,140
2WY 2
(5WR) (5WR) 15A 15A P15 P16
V13
LgR,120
2R 1
2WR 15A W01
P22
Y,120
2W 15A W04
P09 5WR 20A P13
(P09)
P19
LR,120
W02
(P09)
V12
YG,100
W05
(P09)
2WY,200
P10
3BR,100
P07 3WL 20A P12
(P09)
B,200
P25
3BY,100
P07 3WL 20A P23
(P09)
GrY,200
UNI F630
Fuse 13
Fuse box (2)
UNI F630 P23 Fuse 1
5 2
4
UNI F630 P12
UNI F630 P07 1
YL,200
Lg,160
1.25WL,200
Br,160
YR,180
RY,160
5WR,180
P,160
RL,180
RY,160
WL,160
GY,160
WB,160
BrR,120
2RY,140
B,120
2WG,140
BrY,120
5WR,140
O,120
2LW,120
BW,120
2WR,120
B,120
2LR,120
LB,120
2W,120
B,120
2WY,100
BrR,120
2R,100
B,120
3WL,100
BW,120 RG,120
W03 FASTON F480 (1) N
FASTON F480 (2)
P12 FASTON F630 (3)
Relay 7
W01 FASTON F630 (5) W06 FASTON F480 (1) N
FASTON F480 (2)
P12 FASTON F630 (3)
Relay 6
W04 FASTON F630 (5) W09 FASTON F480 (1) N
FASTON F480 (2)
W10 FASTON F630 (3)
Relay 5
W08 FASTON F480 (4) G09 FASTON F630 (5) P15 FASTON F480 (1) L14 FASTON F480 (2) P15 FASTON F630 (3)
Relay 4
Relay box
L15 FASTON F630 (5) V75 FASTON F480 (1) N
FASTON F480 (2)
V34 FASTON F630 (3)
Relay 3
V14 FASTON F480 (4) G11 FASTON F480 (1) N
FASTON F480 (2)
V30 FASTON F630 (3) N
Relay 2
FASTON F630 (5)
V75 FASTON F480 (1) N
FASTON F480 (2) Relay 1
G11 FASTON F630 (3) K06 FASTON F630 (5)
Pin position Fuse relay harness (1) (P.5-009)
1559-09084-0-11188-0
5-011
ELECTRICAL SYSTEM
No.
SIZE, COLOR
CONTACT POINTS
G07
LW
2
G08
OW
G09
CONNECTION
CONNECTION
No.
SIZE, COLOR
CONTACT POINTS
Diode unit, Main harness (6F)
P18
RL
2
Main harness (8F)
Fuse 9
2
Diode unit, Main harness (6F)
P19
LR
2
Main harness (8F)
Fuse 15
Br
2
Main harness (6F)
Relay 5-5
P20
1.25WL
2
Main harness (4F)
Fuse 11
G11
BW
3
Main harness (6F)
Relay 1-3, 2-1
P21
YL
2
Main harness (8F)
Fuse 12
K01
5BY
2
ECU harness, Glow relay
P22
Y
2
Main harness (8F)
Fuse 15
K02
3BW
2
STR , ECU harness
P23
2R
3
Fuse 1
K04
PG
2
Diode unit, Main harness (6F)
Main harness (4M), Liguid spray relay (option)
K05
GY
2
STR
P25
3BY
2
STR
Fuse 13
K06
RG
2
S13
RY
2
ECU harness, Sub ECU lamp
K07
2Y
2
ECU harness
S22
R,3R
4
MAI × 2, ECU harness
Fuse 18
K13
OG
2
Diode unit, Main harness (6F)
V01
WB,3WB
5
MAI , ECU harness, Main harness (14F), Sub ECU lamp
Fuse 20
L06
LY
2
Flasher unit, Main harness (14F)
V03
LgY
2
MAI , ECU harness
L14
P
2
Main harness (14F)
Relay 4-2
V05
YB
2
STR , ECU harness
L15
GY
2
Main harness (14F)
Relay 4-5
V12
YG
2
ECU harness
Fuse 14
V13
LgR
3
ECU harness, Main harness (14F)
Fuse 16
14
Battery relay harness, Flasher unit, Glow relay, Ground, Main harness (4F), Liguid spray relay (option), Liguid spray solenoid (option)
V14
O
2
ECU harness
Relay 3-4
V24
BR
2
ECU harness, Glow relay
V30
LB
2
ECU harness
Relay 2-3
V34
BrY
3
ECU harness, Main harness (14F)
Relay 3-3
V75
BrR
4
ECU harness, Main harness (14F)
Relay 1-1, 3-1
N
B,2B,3B
(1)
(2)
Fuse 19 Fuse 19, Relay 1-5 Fuse 20
Relay 1-2, 2-2, 2-5, 3-2, 5-2, 6-2, 7-2
(1)
(2)
P02
5R
2
Battery relay harness, Glow relay
P04
5W
3
Battery relay harness, Main harness (2F)
Fuse 17
P05
BW
2
Main harness (8F)
Fuse 17
W01
2LW
2
P07
3WL
2
Battery relay harness
Fuse 1
W02
2WR
2
Main harness (4M)
Fuse 4
P09
5WR
3
Battery relay harness
Fuse 5, 10
W03
GrY
3
Diode unit, Main harness (14F)
Relay 7-1
P10
3BR
2
Main harness (2F)
Fuse 13
W04
2LR
2
P11
LgR
2
Battery relay harness, ECU harness
W05
2W
2
Main harness (4M)
Fuse 3
P12
WY,2WY
4
Main harness (4M)
Fuse 2, Relay 6-3, 7-3
W06
LgB
3
Diode unit, Main harness (14F)
Relay 6-1
P13
2WG
2
Main harness (4F)
Fuse 5
W08
Lg
2
Main harness (14F)
Relay 5-4
P14
YR
2
Main harness (8F)
Fuse 10
W09
GrW
2
Main harness (14F)
Relay 5-1
P15
RY,2RY
5
Flasher unit, Main harness (4F)
Fuse 6, Relay 4-1, 4-3
W10
Gr
2
Main harness (14F)
Relay 5-3
P16
WB
2
Main harness (8F)
Fuse 7
2
Main harness (8F)
Fuse 8
GY
2
P17
WL
W11 W12
YB,2YB
3
Fuse 4, Relay 7-5
Fuse 3, Relay 6-5
Main harness (14F), Liguid spray relay (option) Main harness (14F), Liguid spray relay (option), Liguid spray solenoid (option)
5-012
ELECTRICAL SYSTEM
4-4. ECU Harness
ECU
Marking tape (Color:white)
20
Shield cable V50, V66, V67 (AVSSCS 0.5mm2×3C)
80 Tape 20 Tape 50 Tape
5-013
30
Corrugate (HCOT-FR)
Corrugate (HCOT-FR)
Tape
V01 K14 20 WB BrY S12 P17 Load relay GR WL
N LA208 Ground
380
560
V13 V36 LgR BrW N V16 B Br
CAN1-H V16 Br CAN1-L
Twist pair cable V16, V36 (AVSS 0.75mm2×2C) Twist pair cable S23, S24 (AVSS 0.75mm2×2C)
TYCO : 174257-2 ECU(CAN) (service tool)
V37 V17
V36 BrW
V36 BrW
A36 V16 Br A31
E13 0.5B
E78 0.5R E13 0.5B
A19 E52 0.5W A15 E72 0.5R A18 E73 0.5B
A23 E54 0.5W A40 E53 0.5R A14 V65 0.5B
A01
3 wire shield cable
B05 E14 1.25B B02 E15 1.25R B08 B11
E16 1.25W E18 1.25B
B04 E18 1.25W B03 E20 1.25R B09 B10 B06 B12
Corrugate (HCOT-FR)
V65 V48 V50
N 2B E14 1.25G
Shield cable E13, E49, E78 E13, E52, E72 E53, E54, E73 (AVSSCS 0.5mm2×3C)
E52 E72 E75 E73 E54 E53
E19 1.25G N B N B
CB104
N
CA104
N K14 B BrY
DT06-2S
E14 E34 E15 E35 E16 E36 E18 E38 E20 E40 E19 E39
V51 V47 V46
GND1
V50 0.5R
+V2 V67 0.5W OUT2 V66 0.5B GND2
V50 V67 V66 N B
2 wire twist cable Sub ECU (CAN)
CAN-H CAN-L
S23 GW S24 LR
1 7
ECU
4 wire shield cable
V51 0.5R +V1 V47 0.5W OUT1 V46 0.5B
3 wire shield cable
K14
G G R R W W W W R R G G
Machine side connector/engine side connector
Engine connector A
A39
E13 E49 E68 E78
A22 V48 0.5W A17 V50 0.5R A12
KUBOTA engine harness
Shield cable E14, E15, E16 E18, E19, E20 (MVVS 1.25mm2×4C) 5 2 N E14 E18 E18 E14 * 6 20 B 1.25G 1.25B 1.25W 1.25B * N E16 E19 E20 E15 * 12 B 1.25W 1.25G 1.25R 1.25R * 11 8 MOLEX : 12pf Engine connector B
V36 V16
3 wire shield cable
A26 E49 0.5W A28
Shield cable E14, E15, E16 (MVVS 1.25mm2×4C)
BrY,50
#23 #24
Ground
Sub ECU
Twist cable and shield cable processing diagram
Load solenoid
B,50
S23 GW S24 LR
50
V09 V08 V07 V06 YW YL GL YG V56 V28 V27 V26 BrB YR LgW YB 20 SWP-16M V37 * * P11 RW * * LgR V17 * * * Twist pair cable RB * * * V17, V37 (AVSS 0.75mm2×2C)
300
6110-4643
20
SWP-2M
K08 K03 20 GB WY
600 Corrugate (HCOT-FR) 3B,20
Main harness (P.5-007)
SWP-2F
460
20 Tape 80 Tape
P17 L13 20 WL GrB
3140
(Color:white)
160 Tape
20
200 Corrugate(HCOT-FR) 800 Corrugate(HCOT-FR) 400 Corrugate(HCOT-FR)
250 Tape
Marking tape
200
S22 V01 R 3BW 20 K07 2Y
ECU(CAN) (service tool)
Potentio meter
Corrugate (HCOT-FR)
K02 K01 20 3BW 5BY
V13 V12 V05 V03 LgR YG YB LgY V34 V30 V24 V14 SWP-12M BrY LB BR O * P11 S13 V75 * LgR RY BrR
Shield cable V46, V47, V51 V48, V50, V65 V50, V66, V67 (AVSSCS 0.5mm2×3C)
Corrugate (HCOT-FR)
58X-3M
Twist pair cable V16, V36 (AVSS 0.75mm2×2C)
V37 RW SWP-16M V17 RB
20
Fuse relay harness (1) (P.5-009)
Twist pair cable V17, V37 (AVSS 0.75mm2×2C)
Shield cable E18, E19, E20 (MVVS 1.25mm2×4C)
180 Corrugate (HCOT-FR)
1380
58Y-2M
280
Corrugate (HCOT-FR)
Shield cable V46, V47, V51 (AVSSCS 0.5mm2×3C)
700
6189-0319
V46 V47 V51 0.5B 0.5W 0.5R V66 V67 V50 0.5B 0.5W 0.5R
920
340
30
400
TS-5F
V01 N E69 V49 V45 0.5WB 0.5B 0.5LY 0.5GY 0.5BY
Corrugate (HCOT-FR)
58Y-2F
20
Corrugate
Tape
K01 K02 5BY 3BW
Corrugate (HCOT-FR)
Potentiometer
100
E80 E60 E40 E20 * * E20 E20 * * R R * * E19 E19 * * G G E78 E58 E18 E18 0.5R GW W W E77 E57 * * WG BW * * E76 E56 E16 E16 P LW W W E72 * E15 E15 0.5R * R R * E54 E14 E14 * 0.5W G G E73 E53 E33 E13 0.5B 0.5R GrR 0.5B E72 E52 * * 0.5R 0.5W * * * * * * * * * * E10 E10 E70 * * E10 * * BR BR E69 E49 E09 E09 0.5LY 0.5W Gr Gr E49 E48 * * 0.5W GB * * E67 E47 * * WR GR * * E66 * * * LR * * * E45 * * * WY * * * E44 * * * RY * * * E63 E43 * * RB RW * * * * * * * * * * E21 E01 * * * * L WL E61 E41 E21 E01
Corrugate (HCOT-FR)
Engine harness (P.5-020)
Air flow sensor
20
P11 K03 K08 LgR WY GB
SWP-3F
Tape
V80 V60 V40 V20 N N N N B B B B N N N * B B B * V01 V01 V01 V01 WB WB WB WB * * V37 V17 * * RW RB * V56 V36 V16 * BrB BrW Br V75 * * * BrR * * * V74 * V34 V14 Lg * BrY O * * V13 V13 * * LgR LgR * * * V12 * * * YG V71 V51 * * RG 0.5R * * V50 V30 * V70 * V10 * 0.5R LB * * V49 V29 V09 * 0.5GY Lg YW * V48 V28 V08 * 0.5W YR YL V67 V47 V27 V07 0.5W 0.5W LgW GL V66 V46 V26 V06 0.5B 0.5B YB YG V65 V45 * V05 0.5B 0.5BY * YB * * V24 * * * BR * * * V03 V03 * * LgY LgY * * * * * * * * * * V01 V01 * * WB WB V61 V41 V21 V01
2 wire twist cable
Main harness (P.5-007)
TYCO:1376886-1
150
200
Twist pair cable V16, V36 (AVSS 0.75mm2×2C)
Engine side connector MOLEX : 80pf (blue)
Engine connector B
20
20
16
* * * *
Tape
8
Engine connector C MOLEX : 16pf 6 3 * E57 E44 E57 E63 E57 E43 1 * BW RY BW RB BW RW * * * * V71 V65 E45 9 * * * * RG B WY 14 11
Machine side connector MOLEX : 80pf (gray)
6189-0319
Shield cable E13, E49, E78 E13, E52, E72 E53, E54, E73 V48, V50, V65 (AVSSCS 0.5mm2×3C)
Engine connector A TYCO : 42pf 2 3 N N E10 E01 1 4 2B 2B BR WL K07 E09 E21 * 5 8 L * 2Y Gr V50 E77 * * 9 12 WG * 0.5R * E76 E53 E52 * V48 13 17 P 0.5R 0.5W * 0.5W E72 E13 E58 V29 V65 18 22 0.5R 0.5B GW Lg 0.5B E73 E48 * E13 * 23 27 0.5B GB * 0.5B * E49 E47 E56 V16 * 28 32 0.5W GR LW Br * E67 * * V36 * 33 37 WR * * BrW * E66 E78 E54 E33 * 38 42 LR 0.5R 0.5W GrR * 39 40 41
* * * *
TYCO : 174259-2 Sub ECU(CAN)
22 S22 R V01 WB 44
18 * * * *
* * * *
* * * *
* * N * * B * V74 * * Lg * 40
13 * * * *
* * * *
80 Tape 10
S13 S12 * * * RY GR * * * L13 * * * * GrB * * * * 35 32 TYCO : 1376886-1 Sub ECU
20
5 * * * *
* * * *
* * * *
* * * * 27
Diode
1 * * * *
* * * * * * * S24 S23 LR GW * 23
Twist pair cable S23, S24 (AVSS 0.75mm2×2C)
1559-09088-0-11243-0
ELECTRICAL SYSTEM
No.
SIZE, COLOR
CONTACT POINTS
No.
SIZE, COLOR
CONTACT POINTS
ECU-E01, Engine connector A-4
E76
P
2
ECU-E76, Engine connector A-13
V13
LgR
4
ECU(CAN)(service tool), ECU-V13, -V33, Fuse • relay harness (1)
3
ECU-E09, -E29, Engine connector A-7
E77
WG
2
ECU-E77, Engine connector A-9
BR
3
ECU-E10, -E30, Engine connector A-3
E78
0.5R
2
ECU-E78, Engine connector A-39
V14
O
2
ECU-V14, Fuse • relay harness (1)
E13
0.5B
3
ECU-E13, Engine connector A-19, -26
K01
5BY
2
Engine harness, Fuse • relay harness (1)
V16
Br
3
ECU(CAN)(service tool), ECU-V16, Engine connector A-31
E14
G,1.25G
4
ECU-E14, -E34, Engine connector B-2, -5
K02
3BW
2
Engine harness, Fuse • relay harness (1)
V17
RB
2
ECU-V17, Main harness
E15
R,1.25R
3
ECU-E15, -E35, Engine connector B-8
K03
WY
2
Engine harness, Main harness
V24
BR
2
ECU-V24, Fuse • relay harness (1)
E16
W,1.25W
3
ECU-E16, -E36, Engine connector B-11
K07
2Y
2
Engine connector A-6, Fuse • relay harness (1)
V26
YB
2
ECU-V26, Main harness
E18
W,1.25W
4
ECU-E18, -E38, Engine connector B-3, -4
K08
GB
2
Engine harness, Main harness
V27
LgW
2
ECU-V27, Main harness
E19
G,1.25G
3
ECU-E19, -E39, Engine connector B-10
K14
BrY
3
Diode, Load relay, Load solenoid
V28
YR
2
ECU-V28, Main harness
E20
R,1.25R
3
ECU-E20, -E40, Engine connector B-9
L13
GrB
2
Main harness, Sub ECU-35
V29
Lg
2
ECU-V29, Engine connector A-21
E21
L
2
ECU-E21, Engine connector A-8
LB
2
ECU-V30, Fuse • relay harness (1)
GrR
2
ECU-E33, Engine connector A-41
N
V34
BrY
2
ECU-V34, Fuse • relay harness (1)
E43
RW
2
ECU-E43, Engine connector C-1
V36
BrW
3
E44
RY
2
ECU-E44, Engine connector C-5
P11
LgR
3
ECU(CAN)(service tool), ECU-V36, Engine connector A-36
V37
RW
2
ECU-V37, Main harness
E45
WY
2
ECU-E45, Engine connector C-9
ECU-V20, -V39, -V40, -V59, -V60, -V79, -V80, Air flow sensor, ECU(CAN)(service tool), Engine connector A-1, -2, B-6, -12, Diode, Ground, Load solenoid, Sub ECU-16 Engine harness, Fuse • relay harness (1), Main harness
V30
E33
0.5B,B, 2B,3B
P17
WL
2
Main harness, Load relay
V45
0.5BY
2
ECU-V45, Air flow sensor
E47
GR
2
ECU-E47, Engine connector A-29
S12
GR
2
Load relay, Sub ECU-12
V46
0.5B
2
ECU-V46, Potentiometer
E48
GB
2
ECU-E48, Engine connector A-24
S13
RY
2
Fuse • relay harness (1), Sub ECU-13
V47
0.5W
2
ECU-V47, Potentiometer
E49
0.5W
3
ECU-E49, -E68, Engine connector A-28
S22
R
2
Fuse • relay harness (1), Sub ECU-22
V48
0.5W
2
ECU-V48, Engine connector A-17
E52
0.5W
2
ECU-E52, Engine connector A-15
S23
GW
2
Sub ECU(CAN), Sub ECU-23
V49
0.5GY
2
ECU-V49, Air flow sensor
E53
0.5R
2
ECU-E53, Engine connector A-14
S24
LR
2
Sub ECU(CAN), Sub ECU-24
E54
0.5W
2
ECU-E54, Engine connector A-40
0.5R
3
0.5WB, WB,3WB
ECU-V50, Engine connector A-12, Potentiometer
V01
10
ECU-V01, -V18, -V21, -V38, -V58, -V78, Air flow sensor, Fuse • relay harness (1), Load relay, Sub ECU-44
V50 V51
0.5R
2
ECU-V51, Potentiometer
V56
BrB
2
ECU-V56, Main harness
V65
0.5B,B
3
ECU-V65, Engine connector A-22, C-10
V66
0.5B
2
ECU-V66, Potentiometer
V67
0.5W
2
ECU-V67, Potentiometer
V71
RG
2
ECU-V71, Engine connector C-11
V74
Lg
2
ECU-V74, Sub ECU-39
V75
BrR
2
ECU-V75, Fuse • relay harness (1)
No.
SIZE, COLOR
CONTACT POINTS
E01
WL
2
E09
Gr
E10
CONNECTION
17
CONNECTION
E56
LW
2
ECU-E56, Engine connector A-30
E57
BW
4
ECU-E57, Engine connector C-2, -4, -6
V03
2
ECU-E58, Engine connector A-20
3
ECU-V03, -V23, Fuse • relay harness (1)
E58
GW
LgY
2
ECU-E63, Engine connector C-3
YB
2
ECU-V05, Fuse • relay harness (1)
E63
RB
V05
2
ECU-E66, Engine connector A-38
YG
2
ECU-V06, Main harness
E66
LR
V06
2
ECU-E67, Engine connector A-33
GL
2
ECU-V07, Main harness
E67
WR
V07 V08
2
ECU-E69, Air flow sensor
2
ECU-V08, Main harness
E69
0.5LY
YL
3
ECU-E72, -E75, Engine connector A-18
YW
2
ECU-V09, Main harness
E72
0.5R
V09 V12
2
ECU-E73, Engine connector A-23
2
ECU-V12, Fuse • relay harness (1)
E73
0.5B
YG
CONNECTION
5-014
ELECTRICAL SYSTEM
4-5. Control Panel Harness
L07
(4)
FASTON 187
L06
(5)
FASTON 187
L08
(1)
FASTON 187
L11
(2)
Parking brake switch
Cord (P.5-032)
Speed change switch
Lighting switch
Lighting Lo-Hi switch
FASTON 187
L13
(4)
FASTON 187
L12
(5)
FASTON 187
N
(1)
FASTON 187
(2)
FASTON 187
P17
(2)
FASTON 187
K12
(2)
FASTON 250
P13
(3)
FASTON 250
L01
(5)
FASTON 250
P13
(6)
FASTON 250
L02
(7)
FASTON 250
N
(1)
FASTON 250
L03
(2)
FASTON 250
L02
(3)
FASTON 250
L04
DPF meter
FASTON 250
P15
(3)
FASTON 250
L05
(5)
FASTON 250
P14
(6)
FASTON 250
Z01
(7)
FASTON 250
N
DT06-6S
V17 V37 0.75RB 0.75RW * *
Resistor
DT04-3P-P006
5-015
V13 K11 LgR Sb N V17 B 0.75RB * V37 * 0.75RW
DT06-3S
200 Corrugate 10
BrR,200 GrB,200 LB,200
100 Tape
WR,100 W,100
50 Tape
WB,150 BrB,150
WL,100
100 Tape
PL,100
WB,100 50 Tape
2WG,100 BY,100 2WG,100 2Y,100
100 Tape
YB,70
220 Corrugate
10
WB,50 LgW,50
2RB,100
2RW,100
70 Tape
B,100
WB,70 50 Tape
YW,90
2RG,100
PB,100
50 Tape
B,100
20
180 Tape
Twist pair cable V17, V37 (AVSS 0.75mm2×2C) 20
80 Tape
YL,70 WB,90
2RY,100
YR,100
YR,100 WB,70
B,100
2Y,100
* V13 * P05 * LgR * BW L01 L08 L07 L01 BY G GR BY K13 W12 K04 L05 OG YB PG RG
30
B,200
N
(2)
30
O,200
L16
FASTON 187
Gr,90 K08 K09 V34 N GB P BrY B V06 K10 L12 K03 YG LR LB WY N * V07 K03 B * GL WY * * * * * * * *
40 Tape
G,100
L09
(1)
FASTON 250
LY,100
V75
(3)
(7)
Flood lamp switch
FASTON 187
GR,100
A
B
V08 V07 V06 V01 YL GL YG WB V27 V26 V13 V09 LgW YB LgR YW V75 V56 V34 V28 BrR BrB BrY YR * * V37 V17 * * 0.75RW 0.75RB
G06 G03 G02 G01 BR L GW BrW * G09 G08 G07 * Br OW LW K09 K08 K04 K03 P GB PG WY * K13 K12 K10 * OG PL LR
SWP-16M
SWP-16M Twist pair cable V17, V37 (AVSS 0.75mm2×2C)
70
FASTON 187
70
(2)
380 Corrugate 18
LY,100
P14 P12 P05 YR WY BW * P21 P18 P17 * YL RL WL W08 W06 W03 Lg LgB GrY W12 W11 W10 W09 YB GY Gr GrW
L08 L07 L06 L01 G GR LY BY L16 L13 L11 L09 W GrB O WR Z03 Z01 * * YW PB * *
P15 P13 2RY 2WG
L04 L03 2RW 2RB
N P23 3B 2R
L05 2RG
SWP-14M
SWP-12M
58X-4M
Main harness (P.5-007)
20
15
70
L06
22
FASTON 187
80 Tape
450 Corrugate
(1)
SWP-2M Cap
* *
N B W08 Lg
100
70
K11
* *
Rotatory lamp switch (option)
340 Corrugate
20 Tape
CA104
SWP-2F
Sb,50
50
(B)
20 P21 Z03 YL YW
LgR,50
V13
20 Tape
Hazard switch
CB104
50
(YG)
ECO lamp
80 Tape
40 Tape
GrY,90
Gr,90 40 Tape
Combination meter (P.5-035)
LgB,90
WY,90
SWP-12F
LgY,90 40 Tape
FASTON 187
(1)
V56
FASTON 187
(2)
V01
R1.25-3
(X2)
V28
R1.25-3
(X1)
V01
R1.25-3
(X2)
V26
R1.25-3
(X1)
Lg,90 WY,90 GrW,90
DPF switch
Br,100
DPF request lamp (amber)
70 Tape
DPF active lamp (green)
BR,100 L,100
RL,100 BrW,100
CB104
(R)
V27
CA104
(G)
V01
CB104
(R)
V08
CA104
(G)
V01
CB104
(R)
V09
RB4B-SL ACR6
Water spray timer
P23 W11 2R GY
58X-2F
Liquid spray switch (option)
* *
* *
58X-2M Cap
W10
FASTON 187
(1)
W03
FASTON 187
(2)
W10
FASTON 187
(1)
W06
FASTON 187
(2)
P12
FASTON 187
(1)
W07
FASTON 187
(2)
W08
FASTON 187
(3)
P12
FASTON 187
(4)
W09
FASTON 187
(5)
G09
FASTON 187
(1)
G06
FASTON 187
(2)
G03
FASTON 187
(3)
P18
FASTON 187
(1)
G01
FASTON 187
(2)
P18
FASTON 187
(4)
G02
FASTON 187
(5)
G06
FASTON 187
(1)
G08
FASTON 187
(2)
G06
FASTON 187
(4)
G07
FASTON 187
(5)
Water spray switch (F)
SWP-16M
V01
V01
W07 LgY W07 LgY
ENGINE OVER HEAT lamp
100 Tape
RL,100 GW,100
ENGINE STOP lamp
BR,100 OW,100
CA104
(G)
ENGINE WARNING lamp
BR,100 LW,100
(120Ω)
DPF meter
70 Tape
Water spray switch (R)
Water spray mode select switch
Vibration mode change switch
Vibratory drum select switch
Vibration switch
2 wire twist cable
V37 RW CAN2-H V17 RB
A
CAN2-L
Main harness (P.5-007)
Twist cable processing diagram 58X-3M
1559-09083-0-11183-A
ELECTRICAL SYSTEM
No.
SIZE, COLOR
CONTACT POINTS
No.
SIZE, COLOR
CONTACT POINTS
G01
BrW
2
B , Vibratory drum select switch -2
P13
2WG
3
Lighting switch -2, -5, Main harness (4M)
G02
GW
2
B , Vibratory drum select switch -5
P14
YR
2
Flood lamp switch -5, Main harness (14M)
G03
L
2
B , Vibration mode change switch -3
P15
2RY
2
Flood lamp switch -2, Main harness (4M)
G06
BR
4
B , Vibration mode change switch -2, Vibration switch -1, -4
P17
WL
2
Main harness (14M), Speed change switch -1
G07
LW
2
B , Vibration switch -5
P18
RL
3
Main harness (14M), Vibratory drum select switch -1, -4
G08
OW
2
B , Vibration switch -2
P21
YL
2
Main harness (14M), Rotatory lamp (option)
G09
Br
2
B , Vibration mode change switch -1
P23
2R
2
Main harness (4M), Liguid spray switch (option)
K03
WY
3
B , Combination meter (16M) × 2
K04
PG
2
B , Combination meter (12F)
K08
GB
2
B , Combination meter (16M)
K09
P
2
B , Combination meter (16M)
K10
LR
2
B , Combination meter (16M)
K11
Sb
2
DPF meter, ECO lamp -B
K12
PL
2
B , Speed change switch -2
K13
OG
2
B , Combination meter (12F)
CONNECTION
CONNECTION
V01
WB
7
A , DPF active lamp -X2, DPF request lamp -X2, DPF switch -1, ENGINE OVER HEAT lamp -R, ENGINE STOP lamp -R, ENGINE WARNING lamp -R
V06
YG
2
A , Combination meter (16M)
V07
GL
2
A , Combination meter (16M)
V08
YL
2
A , ENGINE STOP lamp -G
V09
YW
2
A , ENGINE WARNING lamp -G
V13
LgR
4
A , Combination meter (12F), DPF meter, ECO lamp -YG
V17
0.75RB
3
A , DPF meter, Resistor
V26
YB
2
A , DPF active lamp -X1
L01
BY
4
Combination meter (12F) × 2, Lighting switch -3, Main harness (12M)
L02
2Y
2
Lighting Lo-Hi switch -2, Lighting switch -6
V27
LgW
2
A , ENGINE OVER HEAT lamp -G
L03
2RB
2
Lighting Lo-Hi switch -1, Main harness (3M)
V28
YR
2
A , DPF request lamp -X1
L04
2RW
2
Lighting Lo-Hi switch -3, Main harness (3M)
V34
BrY
2
A , Combination meter (16M)
L05
RG,2RG
3
Combination meter (12F), Flood lamp switch -3, Main harness (3M)
V37
0.75RW
3
A , DPF meter, Resistor
L06
LY
3
Hazard switch -1, -4, Main harness (12M)
V56
BrB
2
A , DPF switch -2
L07
GR
3
Combination meter (12F), Hazard switch -2, Main harness (12M)
V75
BrR
2
A , Parking brake switch -2
L08
G
3
Combination meter (12F), Hazard switch -5, Main harness (12M)
W03
GrY
2
Main harness (14M), Water spray switch (F)-2
L09
WR
2
Cord, Main harness (12M)
W06
LgB
2
Main harness (14M), Water spray switch (R)-2
L11
O
2
Parking brake switch -1, Main harness (12M)
W07
LgY
3
Water spray mode select switch -2, Water spray timer × 2
L12
LB
2
Combination meter (16M), Parking brake switch -4
W08
Lg
3
L13
GrB
2
Parking brake switch -3, Main harness (12M)
Main harness (14M), Water spray mode select switch -3, Water spray timer
L16
W
2
Cord, Main harness (12M)
W09
GrW
2
Main harness (14M), Water spray mode select switch -5
W10
Gr
3
Main harness (14M), Water spray switch (F)-1, Water spray switch (R)-1
W11
GY
2
Main harness (14M), Liguid spray switch (option)
W12
YB
2
Combination meter (12F), Main harness (14M)
Z01
PB
2
Flood lamp switch -6, Main harness (12M)
Z03
YW
2
Main harness (12M), Rotatory lamp (option)
N
B,3B
9
Combination meter (16M) × 2, DPF meter, Flood lamp switch -7, Lighting Lo-Hi switch -7, Lighting switch -7, Main harness (4M), Parking brake switch -5, Water spray timer
P05
BW
2
Combination meter (12F), Main harness (14M)
P12
WY
3
Main harness (14M), Water spray mode select switch -1, -4
5-016
ELECTRICAL SYSTEM
4-6. Battery Relay Harness
65A
P01 5BR P02
65A(black)
130
3WL,50
65A
5R
5BR,50
65A
5W 50 Corrugate
Fusible link
240 Corrugate
LA308
(NO)
P01
LA308
(COM)
250 Corrugate
Battery relay 5W,50
P08 5WR
65A(black)
P08
150
P04
65A
(NO)
P03 5W
65A(black)
LA308
150 Corrugate 5WR,50
65A
P06
P03
LA308
(COM)
P11
LA204
(B)
N
LA204
(E)
190
P09 65A
5WR
45A(red)
100
P06 3WL
230
P07
Terminal cover
100 Corrugate
Corrugate
45A
LgR,50
B,100
Terminal cover
3WL
45A
30
30
30
100 Tape
P02 P04 5R 5W
P07 P09 3WL 5WR
P11 N LgR B
58Y-2F
58Y-2M
SWP-2M
30
N P11 B LgR
DT06-2S
DT04-2P-RT01
Diode
Fuse relay harness (1) (P.5-009)
1559-09075-0-11155-A
5-017
ELECTRICAL SYSTEM
No.
SIZE, COLOR
CONTACT POINTS
N
B
3
Battery relay -E, Diode, Fuse • relay harness (1)
P01
5BR
2
Fusible link 65A, Battery relay -COM
P02
5R
2
Fusible link 65A, Fuse • relay harness (1)
P03
5W
2
Fusible link 65A, Battery relay -COM
P04
5W
2
Fusible link 65A, Fuse • relay harness (1)
P06
3WL
2
Fusible link 45A, Battery relay -NO
P07
3WL
2
Fusible link 45A, Fuse • relay harness (1)
P08
5WR
2
Fusible link 65A, Battery relay -NO
P09
5WR
2
Fusible link 65A, Fuse • relay harness (1)
P11
LgR
3
Battery relay -B, Diode, Fuse • relay harness (1)
CONNECTION
5-018
ELECTRICAL SYSTEM
4-7. Stater Switch Harness
(ACC)
LA105
P19
(BR)
LA105
P11
LR,80
30
Turn signal switch
700 Corrugate
(B)
LA305
P04
G(R)
CB104
L07
GR(L)
CB104
L08
GY
CB104
L06
Horn switch CB104
L14
3BR,80
5W,80
GR,50
G,50
10
ST
30
7
P10
Main harness (P.5-007)
P04 P10 5W 3BR
58Y-2M
300 Corrugate
LA205
SWP-6M
LgR,80
Starter switch (C)
L08 L07 L06 G GR LY P19 P11 L14 LR LgR P
200 Tape
LY,50
P,50
200 Vinyl tube
1559-09076-0-21156-0
No.
SIZE, COLOR
CONTACT POINTS
P06
LY
2
ST , Turn signal switch (GY)
P07
GR
2
ST , Turn signal switch -R(G)
P08
G
2
ST , Turn signal switch -L(GR)
L14
P
2
ST , Horn switch
P04
5W
2
ST , Starter switch -B
P10
3BR
2
ST , Starter switch -C
P11
LgR
2
ST , Starter switch -BR
P19
LR
2
ST , Starter switch -ACC
5-019
CONNECTION
ELECTRICAL SYSTEM
4-8. Engine Harness Thermo unit
LA406
LE204
LA104
49
010
46
B
7 200 Corrugate
100 Tape
50
Terminal cover AV15 B,80
28 21 * BrR LgR *
50 Tape
150 Corrugate
400 Corrugate
150 Corrugate
7
10
ALT
350 Corrugate
6189-0443
7
(B)
Terminal cover YW,50
Glow heater
Terminal cover 5W,50
Alternator
10
50 Tape 100 Corrugate
ECU harness (P.5-013) 50 Tape
I
50 46 28 21 YW BrR LgR
SWP-3M
110
AV15 B,100
58Y-2M
10
STA
B
001 010
H 50 3RW 5W
001 3RW
49 LA408 (B)
PB104 (S)
Starter motor 1634-09119-0-21489-0
No.
SIZE, COLOR
CONTACT POINTS
001
3RW
2
H , STA
010
5W
2
H , Glow heater
21
LgR
2
ALT , I
28
BrR
2
ALT , I
46
YW
2
I , Thermo unit
49
B
2
ALT - B , STA - B
CONNECTION
5-020
ELECTRICAL SYSTEM
4-9. Head Lamp Harness
LA108
N
PB104
L15
N B
50
GY,50
0 20 e Tap
50
RB3B-SL
N B
50
L04 L03 1.25RW 1.25RB
150
900
Tape
Corrugate
400
7
Corrugate
50
10
Tape
L04 N 2RW 2B L03 L15 2RB GY
58X-4M
Member (F) harness (P.5-022)
F
50
1 rru 500 ga te
7
Head lamp (L)
Head RB3B-SL lamp (R)
L04 L03 1.25RW 1.25RB
15 0 Ta pe
Horn
B,50
Z05 Z01 Br PB * *
SWP-4M
Co
Z02 LB
Mihaalu (F) (option)
SWP-6F
Z01 N Z05 LY GR G * * Z02 * * LB
SWP-6M Cap
* * * *
* * * *
30
MF
* * * *
1559-09093-0-31249-0
No.
SIZE, COLOR
CONTACT POINTS
L03
1.25RB,2RB
3
F , Head lamp (L), (R)
L04
1.25RW,2RW
3
F , Head lamp (L), (R)
L15
GY
2
F , Horn
N
B,2B
5
F , MF , Head lamp (L), (R), Horn
Z01
PB
2
F , MF
Z02
LB
2
F , MF
Z05
Br
2
F , MF
5-021
CONNECTION
ELECTRICAL SYSTEM
4-10. Member (F) Harness
58X-4F
N L04 2B 2RW L15 L03 GY 2RB
20
20
Head lamp harness (P.5-021)
F
SWP-4F
Z01 Z05 PB Br * Z02 LB *
L04 N 2RW 2B L03 L15 2RB GY
58X-4M
Main harness (P.5-007)
3400 Corrugate
20
20
Z05 Z01 Br PB Z02 * LB *
SWP-4M
1559-09094-0-31250-0
No.
SIZE, COLOR
CONTACT POINTS
L03
2RB
2
F , Main harness
L04
2RW
2
F , Main harness
L15
GY
2
F , Main harness
N
2B
2
F , Main harness
Z01
PB
2
F , Main harness
Z02
LB
2
F , Main harness
Z05
Br
2
F , Main harness
CONNECTION
5-022
ELECTRICAL SYSTEM
4-11. Combination Lamp (F) Harness
Combination lamp (F,R)
Combination lamp (F,L) (Side marker (Turn signal lamp) lamp)
(Side marker (Turn signal lamp) lamp)
(Ground)
(Ground) B CA104
L01
L08
N
L01
L07
N
500 Corrugate
B,20 1250 Corrugate
B,20
G CB104
GR,20
Y CB104
BY,20
B CA104
G,20
G CB104
BY,20
Y CB104
1300 Corrugate
H
30
N L01 B BY L08 L07 G GR
SWP-4M
Main harness (P.5-007)
1559-09086-0-21196-0
No.
SIZE, COLOR
CONTACT POINTS
L01
BY
3
H , Combination lamp (F,L), (F,R)
L07
GR
2
H , Combination lamp (F,R)
L08
G
2
H , Combination lamp (F,L)
N
B
3
H , Combination lamp (F,L), (F,R)
5-023
CONNECTION
ELECTRICAL SYSTEM
4-12. Member (R) Harness
SWP-12M
* * * * N B
L01 L07 L08 BY GR G 20 L09 L10 L16 WR GY W Z01 * Z04 PB * GY
L08 L07 L01 G GR BY L16 L10 L09 20 W GY WR Z04 * Z01 GY * PB 1500 Corrugate
Main harness (P.5-007)
58X-2M
L05 2RG
SWP-12F
Combination lamp (R) harness (P.5-025)
R
20
* *
* * * * N B
20
* *
L05 2RG
58X-2F
1559-09095-0-21251-0
No.
SIZE, COLOR
CONTACT POINTS
L01
BY
2
R , Main harness
L05
2RG
2
R , Main harness
L07
GR
2
R , Main harness
L08
G
2
R , Main harness
L09
WR
2
R , Main harness
L10
GY
2
R , Main harness
L16
W
2
R , Main harness
N
B
2
R , Main harness
Z01
PB
2
R , Main harness
Z04
GY
2
R , Main harness
CONNECTION
5-024
ELECTRICAL SYSTEM
4-13. Combination Lamp (R) Harness
Combination lamp (R,L)
L08 L09 * G WR * L01 L10 N BY GY B
SWP-6F
* * * * N B
SWP-12M
Member (R) harness (P.5-024)
L08 L07 L01 G GR BY L16 L10 L09 W GY WR Z04 * Z01 GY * PB
50
B,150
50
L05 * 2RG *
400 Corrugate
10
900 Corrugate
150 Tape
10
CB104
L05
LA108
N
CB104
N
LA108
Backup buzzer
L07 L09 * 50 GR WR * L01 L10 N BY GY B
SWP-6F Combination lamp (R,R)
50
5 Ta 0 pe
Flood lamp (L)
L16
50
R Tape 58X-2M
W,100
150 Tape
1.25RG,100 50
1.25RG,100
Tape
B,150
7
MR
L05
CB104
N
LA108
Flood lamp (R)
B,150
1500 Corrugate
30
Z01 PB * *
N Z04 B GY * L09 * WR
SWP-6F
* * * *
* * * *
SWP-6M Cap
* * * *
Mihaalu (R) (option)
1559-09092-0-21248-0
No.
SIZE, COLOR
CONTACT POINTS
L01
BY
3
R , Combination lamp (R,L), (R,R)
L05
1.25RG,2RG
3
R , Flood lamp (L), (R)
L07
GR
2
R , Combination lamp (R,R)
L08
G
2
R , Combination lamp (R,L)
L09
WR
4
R , Combination lamp (R,L), (R,R), MR (option)
L10
GY
3
R , Combination lamp (R,L), (R,R)
L16
W
2
R , Backup buzzer
N
B
7
R , Backup buzzer, Combination lamp (R,L), (R,R), Flood lamp (L), (R), MR (option)
Z01
PB
2
R , MR (option)
Z04
GY
2
R , MR (option)
5-025
CONNECTION
ELECTRICAL SYSTEM
4-14. Dashboard Harness
F-R lever vibration switch (R) harness (P.5-028)
Foot brake switch
(Br/COM)
G03
(W/NC)
G04
(G/NO)
G05
(B)
P16
(R)
L11
(W)
L10
(B)
P18
Vibration AUTO switch
F-R lever switch
Backup buzzer switch
(W)
G09
(W)
G11
(B)
P22
(R)
Z02
(W)
L09
L,50 YW,50
50 Tape
W,50 WB,50 O,50
300 Tape
GY,50
RL,50 100 Tape
Br,50
BW,50
300 Corrugate
V 10
50 Tape
G09 G05 G04 G03 Br W YW L L11 L10 L09 G11 O GY WR BW Z02 P22 P18 P16 LB Y RL WB
SWP-12M
Main harness (P.5-007)
100 Tape
Y,50 LB,50
100 Tape
WR,50
1559-09078-0-21161-0
No.
SIZE, COLOR
CONTACT POINTS
G03
L
2
V , F-R lever vibration switch (R) harness -Br/COM
G04
YW
2
V , F-R lever vibration switch (R) harness -W/NC
G05
W
2
V , F-R lever vibration switch (R) harness -G/NO
G09
Br
2
V , Vibration AUTO switch -W
G11
BW
2
V , F-R lever switch -W
L09
WR
2
V , Backup buzzer switch -W
L10
GY
2
V , Foot brake switch -W
L11
O
2
V , Foot brake switch -R
P16
WB
2
V , Foot brake switch -B
P18
RL
2
V , Vibration AUTO switch -B
P22
Y
2
V , Backup buzzer switch -B
Z04
LB
2
V , Backup buzzer switch -R
CONNECTION
5-026
ELECTRICAL SYSTEM
4-15. F-R Lever Vibration Switch (L) Harness
Br,55 Main harness (P.5-007)
635 PVC tube ( 6×0.5)
G,55 W,55
Br,65
(1)
G,65
(2)
W,65
(3)
F-R lever vibration switch (L)
See “Wiring Harness Layout (1), DETAIL F”. (P.5-004)
1539-12013-0-30226-0
No.
SIZE, COLOR
CONTACT POINTS
–
Br
2
Main harness, F-R lever vibration switch (L)-1
–
G
2
Main harness, F-R lever vibration switch (L)-2
–
W
2
Main harness, F-R lever vibration switch (L)-3
5-027
CONNECTION
ELECTRICAL SYSTEM
4-16. F-R Lever Vibration Switch (R) Harness
Br,55 Dashboard harness (P.5-026)
635 PVC tube ( 6×0.5)
G,55 W,55
Br,65
(1)
G,65
(2)
W,65
(3)
F-R lever vibration switch (R)
See “Wiring Harness Layout (2), DETAIL Q”. (P.5-005)
1539-12013-0-30226-0
No.
SIZE, COLOR
CONTACT POINTS
–
Br
2
Dashboard harness, F-R lever vibration switch (R)-1
–
G
2
Dashboard harness, F-R lever vibration switch (R)-2
–
W
2
Dashboard harness, F-R lever vibration switch (R)-3
CONNECTION
5-028
ELECTRICAL SYSTEM
4-17. Hydraulic Oil Filter Switch Harness
Main harness CA104 (P.5-007)
LR,420
95
Vinyl
95
LE105
Hydraulic oil filter switch
1559-09024-0-30391-0
No.
SIZE, COLOR
CONTACT POINTS
95
LR
2
5-029
CONNECTION
Main harness, Hydraulic oil filter switch
ELECTRICAL SYSTEM
4-18. Fuel Gauge Unit Harness
P,20
Main harness (P.5-007)
SWP-3M
* *
N K09 B P
20
B2
1400 Corrugate
7
K09
CB104
Fuel gauge unit B,20
N
CA104
1539-09113-0-20885-A
No.
SIZE, COLOR
CONTACT POINTS
K09
P
2
B2 , Fuel gauge unit
N
B
2
B2 , Fuel gauge unit
CONNECTION
5-030
ELECTRICAL SYSTEM
4-19. Water Spray Pump Harness
Main harness (P.5-007)
58X-4M
W05 W02 2W 2WR N * * 2B
50
1000
W
Corrugate
10
200 Tape
200 Tap e
FR
50
RR
50
N
W02
2B 2WR
N W05 2B
2W
Water spray 58X-2F pump (F)
Water spray 58X-2F pump (R)
1559-09072-0-31152-0
No.
SIZE, COLOR
CONTACT POINTS
N
2B
3
W , FR , RR
W02
2WR
2
W , FR
W05
2W
2
W , RR
5-031
CONNECTION
ELECTRICAL SYSTEM
4-20. Cord
Y,100 Control panel harness (P.5-015)
FASTON 187
Vinyl tube
L09,WR L16,W FASTON 187
1559-09087-0-41208-0
No.
SIZE, COLOR
CONTACT POINTS
–
Y
2
CONNECTION Control panel harness ×2
5-032
ELECTRICAL SYSTEM
5. ELECTRICAL COMPONENT SPECIFICATIONS 5-1. Fuse Box (1)
Flood lamp switch (RY) Flasher unit Horn relay Foot brake switch (WB)
(WG) Lighting switch
Speed change switch (WL) Load relay
(LW) Water spray relay (F)
Vibratory drum select switch (RL) Vibration AUTO switch
(LR) Water spray relay (R)
Flood lamp switch (YR)
(WY) Water spray relay (F) Water spray relay (R) Water spray mode select switch
Sub power (WL)
(R) Liguid spray relay (option) Liguid spray switch (option)
Rotatory lamp switch (YL) (option)
12
11
15A 5A
10
9
8
7
6
5
4
3
2
1
5A 15A 15A 15A 15A 20A 15A 15A 20A 20A
(WL) Battery relay (W) Water spray pump (R) (WR) Water spray pump (F) (WR) Battery relay
SW654-05001
Harness color codes W : White R : Red WR : White/Red stripe WB : White/Black stripe WL : White/Blue stripe WY : White/Yellow stripe WG : White/Green stripe
5-033
RY RL YR YL LW LR
: Red/Yellow stripe : Red/Blue stripe : Yellow/Red stripe : Yellow/Blue stripe : Blue/White stripe : Blue/Red stripe
ELECTRICAL SYSTEM
5-2. Fuse Box (2)
(LgR) ECO lamp Combination meter ECU DPF meter ECU(CAN)(service tool)
Combination meter (BW) ECU main relay (R) Sub ECU
(Y) Buckup buzzer switch Parking interlock relay (RG)
(YG) ECU
ECU (Y)
24
23
22
21
(BR) Starter switch
20
N/A N/A N/A N/A
ECU main relay (WB) ECU Air flow sensor Fuel pump DPF switch DPF request lamp DPF active lamp ENGINE OVER HEAT lamp ENGINE STOP lamp ENGINE WARNING lamp Sub ECU lamp Load relay Sub ECU
5A
19
18
17
5A 20A 5A
16
15
14
13
5A 15A 5A 20A
(BY) Starter relay
(LR) Starter switch (W) Starter switch Battery relay (GY) Starter relay
SW654-05002
Harness color codes W : White R : Red Y : Yellow BW : Black/White stripe BY : Black/Yellow stripe BR : Black/Red stripe
WB : White/Black stripe RG : Red/Green stripe GY : Green/Yellow stripe YG : Yellow/Green stripe LR : Blue/Red stripe LgR : Light green/Red stripe
5-034
ELECTRICAL SYSTEM
5-3. Combination Meter
N GB, REV. ratio SEL.2
V06 G, Engine oil pressure warning
SWP-16F
SWP-12M
K08 YW, Coolant temp. meter
OW, Coolant temp. SEL.2
K10 GW, Hydraulic oil filter warning
RB, REV. ratio SEL.1
K09 YR, Fuel meter
WB, Coolant temp. SEL.1
V34 Y, REV. pulse input.2 (square wave) L12 GR, Parking brake
LgY, REV. ratio SEL.4 V07 GY, Preheating OG, REV. ratio SEL.3
N B, Ground K03 BrW, Lamp check
SWP-16F
K03 W, Charge warning
Harness side N B V34 BrY K09 P K08 GB
12V BATT (12V)
KEY SW
Movement
Engine speed 2 Engine speed 3 Engine speed 4
12V
Frequency divider selector
Hour meter
L01 YL, Side maker lamp
O, REV. pulse input.1 (pickup)
K13 L, Vibrator W12 LB, Liquid spray K04 Br, Water spray
Illumination LED
Output interface
Vibration
Input interface
Engine charge warning Engine oil pressure Hydraulic filter
L01 WR, Combination meter illumination
Water spray indicator Liquid spray indicator Position lamp indicator Flood lamp indicator
Liquid spray
L07 GL, Turn signal (R)
P05 R, Battery12V (+)
Turn signal (L)
Parking brake
LCD
SWP-16M
Not in use
Turn signal (R)
Glow plug
Temperature meter
* *
N B
* * * * * * * *
V13 P, Starter switch (ACC)
Backlight
Flood lamp
Movement
K03 WY V07 GL
L08 LR, Turn signal (L)
Position lamp
Water spray
Fuel meter
EEPROM
Output interface
Engine speed 1
Movement
CPU
Fuel sensor Temperature sensor
AD input interface TA input interface
TA pulse (square wave)
Input interface
TA pulse (pickup)
Tachometer
Input interface
CAN interface
12V
5V power supply
Power excitation circuit
K03 WY L12 LB K10 LR V06 YG
Vibration indicator Turn signal indicator (L) Turn signal indicator (R) Parking brake indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator
SWP-12M
L05 LW, Flood lamp
Harness side P05 BW
* *
V13 LgR
* *
L01 BY L07 GR L08 G L01 BY
L05 RG K04 PG W12 YB K13 OG
SWP-12F
Lamp check Coolant temperature 1 Coolant temperature 2 System configuration diagram Note:
5-035
The circuit in the dashed box is not mounted.
SW654-05003
VIBRATORY DRUM
VIBRATORY DRUM
1. PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY • When removing, installing, disassembling or reassembling the unit, 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 pins, and lock plates with new parts. • Properly bend split 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 grease to rotating and sliding components. • Apply gear oil 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.
6-001
VIBRATORY DRUM
3) Precautions when work is completed • If coolant has been drained, securely retighten the drain valve 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.
6-002
VIBRATORY DRUM
2. VIBRATORY DRUM 2-1. Removal and Installation of Vibratory Drum 2-1-1. Removal of vibratory drum 1) Securing machine • Hold drum with chocks. • Lock front and rear frames with steering lock bar (1).
1
SW654-06001
2) Removal of mirror assembly • Remove bolts (2). • Remove mirror assembly (3).
2
3 SW654-06011
WARNING The hydraulic oil in the machine is hot and compressed immediately after the machine is stopped. Disconnecting the hydraulic hoses in this condition can cause burns. Wait for the hydraulic oil to cool down before starting the work.
5
4
3) Disconnecting piping 3-1) Disconnecting propulsion motor piping • Remove bolts (4). • Remove cover (5). Chock SW654-06012
6-003
VIBRATORY DRUM • Disconnect hydraulic hoses (6), (7), (8), (9) and (10) connecting to propulsion motor.
6 7 8
9
(NOTICE) • Plug both ends of the disconnected hoses or implement other actions to prevent entry of foreign matter.
10
SW654-06013
2-2) Disconnecting vibrator motor piping • Remove bolts (11). • Remove cover (12).
11
12
SW654-06014
• Disconnect hydraulic hoses (13), (14), and (15) connecting to vibrator motor.
13 14 15
SW654-06015
6-004
VIBRATORY DRUM
DANGER
Lift with crane.
When lifting the machine body, use an appropriate hoist of sufficient strength. Confirm that the surrounding area is safe, and work in a natural, unstrained posture. Also, to firmly secure the machine body, use a support stand of sufficient strength. 4) Supporting frame • Lift frame with a crane. • Place support stands under frame when drum is slightly off ground to support machine body. Support stand SW652-1-06106
Front axle Rear axle SW654 : 3,360 kg (7,405 lbs.) 3,710 kg (8,180 lbs.) SW654ND : 3,510 kg (7,740 lbs.) 3,860 kg (8,510 lbs.)
5) Removal of cross member 5-1) Remove water spray pipe (16) and electrical harness (17).
17
16 5-2) Flip up scraper blade (20). • Lift cross member (18) with a crane and hold it. • Remove bolts (19) (left and right sides). • Remove cross member (18). (18) Cross member Front : 90 kg (198 lbs.) Rear : 90 kg (198 lbs.)
SW652-1-06107
Lift with crane.
18 19
20 20
SW652-1-06108
6-005
VIBRATORY DRUM 6) Removal of drum assembly • Lift left plate (21), right plate (22) and hold them. • Remove bolts (23) (left and right sides). • Remove drum assembly together with plates (21), (22) from frame. • Remove rear drum assembly in same way.
Lift with crane. 23
21,22
(NOTICE) • Damper mounting bolts and nuts must not be stressed during the removal. Front drum assembly Rear drum assembly SW654 : 1,825 kg (4,023 lbs.) 1,820 kg (4,012 lbs.) SW654ND : 2,030 kg (4,475 lbs.) 2,025 kg (4,464 lbs.)
SW652-1-06109
7) Removal of plates • Hold drum (24) with chocks. • Remove nuts and bolts (25) (left and right sides). • Remove plate (21), (22).
Lift with crane. 21,22
(21) Front left plate : 175 kg (386 lbs.) (22) Front right plate : 190 kg (419 lbs.) • Remove rear drum assembly in same way. Rear left plate Rear right plate
: 185 kg (408 lbs.) : 175 kg (386 lbs.)
25
24
Chock SW652-1-06110
6-006
VIBRATORY DRUM
2-1-2. Installation of vibratory drum 1) Install vibratory drum in reverse order in which it was removed. • Tightening torque for bolts where particular care is required when installing vibratory drum. N•m
(19) Bolt M16×50 : 265 N·m (195 lbf·ft) (23) Bolt M16×50 : 265 N·m (195 lbf·ft) (25) Nut M12 : 110 N·m ( 81 lbf·ft)
2) Upon installing vibratory drum, pay particular attention to items mentioned below. • Fill hydraulic oil tank to specified level to make up for any oil leakage. • Start engine and circulate oil through piping. Then check oil level again, ensuring that oil is at specified level. (NOTICE) • If the engine is run at high speed or the cylinder is operated to full stroke when the engine is started for the first time after the work is completed, the piston packing or other items may be damaged by air entering into the cylinder.
6-007
VIBRATORY DRUM
3. VIBRATORY DRUM ASSEMBLY (SW654) 3-1. Vibratory Drum Assembly 1
3
2
4
5
8
7
6
9
10
11
12
13 14 15
16 17
47
18
A
19,20
46 21
A 22
45
23
44
24 42,43
25 26 27,28
41
40
39
38
36 35
37
34
33
32
31
30
29
9-1 (Oil filler plug)
Vibration mode: Low Counterclockwise rotation
SECTION A-A
Vibration mode: High Clockwise rotation
32 (Level plug) Vibrator motor side
9-2 (Drain plug)
(1) Drum (2) Housing (3) Bolt (4) Bolt (5) Vibrator bearing (6) Eccentric shaft (7) Vibrator bearing (8) Bolt (9) Plug (10) Oil seal (11) Roller bearing (12) Roller bearing (13) Bolt (14) O-ring (15) Breather (16) Bolt (17) Bolt (18) Bolt (19) Sleeve (20) Spring pin (21) Vibrator motor (22) O-ring (23) Cover (24) Shim (25) Flange (26) Housing (27) Bolt (28) Nut (29) Damper (30) Bolt (31) Disc (32) Level plug (33) O-ring (34) Axle shaft (35) O-ring (36) O-ring (37) Bolt (38) Disc (39) Disc (40) Bolt (41) Damper (42) Bolt (43) Nut (44) Bolt (45) Cover (46) Propulsion motor (47) Bolt
: M 8×20 : M16×45
: M16×45
: M16×45
: M10×30 : M12×30 : M10×30
: M12×40 : M12 : M12×30
: M16×45
: M12×30 : M12×40 : M12 : M16×45
: M16×45
0558-43801-0-10013-H
6-008
SW654
VIBRATORY DRUM
3-2. Disassembly and Reassembly of Vibratory Drum • Lead line numbers shown in the illustrations for the following vibratory drum disassembly and reassembly procedures are constant with part numbers of vibratory drum assembly shown on page 6-008.
Drum assembly
9-1
32
9-2
3-2-1. Disassembly of vibratory drum 1) Lay drum assembly with plugs (9-1), (9-2), and level plug (32) positioned as shown on the right. • Hold with chocks. Drum assembly : 1,460 kg (3,219 lbs.)
Chock
2) Remove plugs (9-1) and (9-2). • Drain gear oil. • Quantity of gear oil : 4.0 L (1.1 gal.)
Supply port
SW652-1-06001
9-1
Drain port 9-2 SW652-1-06002
WARNING
21
Drum assembly
• When standing the vibratory drum, use wooden blocks of sufficient strength to securely support the drum. • Carry out the work in an unstrained posture using a work stool or the like. 3) Stand drum assembly with its vibrator motor (21) side facing up. Drum assembly : 1,455 kg (3,208 lbs.) SW652-1-06003
6-009
VIBRATORY DRUM
SW654
4) Remove breather (15). • Remove bolts (17). • Remove vibrator motor (21). (21) Vibrator motor : 15 kg (33 lbs.)
21
17
15 SW652-1-06004
5) Remove sleeve (19).
19
SW652-1-06005
6) Lift disc subassembly. • Remove bolts (13).
Disc subassembly
13
SW652-1-06006
6-010
SW654
VIBRATORY DRUM
7) Remove disc subassembly. Disc subassembly : 75 kg (165 lbs.)
Disc subassembly
SW652-1-06007
8) Remove bolts (8).
8
SW652-1-06008
9) Lift axle shaft (34) using two pulling bolts (M16×45). Pulling bolt
34
SW652-1-06009
6-011
VIBRATORY DRUM
SW654
WARNING When installing lifting bolts, screw in the threads fully before using.
Lifting bolt
34
10) Install lifting bolts (M16) to axle shaft (34).
SW652-1-06010
11) Remove axle shaft subassembly. (NOTICE) • In order not to lift eccentric shaft together with axle shaft subassembly, tap on the eccentric shaft end with a wooden hammer via a wooden bar during lifting.
Wooden hammer Wooden bar
Axle shaft subassembly : 65 kg (143 lbs.)
Axle shaft subassembly
SW652-1-06011
12) Put axle shaft subassembly on wooden blocks. Wooden block
Axle shaft subassembly SW652-1-06012
6-012
SW654
VIBRATORY DRUM
13) Install a lifting bolt (M8) to eccentric shaft (6).
Lifting bolt
6
SW652-1-06013
WARNING Take care not to get your fingers caught in movable weights.
Movable weight
6
14) Remove eccentric shaft (6). (6) Eccentric shaft : 60 g (132 lbs.) (NOTICE) • Put the movable weight at its outmost position.
SW652-1-06014
WARNING Be careful because reversing the vibratory drum involves risk. Confirm that the surrounding area is safe, and work in a natural, unstrained posture.
Drum subassembly
15) Reverse drum subassembly. Drum subassembly : 1,240 kg (2,734 lbs.)
SW652-1-06015
6-013
VIBRATORY DRUM 16) Lift disc subassembly. • Remove bolts (47).
SW654
47
Disc subassembly
SW652-1-06016
17) Remove disc subassembly. Disc subassembly
Disc subassembly : 75 kg (165 lbs.)
SW652-1-06017
18) Install lifting bolts (M16) to propulsion motor (46).
Lifting bolt
• Remove bolts (44). 44
46
SW652-1-06018
6-014
SW654
VIBRATORY DRUM
19) Remove propulsion motor subassembly. Propulsion motor subassembly : 80 kg (176s lbs.)
Propulsion motor subassembly
SW654-06002
20) Install lifting bolts (M16) to housing (2). • Remove bolts (4).
Lifting bolt 2
4
SW654-06003
21) Remove housing subassembly. Housing subassembly : 50 kg (110 lbs.)
Housing subassembly
SW654-06004
6-015
VIBRATORY DRUM
SW654
22) Disassembly of axle shaft subassembly. • Remove bolts (16). • Remove flange (25).
16
25
Axle shaft subassembly SW652-1-06022
23) Remove bolts (18). 18
• Remove cover (23). • Remove shim (24).
23 24
SW652-1-06023
24) Put a piece of wooden board on end of axle shaft (34). Puller
• Set a puller on housing (26). • Remove housing subassembly with roller bearing from axle shaft subassembly. 26
Wooden board
34
SW652-1-06024
6-016
SW654
VIBRATORY DRUM
25) Install lifting bolts (M10) to housing (26).
Lifting bolt
26
SW652-1-06025
26) Remove housing subassembly from axle shaft subassembly. Housing subassembly : 20 kg (44 lbs.)
Housing subassembly
Axle shaft subassembly
SW652-1-06026
6-017
SW654
3-2-2. Reassembly of vibratory drum
1
• Before reassembling, clean disassembled parts well and check that there is no abnormality.
a
VIBRATORY DRUM
WARNING • When standing the vibratory drum, use wooden blocks of sufficient strength to securely support the drum. • Carry out the work in an unstrained posture using a work stool or the like. 1) Stand drum (1) with its propulsion motor side facing up. (1) Drum : 1,035 kg (2,282 lbs.)
SW652-1-06027
(NOTICE) • Propulsion motor side dimension “a” : 459 mm (18 in.)
5
2
2) Reassembly of housing subassembly 2-1) Apply a coat of gear oil to housing (2) at where bearing will be press-fitted. • Drive in vibrator bearing (5). (NOTICE) • Take care not to damage the bearing when installing it.
SW652-1-06028
2-2) Apply grease to O-ring (36). • Install O-ring to housing (2).
36
2
SW652-1-06029
6-018
SW654
VIBRATORY DRUM
2-3) Apply grease to O-ring (35). • Install O-ring to cover (45). 35
45
SW654-06005
2-4) Reverse housing subassembly. Housing subassembly : 50 kg (110 lbs.)
3
45
Housing subassembly
• Install cover (45) to housing subassembly with four bolts (3), spring washers and washers.
SW654-06006
WARNING When installing lifting bolts, screw in the threads fully before using.
Lifting bolt
2
3) Install lifting bolts (M16) to housing (2).
SW654-06007
6-019
VIBRATORY DRUM 4) Lower housing subassembly on mounting surface of drum (1).
SW654
1
Housing subassembly
Housing subassembly : 50 kg (110 lbs.) (NOTICE) • Take care not to let O-ring to protrude from its groove.
SW654-06008
5) Secure housing subassembly with sixteen bolts (4) and washers. N•m
(4) Bolts M16×45 : 265 N·m (195 lbf·ft)
Housing subassembly
4
SW654-06009
6) Reassembly of propulsion motor subassembly • Secure disc (38) to propulsion motor (46) with sixteen bolts (37) and washers. N•m
(37) Bolts M16×45 : 265 N·m (195 lbf·ft)
37 38
46
SW652-1-06034
6-020
SW654
VIBRATORY DRUM
7) Reverse propulsion motor subassembly. Propulsion motor subassembly : 80 kg (176 lbs.)
46
Lifting bolt
• Install lifting bolts (M16) to propulsion motor (46).
SW652-1-06111
8) Lower propulsion motor subassembly on mounting surface of housing (2).
Propulsion motor subassembly
Propulsion motor subassembly : 80 kg (176 lbs.)
2
SW652-1-06036
9) Secure propulsion motor subassembly with sixteen bolts (44) and washers. N•m
Propulsion motor subassembly
44
(44) Bolts M16×45 : 265 N·m (195 lbf·ft)
SW652-1-06037
6-021
VIBRATORY DRUM
SW654
10) Lift disc subassembly.
Disc subassembly
Disc subassembly : 75 kg (165 lbs.)
SW652-1-06038
11) Lower disc subassembly on mounting surface of propulsion motor (46). Disc subassembly
46
SW652-1-06039
(NOTICE) • The recess of the disc must be parallel with the side of the propulsion motor ports A and B.
Recess of disc Propulsion motor ports A and B
SW652-1-06073
6-022
SW654
VIBRATORY DRUM
12) Secure disc subassembly with eleven bolts (47) and washers. N•m
Disc subassembly
47
(47) Bolts M16×45 : 265 N·m (195 lbf·ft)
SW652-1-06040
WARNING Be careful because reversing the vibratory drum involves risk. Confirm that the surrounding area is safe, and work in a natural, unstrained posture.
Drum subassembly
13) Reverse drum subassembly. Drum subassembly : 1,240 kg (2,734 lbs.)
SW652-1-06041
14) Install a lifting bolt (M8) to eccentric shaft (6).
Lifting bolt
6
SW652-1-06042
6-023
VIBRATORY DRUM
SW654
WARNING Take care not to get your fingers caught in movable weights.
Movable weight
6
15) Apply a coat of gear oil to eccentric shaft (6) at where bearing will be installed. • Install eccentric shaft. (6) Eccentric shaft : 60 kg (132 lbs.) (NOTICE) • Put the movable weight at its outmost position. SW652-1-06043
16) Insert eccentric shaft (6) into vibrator bearing (5) while taking care not to tilt vibrator bearing inner race.
6
5 Inner race
17) Reassembly of axle shaft subassembly 17-1) Apply a coat of gear oil to axle shaft (34) at where bearing will be press-fitted. • Drive in vibrator bearing (7).
SW652-1-06044
7 34
Wooden block SW652-1-06045
6-024
SW654
VIBRATORY DRUM
WARNING
11
Wear heat resistant gloves when handling heated parts to avoid burns. 17-2) Reverse axle shaft subassembly.
Axle shaft subassembly
Axle shaft subassembly : 40 kg (88 lbs.) • Heat up roller bearing (11) inner race by using a ring heater or the like. • Apply a coat of gear oil to axle shaft at where bearing inner race will be press-fitted. • Drive in heated roller bearing inner race.
17-3) Apply grease to O-rings for plugs (9-1), (9-2) and level plug (32). • Install plugs and level plug. • Apply sufficient amount of lithium-based grease to rollers of roller bearing (11) inner race.
SW652-1-06046
32
9-2
11
9-1
SW652-1-06047
17-4) Apply a coat of gear oil to housing (26) at where bearing outer races will be press-fitted. • Drive roller bearings (11) and (12) outer races into housing. • Apply liquid packing to periphery of oil seal (10). • Drive in oil seal. • Apply grease to lip of oil seal.
12
10
26
11 SW652-1-06048
6-025
VIBRATORY DRUM
SW654
17-5) Install lifting bolts (M10) to housing (26). Lifting bolt
26
SW652-1-06049
17-6) Install housing subassembly to axle shaft subassembly. Housing subassembly : 20 kg (44 lbs.) Housing subassembly
Axle shaft subassemby
SW652-1-06050
17-7) Apply sufficient amount of lithium-based grease to rollers of roller bearing (12) inner race. • Drive in roller bearing inner race until rollers come in contact with outer race.
12
SW652-1-06051
6-026
SW654
VIBRATORY DRUM
17-8) Preload adjustment of roller bearing ① Install a shim of about 1 mm (0.04 in.) and secure cover (23) to axle shaft (34) with six bolts (18) and spring washers.
18 23 Shim 34
SW652-1-06052
② A gap will remain between end of axle shaft (34) and inside of cover (23). • Tighten bolts (18) to a torque of 60 N·m (44 lbf·ft). • Give housing (26) two to three turns. • Tighten bolts to a torque of 60 N·m (44 lbf·ft) again. • Repeat this work several times until tightening torque of bolts no longer fluctuates.
26
Shim
18
23
Gap
(NOTICE) • Tighten the bolts alternately in diagonal directions.
34 SW652-1-06053
(NOTICE) • Push in the inner race while rotating the bearing. Otherwise, even strongly trying to push the inner race, the bearing rollers will not be pushed up and therefore bearing will not be seated.
End of rollers in close contact with inner race shoulder
Gap Gap
(1) Bearing not seated
(2) Bearing correctly seated
SW800-06080
6-027
VIBRATORY DRUM
SW654
③ Remove bolts (18). • Remove cover (23). • Remove shim.
18 23
(NOTICE) • Do not turn the housing after the cover is removed.
Shim
SW652-1-06075
④ Without inserting shim, install cover (23) to axle shaft (34) with six bolts (18) and spring washers. 18 23 34
SW652-1-06054
No gap
reload adjusting ★ P = A + 0.1 mm (0.004 in.) shim thickness
A
⑤ Using a thickness gauge, measure clearance “A”.
SW652-1-06055
6-028
SW654
VIBRATORY DRUM
⑥ Remove bolts (18). • Remove cover (23). 18 23
SW652-1-06074
⑦ Install shim (24) of preload adjusting shim thickness = “A + 0.1 mm (0.004 in.)”. • Secure cover (23) to axle shaft (34) with six bolts (18) and spring washers. N•m
(18) Bolts M10×30 : 60 N·m (44 lbf·ft)
18 23 24 34
SW652-1-06076
17-9) Apply grease to O-ring (14). • Install O-ring to flange (25).
14
25
SW652-1-06056
6-029
VIBRATORY DRUM 17-10) Secure flange (25) to housing (26) with eight bolts (16) and spring washers. N•m
SW654
26
16
25
(16) Bolts M10×30 : 60 N·m (44 lbf·ft)
SW652-1-06057
18) Install lifting bolts to axle shaft (34). Lifting bolt
34 SW652-1-06058
19) Lift axle shaft subassembly. Axle shaft subassembly : 65 kg (143 lbs.) • Apply grease to O-ring (33). • Install O-ring to axle shaft (34).
33 Axle shaft subassembly
6-030
SW652-1-06059
SW654
VIBRATORY DRUM
20) Lower axle shaft subassembly on mounting surface of drum slowly.
Pipe
(NOTICE) • Support the eccentric shaft (6) with a pipe or the like, to prevent tilting of the vibrator bearing inner race during installation.
6
Axle shaft subassembly
SW652-1-06060
21) Secure axle shaft subassembly with sixteen bolts (8) and washers. N•m
Axle shaft subassembly
8
(8) Bolts M16×45 : 265 N·m (195 lbf·ft)
SW652-1-06061
22) Install a lifting bolt (M8) to end of eccentric shaft (6). 6
Lifting bolt
SW652-1-06062
6-031
VIBRATORY DRUM
SW654
23) Slowly lift eccentric shaft with a crane and check that there is an axial play of 1 to 3 mm (0.04 to 0.12 in.).
SW652-1-06063
24) Lift disc subassembly. Disc subassembly : 75 kg (165 lbs.)
Disc subassembly
SW652-1-06064
25) Lower disc subassembly on mounting surface of housing (26).
Disc subassembly
26
SW652-1-06065
6-032
SW654
VIBRATORY DRUM
(NOTICE) • The recess of the disc must face the same direction as the breather mounting hole in the flange.
Recess of disc Breather mounting hole
SW652-1-06066
26) Secure disc subassembly with sixteen bolts (13) and washers. N•m
Disc subassembly
13
(13) Bolts M16×45 : 265 N·m (195 lbf·ft)
SW652-1-06067
27) Drive two spring pins (20) into sleeve (19). 19
20 SW652-1-06068
6-033
VIBRATORY DRUM
SW654
28) Apply molybdenum-based grease to splined portion of sleeve (19). • Fit sleeve to splined portion on eccentric shaft end.
19
SW652-1-06069
29) Apply grease to O-ring (22). • Install O-ring to vibrator motor (21). 21
22 SW652-1-06070
30) Wind seal tape around threaded portion of breather (15). • Install breather. • Secure vibrator motor (21) to flange (25) with two bolts (17) and washers.
21
(21) Vibrator motor :15 kg (33 lbs.) N•m
(17) Bolts M12×30 : 110 N·m (81 lbf·ft)
17
25
15 SW652-1-06071
6-034
SW654
VIBRATORY DRUM
31) Lay drum assembly with plugs (9-1), (9-2), and level plug (32) positioned as shown right. • Hold with chocks.
Drum assembly
9-1
32
9-2
Drum assembly : 1,455 kg (3,208 lbs.)
Chock
32) Remove plug (9-1) and level plug (32). • Supply gear oil from oil supply port. • Check that oil drips from gauge port.
SW652-1-06001
9-1
Supply port
• Quantity of gear oil : 4.0 L (1.1 gal.) • Reinstall plug and level plug.
Gauge port
32
SW652-1-06072
6-035
VIBRATORY DRUM
4. VIBRATORY DRUM ASSEMBLY (SW654ND) 4-1. Vibratory Drum Assembly 1
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19
20
21
22
23 24 25 26 27 28 29 30 31
32
A
33
75 34 35,36
74
37
38 39
73
40 71,72
41
A
42 43
70
44,45 69
68
67
66 65 64 63 62
Vibration mode: Normal Counterclockwise rotation
SECTION A-A
61 60
59 58 57 56 55 54
Vibration mode: Oscillation Clockwise rotation
53
52 51 50 49
48
47
46
21-1 (Oil filler plug) 52 (Level plug)
21-2 (Drain plug)
Vibrator motor side
(1) Drum (2) Housing (3) Cover (4) Bolt : M12×30 (5) Vibrator bearing (6) O-ring (7) Pin (8) Eccentric shaft (9) Retaining ring (10) Shaft (11) Sunk key (12) Retaining ring (13) Collar (14) Gear (15) O-ring (16) Sunk key (17) Gear (18) Retaining ring (19) Vibrator bearing (20) Pin (21) Plug (22) Bolt : M12×30 (23) Cover (24) Ball bearing (25) Ball bearing (26) Oil seal (27) Roller bearing (28) Roller bearing (29) Bolt : M16×45 (30) O-ring (31) Breather (32) Bolt : M10×30 (33) Bolt : M12×30 (34) Bolt : M10×30 (35) Sleeve (36) Spring pin (37) Vibrator motor (38) O-ring (39) Cover (40) Shim (41) Flange (42) Housing (43) Axle shaft (44) Bolt : M12×40 (45) Nut : M12 (46) Damper (47) Cover (48) Bolt : M12×30 (49) Disc (50) Bolt : M12×30
(51) Vibrator bearing (52) Level plug (53) Bolt : M16×45 (54) O-ring (55) Retaining ring (56) Gear (57) Sunk key (58) O-ring (59) Eccentric shaft (60) O-ring (61) O-ring (62) Bolt : M16×45 (63) Vibrator bearing (64) Bolt : M12×30 (65) Cover (66) Bolt : M16×45 (67) Disc (68) Disc (69) Bolt : M12×30 (70) Damper (71) Bolt : M12×40 (72) Nut : M12 (73) Bolt : M16×45 (74) Propulsion motor (75) Bolt : M16×45
0559-43802-0-10060-0
6-036
SW654ND
VIBRATORY DRUM
4-2. Disassembly and Reassembly of Vibratory Drum • Lead line numbers shown in the illustrations for the following vibratory drum disassembly and reassembly procedures are constant with part numbers of vibratory drum assembly shown on page 6-036.
Drum assembly 21-1
4-2-1. Disassembly of vibratory drum 1) Lay drum assembly with plugs (21-1), (21-2), and level plug (52) positioned as shown on the right. • Hold with chocks. Drum assembly : 1,675 kg (3,693 lbs.)
52
21-2
Chock 2) Remove plugs (21-1) and (21-2). • Drain gear oil.
Supply port
SW652ND-1-06001
21-1
• Quantity of gear oil : 10.4 L (2.7 gal.)
21-2 Drain port SW652ND-1-06002
WARNING • When standing the vibratory drum, use wooden blocks of sufficient strength to securely support the drum. • Carry out the work in an unstrained posture using a work stool or the like.
37
Drum assembly
3) Stand drum assembly with its vibrator motor (37) side facing up. Drum assembly : 1,665 kg (3,671 lbs.)
SW652ND-1-06003
6-037
VIBRATORY DRUM 4) Remove breather (31). • Remove bolts (33). • Remove vibrator motor (37). (37) Vibrator motor : 15 kg (33 lbs.)
SW654ND
37 33
31 SW652ND-1-06004
5) Remove sleeve (35).
35
SW652ND-1-06005
6) Lift disc subassembly. • Remove bolts (29).
Disc subassembly
29
SW652ND-1-06006
6-038
SW654ND
VIBRATORY DRUM
7) Remove disc subassembly. Disc subassembly : 75 kg (165 lbs.)
Disc subassembly
SW652ND-1-06007
8) Remove bolts (22) and (50). • Remove covers (23) and (47). • Remove bolts (53).
47
50
53
22
23
SW652ND-1-06008
WARNING
43
Lifting bolt
When installing lifting bolts, screw in the threads fully before using. 9) Install lifting bolts (M12) to axle shaft (43).
SW652ND-1-06009
6-039
VIBRATORY DRUM 10) Remove axle shaft subassembly. Axle shaft subassembly : 205 kg (452 lbs.)
SW654ND Wooden hammer
Axle shaft subassembly
(NOTICE) • In order not to lift eccentric shaft together with axle shaft subassembly, tap on the eccentric shaft ends alternately with a wooden hammer during lifting.
SW652ND-1-06010
11) Put axle shaft subassembly on wooden blocks. Axle shaft subassembly
Wooden block SW652ND-1-06011
12) Install lifting bolts (M8) to eccentric shaft (8). Lifting bolt
8
SW652ND-1-06012
6-040
SW654ND
VIBRATORY DRUM
WARNING Take care not to get your fingers caught in movable weights.
Movable weight
8
13) Remove eccentric shaft (8). (8) Eccentric shaft : 70 kg (154 lbs.) (NOTICE) • Put the movable weight at its outmost position.
SW652ND-1-06013
14) Install a lifting bolt (M8) to eccentric shaft (59). Lifting bolt
59
SW652ND-1-06014
15) Remove eccentric shaft (59). (59) Eccentric shaft : 70 kg (154 lbs.)
59
Movable weight
(NOTICE) • Put the movable weight at its outmost position.
SW652ND-1-06015
6-041
VIBRATORY DRUM
WARNING
SW654ND Drum subassembly
Be careful because reversing the vibratory drum involves risk. Confirm that the surrounding area is safe, and work in a natural, unstrained posture. 16) Reverse drum subassembly. Drum subassembly : 1,230 kg (2,712 lbs.)
SW652ND-1-06016
17) Lift disc subassembly. • Remove bolts (75).
75
Disc subassembly
SW652ND-1-06017
18) Remove disc subassembly. Disc subassembly : 75 kg (165 lbs.)
Disc subassembly
SW652ND-1-06018
6-042
SW654ND
VIBRATORY DRUM
19) Install lifting bolts (M16) to propulsion motor (74). • Remove bolts (73).
Lifting bolt 73
74
SW652ND-1-06019
20) Remove propulsion motor subassembly.
Propulsion motor subassembly
Propulsion motor subassembly : 80 kg (176 lbs.)
SW652ND-1-06020
21) Install lifting bolts (M16) to housing (2). • Remove bolts (62).
Lifting bolt
62
2
SW652ND-1-06021
6-043
VIBRATORY DRUM
SW654ND
22) Remove housing subassembly.
Housing subassembly
Housing subassembly : 160 kg (353 lbs.)
SW652ND-1-06022
23) Disassembly of axle shaft subassembly Axle shaft subassembly
SW652ND-1-06023
24) Remove bolts (32). • Remove flange (41).
32
41
SW652ND-1-06024
6-044
SW654ND
VIBRATORY DRUM
25) Remove bolts (34). • Remove cover (39). • Remove shim (40). 34 39 40
SW652ND-1-06025
26) Put a piece of wooden board on end of axle shaft (43). • Set a puller on housing (42). • Remove housing subassembly with roller bearing from axle shaft subassembly.
Puller Wooder board
42
43
27) Install lifting bolts (M10) to housing (42).
SW652ND-1-06026
Lifting bolt
42
SW652ND-1-06027
6-045
VIBRATORY DRUM
SW654ND
28) Remove housing subassembly from axle shaft subassembly. Housing subassembly : 20 kg (44 lbs.)
Housing subassembly
Axle shaft subassembly
SW652ND-1-06028
29) Remove vibrator bearings (19) and (51) from axle shaft subassembly.
51
Axle shaft subassembly
19
SW652ND-1-06029
6-046
SW654ND
VIBRATORY DRUM
4-2-2. Reassembly of vibratory drum
1 a
• Before reassembling, clean disassembled parts well and check that there is no abnormality.
WARNING • When standing the vibratory drum, use wooden blocks of sufficient strength to securely support the drum. • Carry out the work in an unstrained posture using a work stool or the like. 1) Stand drum (1) with its propulsion motor side facing up. (1) Drum : 910 kg (2,006 lbs.) (NOTICE) • Propulsion motor side dimension “a” : 491 mm (19 in.)
SW652ND-1-06030
2
2) Reassembly of housing subassembly • Fix housing (2) with wooden blocks.
SW652ND-1-06031
2-1) Apply a coat of gear oil to housing (2) at where bearings will be press-fitted. • Drive vibrator bearings (5) and (63) into housing.
63
2
5
(NOTICE) • Take care not to damage the bearings when installing them.
SW652ND-1-06032
6-047
VIBRATORY DRUM
5,63
Protruding
(NOTICE) • Stop driving in vibrator bearings (5) and (63) when they come to a position slightly protruding from the boss surface of the housing (2) to avoid driving in too much.
SW654ND
2
SW652ND-1-06033
2-2) Apply grease to O-rings (6) and (60). • Install O-rings to covers (3) and (65).
6,60
3,65
SW652ND-1-06034
N•m
3,65
4,64
Press fit with cover
2-3) Press fit slightly protruding vibrator bearings (5) and (63) into place by securing covers (3) and (65) with four bolts (4), four bolts (64), and washers. (4) and (64) Bolts M12×30 : 110 N·m (81 lbf·ft)
Protruding 5,63
Fitted into position SW652ND-1-06035
6-048
SW654ND
VIBRATORY DRUM
WARNING When installing lifting bolts, screw in the threads fully before using.
Lifting bolt 2
3) Install lifting bolts (M16) to housing (2).
SW652ND-1-06036
4) Lift housing subassembly. Housing subassembly : 160 kg (353 lbs.)
Housing subassembly
• Apply grease to O-ring (61). • Install O-ring to housing subassembly.
61 5) Lower housing subassembly on mounting surface of drum (1).
SW652ND-1-06037
Housing subassembly
(NOTICE) • Take care not to let O-ring to protrude from its groove.
1
SW652ND-1-06038
6-049
VIBRATORY DRUM 6) Drive in two locating pins (7) for housing subassembly and drum (1) temporarily.
SW654ND 7
Housing subassembly
1
SW652ND-1-06039
7) Secure housing subassembly with sixteen bolts (62) and washers. N•m
Housing subassembly
62
7
(62) Bolts M16×45 : 265 N·m (195 lbf·ft)
• Drive in locating pins (7) again.
SW652ND-1-06040
8) Reassembly of propulsion motor subassembly • Secure disc (67) to propulsion motor (74) with sixteen bolts (66) and washers. N•m
(66) Bolts M16×45 : 265 N·m (195 lbf·ft)
66 67
74
SW652ND-1-06041
6-050
SW654ND
VIBRATORY DRUM
9) Reverse propulsion motor subassembly. Propulsion motor subassembly : 80 kg (176 lbs.)
74
Lifting bolt
• Install lifting bolts (M16) to propulsion motor (74).
SW652-1-06112
10) Lower propulsion motor subassembly on mounting surface of housing (2).
Propulsion motor subassembly
Propulsion motor subassembly : 80 kg (176 lbs.)
2
SW652ND-1-06043
11) Secure propulsion motor subassembly with sixteen bolts (73) and washers. N•m
Propulsion motor subassembly
73
(73) Bolts M16×45 : 265 N·m (195 lbf·ft)
SW652ND-1-06044
6-051
VIBRATORY DRUM
SW654ND
12) Lift disc subassembly.
Disc subassembly
Disc subassembly : 75 kg (165 lbs.)
SW652-1-06038
13) Lower disc subassembly on mounting surface of propulsion motor (74). Disc subassembly
74
SW652ND-1-06046
(NOTICE) • The recess of the disc must be parallel with the side of the propulsion motor which have ports A and B.
Recess of disc Propulsion motor ports A and B
SW652-1-06073
6-052
SW654ND
VIBRATORY DRUM
14) Secure disc subassembly with eleven bolts (75) and washers. N•m
Disc subassembly
75
(75) Bolts M16×45 : 265 N·m (195 lbf·ft)
SW652ND-1-06047
WARNING Be careful because reversing the vibratory drum involves risk. Confirm that the surrounding area is safe, and work in a natural, unstrained posture.
Drum subassembly
15) Reverse drum subassembly. Drum subassembly : 1,230 kg (2,712 lbs.)
SW652ND-1-06048
WARNING
18 17
Wear heat resistant gloves when handling heated parts to avoid burns. 16) Heat up gear (17) by using a ring heater or the like. • Drive sunk key (16) into eccentric shaft (8). • Install heated gear. • Install retaining ring (18).
16
8
(NOTICE) • Make sure that the retaining ring is fitted completely in its groove. SW652ND-1-06049
6-053
VIBRATORY DRUM
SW654ND
WARNING
Lifting bolt
Take care not to get your fingers caught in movable weights.
8
17) Install a lifting bolt (M8) to eccentric shaft (8). (NOTICE) • Put the movable weight at its outmost position.
Movable weight
SW652ND-1-06050
18) Apply a coat of gear oil to eccentric shaft subassembly at where vibrator bearing (5) will be installed. • Install eccentric shaft subassembly.
Eccentric shaft subassembly
Eccentric shaft subassembly : 70 kg (154 lbs.)
5
SW652ND-1-06051
19) Insert eccentric shaft subassembly into vibrator bearing (5) while taking care not to tilt vibrator bearing inner race.
Eccentric shaft subassembly
(NOTICE) • After inserting the eccentric shaft subassembly into the bearing, lay the eccentric shaft subassembly against the inner wall of the drum so that it will not fall down.
5
Inner race SW652ND-1-06052
6-054
SW654ND
VIBRATORY DRUM
20) Heat up gear (56) by using a ring heater or the like. • Drive sunk key (57) into eccentric shaft (59). • Install heated gear. • Install retaining ring (55). (NOTICE) • Make sure that the retaining ring is fitted completely in its groove.
55 56
57
59
SW652ND-1-06053
21) Install a lifting bolt (M8) to eccentric shaft (59).
59
Lifting bolt
(NOTICE) • Put the movable weight at its outmost position.
Movable weight
SW652ND-1-06054
22) Apply a coat of gear oil to eccentric shaft subassembly at where vibrator bearing (63) will be installed. • Install eccentric shaft subassembly.
Eccentric shaft subassembly
Eccentric shaft subassembly : 70 kg (154 lbs.)
63
SW652ND-1-06055
6-055
VIBRATORY DRUM
SW654ND
23) Insert eccentric shaft subassembly into vibrator bearing (63) while taking care not to tilt vibrator bearing inner race.
Eccentric shaft subassembly
(NOTICE) • After inserting the eccentric shaft subassembly into the vibrator bearing, lay the eccentric shaft subassembly against the inner wall of the drum so that it will not fall down.
63
Inner race SW652ND-1-06056
24) Reassembly of axle shaft subassembly 24-1) Fix axle shaft (43) with wooden blocks. 43
Wooden block
SW652ND-1-06058
24-2) Making marks on shaft (10) • Draw a X on left side with keyway facing down • Draw a Y on right side with keyway facing down
Y
X 10 Keyway SW652ND-1-06059
6-056
SW654ND
VIBRATORY DRUM
24-3) Apply a coat of gear oil to axle shaft (43) at where bearing will be press-fitted. • Drive ball bearing (25) into axle shaft.
25
43
SW652ND-1-06060
24-4) Apply a coat of gear oil to bearing mounting surface of shaft (10). • Drive in shaft.
10
SW652ND-1-06061
24-5) Apply a coat of gear oil to axle shaft (43) at where bearing will be press-fitted and to drive shaft (10) at where bearing will be installed. • Drive ball bearing (24) into axle shaft. • Install retaining ring (9).
9 24 43
10
SW652ND-1-06062
6-057
VIBRATORY DRUM
SW654ND
24-6) Heat up gear (14) by using a ring heater or the like. • Drive sunk key (11) to shaft (10). • Install heated gear.
14 11
10
SW652ND-1-06063
24-7) Install collar (13). • Install retaining ring (12).
12 13
(NOTICE) • Make sure that the retaining ring is fitted completely in its groove.
SW652ND-1-06064
24-8) Reverse axle shaft subassembly. Axle shaft subassembly : 165 kg (364 lbs.)
Axle shaft subassembly
SW652ND-1-06065
6-058
SW654ND
VIBRATORY DRUM
24-9) H eat up roller bearing (27) inner race by using a ring heater or the like. • Apply a coat of gear oil to axle shaft at where bearing inner race will be press-fitted. • Drive in heated roller bearing inner race.
27
SW652ND-1-06066
24-10) Apply sufficient amount of lithium-based grease to rollers of roller bearing (27) inner race. 27
SW652ND-1-06067
24-11) Apply a coat of gear oil to housing (42) at where bearing outer races will be press-fitted. • Drive roller bearings (27) and (28) outer races into housing. • Apply liquid packing to periphery of oil seal (26). • Drive in oil seal. • Apply grease to lip of oil seal.
28
26
42
27 SW652ND-1-06068
6-059
VIBRATORY DRUM
SW654ND
24-12) Install lifting bolts (M10) to housing (42). Lifting bolt
42
SW652ND-1-06069
24-13) Install housing subassembly to axle shaft subassembly. Housing subassembly : 20kg (44 lbs.)
Housing subassembly
Axle shaft subassemby
SW652ND-1-06070
24-14) Apply sufficient amount of lithium-based grease to rollers of roller bearing (28) inner race. • Drive in roller bearing inner race until rollers come in
28
contact with outer race.
SW652ND-1-06071
6-060
SW654ND
VIBRATORY DRUM
24-15) P reload adjustment of roller bearing ① Install a shim of about 1 mm (0.04 in.) and secure cover (39) to axle shaft (43) with six bolts (34) and spring washers.
34 39 Shim 43
SW652ND-1-06072
② A gap will remain between end of axle shaft (43) and inside of cover (39). • Tighten bolts (34) to a torque of 60 N·m (44 lbf·ft). • Give housing (42) two to three turns. • Tighten bolts to a torque of 60 N·m (44 lbf·ft) again. • Repeat this work several times until tightening torque of bolts no longer fluctuates.
42
Shim
34
39
Gap
(NOTICE) • Tighten the bolts alternately in diagonal directions.
43 SW652ND-1-06073
(NOTICE) • Push in the inner race while rotating the bearing. Otherwise, even strongly trying to push the inner race, the bearing rollers will not be pushed up and therefore bearing will not be seated.
End of rollers in close contact with inner race shoulder
Gap Gap
(1) Bearing not seated
(2) Bearing correctly seated
SW800-06080
6-061
VIBRATORY DRUM
SW654ND
③ Remove bolts (34). • Remove cover (39). • Remove shim.
34 39
(NOTICE) • Do not turn the housing after the cover is removed.
Shim
SW652ND-1-06103
④ Without inserting shim, install cover (39) to axle shaft (43) with six bolts (34) and spring washers. 34 39 43
SW652ND-1-06074
No gap
A
⑤ Using a thickness gauge, measure clearance “A”. reload adjusting ★ P = A + 0.1 mm (0.004 in.) shim thickness
SW652-1-06055
6-062
SW654ND
VIBRATORY DRUM
⑥ Remove bolts (34). • Remove cover (39). 34 39
SW652ND-1-06102
⑦ Install shim (40) of preload adjusting shim thickness = “A + 0.1 mm (0.004 in.)”. • Secure cover (39) to axle shaft (43) with six bolts (34) and spring washers. N•m
(34) Bolts M10×30 : 60 N·m (44 lbf·ft)
34 39 40 43
SW652ND-1-06104
24-16) Apply grease to O-ring (30). • Install O-ring to flange (41).
30
41
SW652ND-1-06075
6-063
VIBRATORY DRUM 24-17) Secure flange (41) to housing (42) with eight bolts (32) and spring washers. N•m
SW654ND 42
32
41
(32) Bolts M10×30 : 60 N·m (44 lbf·ft)
SW652ND-1-06076
25) Install lifting bolts (M12) to axle shaft subassembly. Axle shaft subassembly
Lifting bolt
SW652ND-1-06077
26) Lift axle shaft subassembly.
43
Axle shaft subassembly : 195 kg (430 lbs.) • Apply grease to O-ring (54). • Install O-ring to axle shaft (43).
54
6-064
SW652ND-1-06078
SW654ND
VIBRATORY DRUM
27) Place punch marks on end of eccentric shafts (8) and (59) as shown right.
Punch Scribed line marks
Punch marks
Far Near
59
Far
Near
Scribed line
8
Keyway
Keyway
SW652ND-1-06057
28) Install long guide bolts to end of both eccentric shafts. • Lower axle shaft subassembly on mounting surface of drum while taking care not to move punch marks on each eccentric shaft.
Axle shaft subassembly
(NOTICE) • Take care not to let the eccentric shafts fall down.
Guide bolts SW652ND-1-06079
29) Drive in two locating pins (20) for axle shaft subassembly and drum (1) temporarily.
1
20
Axle shaft subassembly
SW652ND-1-06080
6-065
VIBRATORY DRUM 30) Secure axle shaft subassembly to drum (1) with sixteen bolts (53) and washers. N•m
SW654ND
20 Axle shaft 53 subassembly
1
(53) Bolts M16×45 : 265 N·m (195 lbf·ft)
• Drive in locating pins (20) again.
Near Far
Far
31) Make sure that punch marks on shaft (10) of eccentric shafts (8) and (59) are as shown right.
Near
SW652ND-1-06081
8
10
59 SW652ND-1-06082
32) Apply a coat of gear oil to axle shaft (43) at where bearings will be press-fitted and to eccentric shafts at where bearings will be installed. • Drive in vibrator bearings (19) and (51).
51
43
19
SW652ND-1-06083
6-066
VIBRATORY DRUM
(NOTICE) • Stop driving in vibrator bearings (19) and (51) when they come to a position slightly protruding from the boss surface of axle shaft (43) to avoid driving in too much.
43
19,51
Protruding
SW654ND
33) Press fit slightly protruding vibrator bearings (19) and (51) into place by installing covers (23) and (47) with four bolts (22), four bolts (50), and washers. • After press fitting, remove covers to make sure that vibrator bearings are not protruding.
22,50
23,47
19,51 Protruding
Press fit with cover
SW652ND-1-06084
Fitted into position SW652ND-1-06085 34) Install lifting bolts (M8) to end of eccentric shafts (8) and (59).
59
Lifting bolt
8
SW652ND-1-06086
6-067
SW654ND
35) Measure dimension “a” from end of eccentric shafts (8) and (59) to top of vibrator bearings (19) and (51) by using a depth gauge.
8,59
a
VIBRATORY DRUM
19,51
Depth gauge 8,59
19,51
36) Lift eccentric shafts (8) and (59), and measure dimension “b” from end of eccentric shafts to top of vibrator bearings (19) and (51) again by using a depth gauge.
8,59
Depth gauge
b
SW652ND-1-06087
19,51
8,59 19,51
SW652ND-1-06088
8,59
a
37) Make sure that eccentric shafts (8) and (59) have an axial play of 1 mm (0.04 in.) or more. b = a + 1 mm (0.04 in.) or more
b
(NOTICE) • Two persons are required for taking measurements.
Pull up
6-068
SW652ND-1-06089
SW654ND
VIBRATORY DRUM
38) Apply grease to O-rings (15) and (58). • Install O-rings to covers (23) and (47).
15,58
23,47
SW652ND-1-06090
39) Secure covers (23) and (47) to axle shaft subassembly with four bolts (22), four bolts (50), and washers. N•m
(22) and (50) Bolts M12×30 : 110 N·m (81 lbf·ft)
47
50
22
23
SW652ND-1-06091
40) Apply grease to O-rings for plugs (21-1), (21-2), and level plug (52). • Install plugs and level plug.
21-2
52
21-1
SW652ND-1-06092
6-069
VIBRATORY DRUM
SW654ND
41) Lift disc subassembly. Disc subassembly : 75kg (165 lbs.)
Disc subassembly
SW652-1-06064
42) Lower disc subassembly on mounting surface of housing (42).
Disc subassembly
42
SW652ND-1-06094
(NOTICE) • The recess of the disc must face the same direction as the breather mounting hole in the flange.
Recess of disc Breather mounting hole
SW652ND-1-06095
6-070
SW654ND
VIBRATORY DRUM
43) Secure disc subassembly with sixteen bolts (29) and washers. N•m
Disc subassembly
29
(29) Bolts M16×45 : 265 N·m (195 lbf·ft)
SW652ND-1-06096
44) Drive two spring pins (36) into sleeve (35). 35
36 SW652ND-1-06097
45) Apply molybdenum-based grease to splined portion of sleeve (35). • Fit sleeve to splined portion on drive shaft end.
35
SW652ND-1-06098
6-071
VIBRATORY DRUM
SW654ND
46) Apply grease to O-ring (38). • Install O-ring to vibrator motor (37). 37
38 SW652ND-1-06099
47) Wind seal tape around threaded portion of breather (31). • Install breather. • Secure vibrator motor (37) to flange (41) with two bolts (33) and washers. (37) Vibrator motor : 15 kg (33 lbs.) N•m
37 33
(33) Bolts M12×30 : 110 N·m (81 lbf·ft) 41
31 SW652ND-1-06100
48) Lay drum assembly with plugs (21-1), (21-2), and level plug (52) positioned as shown right. • Hold with chocks.
Drum assembly
Drum assembly : 1,665 kg (3,671 lbs.)
21-1
52
21-2
Chock
6-072
SW652ND-1-06001
SW654ND 49) Remove plug (21-1) and level plug (52). • Supply gear oil from oil supply port. • Check that oil drips from gauge port.
VIBRATORY DRUM Suppy port
21-1
• Quantity of gear oil : 10.4 L (2.7 gal.) • Install plug and level plug.
Gauge port
52
SW652ND-1-06101
6-073
BRAKE
BRAKE
1. BRAKE PEDAL
1 2
3 4 5
A
B
6
A B 8
7
13 12
SECTION A-A
11 10
9
SECTION B-B 0559-51802-0-10797-A
(1) (2) (3) (4) (5) (6) (7)
Split pin Washer (Apply grease) Rod Nut : M10 (Left-hand thread) Rod end : M10 (Left-hand thread) Pedal Bush (Apply grease*)
(8) Spring (9) Foot brake switch (10) Stopper bolt : M10×40 (11) Nut : M10 (12) Stopper bolt : M10×40 (13) Nut : M10
* : Lithium-based grease
7-001
BRAKE
2. BRAKE SYSTEM Fuse 15A
Foot brake switch (Condition in which brake pedal pressed)
Parking brake switch (Brake OFF condition)
Hand pump
3 1
2 6
4
5
To combination meter
Parking brake solenoid valve when brake is OFF. (with solenoid excited)
Parking brake solenoid valve when brake is ON. (without solenoid excited)
Rotary valve
Brake (Brake ON condition)
Steering charge pump
Propulsion motor (F)
Propulsion motor (R)
The arrow (
7-002
) symbol shows the direction of the hydraulic oil flow.
SW654-07001
WATER SPRAY SYSTEM
WATER SPRAY SYSTEM
1. WATER SPRAY PIPING 1-1. Water Spray Piping (1) Water spray pipe (F)
Filler cap
Level gauge
Hose (TR Tee R1)
Hose (TF Tee F1)
Tee F1 Tee F2
FT1
3 way valve Water spray pipe (F) Hose (Tee F5
Hose (Cross
(P.8-002)
Water spray pipe (F)) Filter 1 (FT1)
OUT IN PR OUT
TF
Cross
Tee F4
Water spray diagram
Filler cap
Filler cap
Level gauge
Water spray pipe (R)
Drain valve
B
Water spray tank (R) (TR)
(P.8-002)
C
(P.8-002)
TR
Tee F3
Nozzle
Water spray tank (F) (TF)
IN
Tee R2
Water spray pipe (R))
Filter 2 (FT2)
Tee R1
FT2 IN PF OUT
Tee F5
A
Filler cap
IN
Water spray pipe (R)
OUT
C
(P.8-002)
The letters and figures (such as TF and Tee F1) show each port and the arrow ( show the hose connection and the direction of the flow of the water.
) symbols 0559-75807-0-10911-B
8-001
WATER SPRAY SYSTEM
1-2. Water Spray Piping (2)
Hose (PR OUT
Hose (FT2 OUT
Tee R2)
Water spray pump (R) (PR)
PR IN)
Hose (Tee F2
D
Tee F2
Hose (Tee F4
Bypass valve) Hose (Tee F5
Hose (TR Tee R1)
Tee F5) Hose (Tee F1
Water spray pipe (F))
Tee F2)
Tee F1
Water spray pump (F) (PF)
Breather
Hose (TF Tee F1)
Breather
Drain valve
Tee F5
Drain valve
DETAIL B Hose (FT1 OUT
Hose (FT1 OUT
PF IN)
PF IN)
Filter 1 (FT1)
Hose (PF OUT
Filter 2 (FT2)
Bypass valve
Tee R1
Drain cap
Breather
Breather
Tee F3)
3 way valve
VIEW C Hose (PF OUT
Hose (Cross
Hose (FT2 OUT
Tee F3)
PR IN)
Water spray pipe (R))
Chuck valve Hose (PR OUT
Tee F3 Tee R2)
Hose (PR OUT
Tee R2)
Bypass valve
Chuck valve Hose (Tee F4
Tee F4
Drain valve
Tee F5) Tee R2
Cross
VIEW A
Hose (Tee F1
Hose (Tee F1
VIEW D Tee F2)
The letters and figures (such as TR and Tee R1) show each port and the arrow ( show the hose connection and the direction of the flow of the water.
) symbols
Tee F2) 0559-75006-1-11011-A 0559-75807-0-10911-B
8-002
INSPECTION AND ADJUSTMENT
INSPECTION AND ADJUSTMENT
1. INSPECTION AND ADJUSTMENT 1-1. Safety Precautions for Inspection and Adjustment WARNING
Unexpected machine movement may cause a serious accident. When inspecting the machine while the engine is running, always follow the instructions below. • Park the machine on level, flat ground. • Apply the parking brake. • Set chocks in front and behind each drum or tire. • Make sure that service personnel are given the appropriate information at the appropriate time. • Make sure that no one can enter any hazardous area.
CAUTION
Do not work on the hydraulic system while the engine is running and the system is hot and under pressure. Do not disconnect hydraulic hoses or fittings until the system has cooled and pressure has been properly relieved. Before removing any plugs from the pressure measurement ports, always release any residual pressure from the piping and open the cap of the fluid tank to release and pressure.
WARNING
Inadvertent starting the engine may cause a serious accident. When inspecting the engine, make sure to exchange the appropriate cues and hand signal with the person at the operator station to avoid any accidents.
CAUTION
Before inspecting inside of the engine compartment, always stop the engine. Contact with the fan, V-belt or exhaust system parts while the engine is running may cause serious injury.
1-2. Preparation for Inspection and Adjustment • Prepare the necessary measuring instruments. In addition, particularly when measuring pressure values, make sure to prepare the appropriate hoses, adapters and a plug removal tool for the pressure reading port. • Make sure that the instruments to be used operate normally. When handling the instruments, exercise sufficient caution not to drop or apply any impact to them. Doing so may adversely affect the calibration. Another important point is to inspect the instruments regularly. An instrument that does not start from the appropriate zero point may give an inaccurate reading.
1-3. Precautions for Inspection and Adjustment • When performing inspections and adjustments, pay special attention to safety. • For each inspection, always take three measurements for each measurement point. If the measurements significantly differ, the measurement method may be incorrect. In such a case, take measurements once again and calculate their average.
1-4. Warm-up • Machinery will not exhibit their true performance under the cold condition. Before taking measurements, always warm up the engine and make sure that the fluid and engine coolant are warmed to their specified normal operating temperatures.
1-5. Inspection and Adjustment of Engine Related Items • Refer to shop manual of engine manufacturer for inspection and adjustment of engine itself. 9-001
INSPECTION AND ADJUSTMENT
2. M EASUREMENT AND ADJUSTMENT OF PROPULSION CIRCUIT PRESSURE 2-1. Measurement
WARNING Confirm that the parking brake works properly before measurement. • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Remove plugs from high pressure gauge port (1-7) and (1-14) of propulsion pump. Attach pressure gauge with adapter ⓨ . • Adapter ⓨ : 7/16-20UNF
1-7
• High pressure gauge port (Forward) : (1-7) • High pressure gauge port (Reverse) : (1-14) • Pressure gauge :0 to 50 MPa (0 to 7,250 psi) ② Confirm that F-R lever is “N”. ③ Apply parking brake by pressing parking brake switch button. ”. ④ Set propulsion speed change switch to “ ⑤ Set shift lever to “1st”. ⑥ Start the engine and set throttle lever to “Full”. ⑦ Establish a condition in which machine propulsion load becomes maximum. (Pressure does not build up unless propulsion load is applied.)
1-14
SW652-1-09001
y
⑧ With propulsion load at maximum, slowly move F-R lever to the side to be measured. ⑨ Read pressure indicated by pressure gauge. ⑩ After measuring, promptly return F-R lever to “N”. ★ Maximum circuit pressure (cut off valve setting) : 30.0 ± 1.0 MPa (4,350 ± 145 psi)
PG001011
• The numbers “1-7” and “1-14” appearing in above illustrations are consistent with lead line numbers shown in illustration of hydraulic pump assembly in “2-2. Hydraulic Component Specifications” (P.4-007).
9-002
INSPECTION AND ADJUSTMENT
2-2. Adjustment • If measurement results indicate the pressure deviating from maximum circuit pressure range, make an adjustment in accordance with procedure described below.
2-2-1. If pressures on both forward and reverse sides deviate from maximum circuit pressure range by same value ① Check nut (1) of cut off valve (1-17) for evidence of having loosened. ② If there is evidence of nut having loosened, adjust cut off valve so that pressure becomes within maximum circuit pressure range while watching pressure gauge. • To adjust pressure, loosen nut and turn adjustment screw (2). Adjustment screw turned clockwise : Pressure rise Adjustment screw turned counterclockwise : Pressure drop Pressure change rate : 1 0 MPa/turn (1,450 psi/turn) ③ If there is no evidence of nut having loosened, remove cut off valve. ④ Check removed cut off valve for trapped dirt and scratches on its seat. ⑤ If trapped dirt is present, disassemble and clean cut off valve. ⑥ If a scratch is found on seat, replace cut off valve. ⑦ After adjustment, measure pressure again and check that pressure reaches maximum circuit pressure range. N•m
1-17
1
SW654-09018
2
SW652-1-09003
(1) Nut : 22 N·m (16 lbf·ft) (1-17) Cut off valve : 35 N·m (26 lbf·ft)
(NOTICE) • Carefully disassemble and reassemble after taking steps to prevent foreign material from getting in. • The number “1-17” appearing in above illustrations is consistent with lead line numbers shown in illustration of hydraulic pump assembly in “2-2. Hydraulic Component Specifications” (P.4-007).
9-003
INSPECTION AND ADJUSTMENT
2-2-2. I f pressure on either forward or reverse side deviates from maximum circuit pressure range ① Check high pressure relief valve (1-11) or (1-13) for evidence of having loosened. • High pressure relief valve (Forward) : (1-11) • High pressure relief valve (Reverse) : (1-13) ② If there is evidence of high pressure relief valve having loosened, adjust it so that pressure becomes within maximum circuit pressure range while watching pressure gauge.
1-11
③ Remove high pressure relief valve. ④ Remove lock screw (3). ⑤ Turn adjustment screw (4) to adjust pressure. Adjustment screw turned clockwise : Pressure rise Adjustment screw turned counterclockwise : Pressure drop Pressure change rate : 4.5 MPa/turn (653 psi/turn)
1-13 SW652-1-09004
⑥ If there is no evidence of high pressure relief valve having loosened, remove it. ⑦ Check removed high pressure relief valve for trapped dirt and scratches on its seat. ⑧ If trapped dirt is present, disassemble and clean high pressure relief valve. ⑨ If a scratch is found on seat, replace high pressure relief valve. ⑩ After adjustment, measure pressure again and check that pressure reaches maximum circuit pressure range. N•m
(3) Lock screw : 6.5 N·m (4.8 lbf·ft) (1-11) High pressure relief valve (1-13) : 160 N·m (118 lbf·ft)
3
4
SW652-1-09005
(NOTICE) • Carefully disassemble and reassemble after taking steps to prevent foreign material from getting in. • The number “1-11” and “1-13” appearing in above illustrations are consistent with lead line numbers shown in illustration of hydraulic pump assembly in “2-2. Hydraulic Component Specifications” (P.4-007).
9-004
INSPECTION AND ADJUSTMENT
3. MEASUREMENT AND ADJUSTMENT OF PROPULSION/ VIBRATOR CHARGE CIRCUIT PRESSURE • Since oil in charge circuit is supplied from steering circuit, confirm that steering operation is normal before measurement. • Ensure that neutral positions of F-R lever and hydraulic pump assembly are aligned.
3-1. Measurement • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Remove plug from coupling (1). 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 25 MPa (0 to 3,625 psi) ② Confirm that F-R lever is “N”. ③ Apply parking brake by pressing parking brake switch button. ④ Start the engine and set throttle lever to “Full”. ⑤ Read pressure indicated by pressure gauge.
1
★ Standard charge relief valve setting : 2.4 ± 0.2 MPa (348 ± 29 psi)
SW654-09008
s
u
PG003163
9-005
INSPECTION AND ADJUSTMENT
3-2. Adjustment • If measurement results indicate the pressure deviating from standard charge relief pressure setting range, make an adjustment in accordance with procedure described below. ① Check charge relief valve (1-15) for evidence of having loosened. ② If there is evidence of charge relief valve having loosened, adjust it so that pressure becomes within standard charge relief valve pressure setting range while watching pressure gauge. • To adjust pressure, remove charge relief valve and change thickness of shims (1). Pressure change rate : 0.4 MPa/mm (58 psi/mm) ③ If there is no evidence of charge relief valve having loosened, remove it. ④ Check removed charge relief valve for trapped dirt and scratches on its seat. ⑤ If trapped dirt is present, disassemble and clean charge relief valve. ⑥ If a scratch is found on seat, replace charge relief valve. ⑦ After adjustment, measure pressure again and check that pressure reaches standard charge relief valve setting range. N•m
1-15
SW652-1-09007
(1-15) Charge relief valve : 70 N·m (52 lbf·ft)
(NOTICE) • Carefully disassemble and reassemble after taking steps to prevent foreign material from getting in. 1
SW652-1-09008
• The number “1-15” appearing in above illustrations is consistent with lead line numbers shown in illustration of hydraulic pump assembly in “2-2. Hydraulic Component Specifications” (P.4-007).
9-006
INSPECTION AND ADJUSTMENT
4. MEASUREMENT OF MACHINE HIGH/LOW SPEED CHANGE CIRCUIT PRESSURE • Since oil in charge circuit is supplied from steering circuit, confirm that steering operation is normal before measurement.
4-1. Measurement • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Disconnect hose (1) from propulsion motor. Attach pressure gauge through adapter ⓜ . • Adapter ⓜ : G1/4 • Pressure gauge : 0 to 5 MPa (0 to 725 psi) ② Confirm that F-R lever is “N”. ③ Apply parking brake by pressing parking brake switch button. ”. ④ Set propulsion speed change switch to “ ⑤ Start the engine and set throttle lever to “Full”. ⑥ Read pressure indicated by pressure gauge.
1
★ Standard charge relief valve setting
Propulsion motor
: 2.4 ± 0.2 MPa (348 ± 29 psi)
SW652-1-09009
m
PG002002
9-007
INSPECTION AND ADJUSTMENT
5. M EASUREMENT OF PROPULSION SERVO CIRCUIT PRESSURE 5-1. Measurement • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Disconnect hoses (2) and (3) from propulsion pump (1). Attach pressure gauge through adapter ⓜ . • Adapter ⓜ : G1/4 • Pressure gauge : 0 to 5 MPa (0 to 725 psi) ② Confirm that F-R lever is “N”. ③ Apply parking brake by pressing parking brake switch button. ④ Start the engine and set throttle lever to “Full”. ⑤ Operate F-R lever and then read pressure indicated by pressure gauge. • With parking brake applied (ON), measured pressures of (1-6) and (1-8) are same. • With parking brake released (OFF), measured pressures of (1-6) and (1-8) are different. ★ Standard charge relief pressure setting : 2.4 ± 0.2 MPa (348 ± 29 psi)
2 3
1-6 1-8
1 SW654-09007
m
PG002002
• The numbers “1-6” and “1-8” appearing in above illustrations are consistent with lead line numbers shown in illustration of hydraulic pump assembly in “2-2. Hydraulic Component Specifications” (P.4-007).
9-008
INSPECTION AND ADJUSTMENT
6. MEASUREMENT OF PARKING BRAKE RELEASE PRESSURE • Since oil in charge circuit is supplied from steering circuit, confirm that steering operation is normal before measurement.
6-1. Measurement • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Disconnect hose (1) from propulsion motor. Attach pressure gauge through adapter ⓜ . • Adapter ⓜ : G1/4 • Pressure gauge : 0 to 5 MPa (0 to 725 psi) ② Confirm that F-R lever is “N”. ③ Apply parking brake by pressing parking brake switch button. ④ Start the engine and set throttle lever to “Full”. ⑤ Release parking brake by pressing parking brake switch button. ⑥ Read brake release pressure indicated by pressure gauge.
1 Propulsion motor SW652-1-09010
★ Brake release pressure : More than 1.8 MPa (261 psi)
m
PG002002
9-009
INSPECTION AND ADJUSTMENT
7. M EASUREMENT AND ADJUSTMENT OF VIBRATOR CIRCUIT PRESSURE 7-1. Measurement
CAUTION Take care not to operate the vibratory drum for a longer period of time than necessary with the machine stationary. Otherwise, the vibrator bearing could be seized. • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Remove plugs from high pressure gauge port (2-5) and (2-13) of vibrator pump. Attach pressure gauge with
2-5
adapter ⓨ . : 7/16-20UNF • Adapter ⓨ • High pressure gauge port : (2-5) (Low amplitude/Oscillation) • High pressure gauge port : (2-13) (High amplitude/Normal) : 0 to 50 MPa (0 to 7,250 psi) • Pressure gauge ② Confirm that F-R lever is “N”. ③ Apply parking brake by pressing parking brake switch button. ④ Set shift lever to “1st”. ”. ⑤ Set vibratory drum select switch to “ ”. ⑥ Set vibration mode change switch to “ ⑦ Start the engine and set throttle lever to “Full”. ⑧ Press F-R lever vibration switch ON. ⑨ Slowly move F-R lever to forward or reverse side. ⑩ Read pressure gauge for maximum value of vibrator circuit pressure.
2-13
SW652-1-09011
y
⑪ Turn F-R lever vibration switch OFF or move back F-R lever to “N” as soon as measurement is finished. ★ Maximum circuit pressure (cut off valve setting) : 32.5 ± 1.0 MPa (4,713 ± 145 psi)
PG001011
• The numbers “2-5” and “2-13” appearing in above illustrations are consistent with lead line numbers shown in illustration of hydraulic pump assembly in “2-2. Hydraulic Component Specifications” (P.4-007).
9-010
INSPECTION AND ADJUSTMENT
7-2. Adjustment • If measurement results indicate the pressure deviating from maximum circuit pressure range, make an adjustment in accordance with procedure described below.
7-2-1. If pressures on both Low amplitude/Oscillation and High amplitude/Normal sides deviate from maximum circuit pressure range by same value ① Check nut (1) of cut off valve (2-15) for evidence of having loosened. ② If there is evidence of nut having loosened, adjust cut off valve so that pressure becomes within maximum circuit pressure range while watching pressure gauge. • To adjust pressure, loosen nut and turn adjustment screw (2). Adjustment screw turned clockwise : Pressure rise Adjustment screw turned counterclockwise : Pressure drop Pressure change rate : 1 0 MPa/turn (1,450 psi/turn) ③ If there is no evidence of nut having loosened, remove cut off valve. ④ Check removed cut off valve for trapped dirt and scratches on its seat. ⑤ If trapped dirt is present, disassemble and clean cut off valve. ⑥ If a scratch is found on seat, replace cut off valve. ⑦ After adjustment, measure pressure again and check that pressure reaches maximum circuit pressure range. N•m
2-15 SW654-09019
1
2
SW652-1-09003
(1) Nut : 22 N·m (16 lbf·ft) (2-15) Cut off valve : 35 N·m (26 lbf·ft)
(NOTICE) • Carefully disassemble and reassemble after taking steps to prevent foreign material from getting in. • The number “2-15” appearing in above illustrations is consistent with lead line numbers shown in illustration of hydraulic pump assembly in “2-2. Hydraulic Component Specifications” (P.4-007).
9-011
INSPECTION AND ADJUSTMENT
7-2-2. I f pressure on either Low amplitude/Oscillation or High amplitude/Normal side deviates from maximum circuit pressure range ① Check high pressure relief valve (2-10) or (2-12) for evidence of having loosened. • High pressure relief valve : (2-12) (High amplitude/Normal) • High pressure relief valve : (2-10) (Low amplitude/Oscillation) ② If there is evidence of high pressure relief valve having loosened, adjust it so that pressure becomes within maximum circuit pressure range while watching pressure gauge.
2-10
③ Remove high pressure relief valve. ④ Remove lock screw (3). ⑤ Turn adjustment screw (4) to adjust pressure. Adjustment screw turned clockwise : Pressure rise Adjustment screw turned counterclockwise : Pressure drop Pressure change rate : 4.5 MPa/turn (653 psi/turn)
2-12 SW652-1-09013
⑥ If there is no evidence of high pressure relief valve having loosened, remove it. ⑦ Check removed high pressure relief valve for trapped dirt and scratches on its seat.
3
⑧ If trapped dirt is present, disassemble and clean high pressure relief valve. ⑨ If a scratch is found on seat, replace high pressure relief valve. ⑩ After adjustment, measure pressure again and check that pressure reaches maximum circuit pressure range. 4 N•m
(3) Lock screw : 6.5 N·m (4.8 lbf·ft) (2-10) High pressure relief valve (2-12) : 160 N·m (118 lbf·ft)
SW652-1-09005
(NOTICE) • Carefully disassemble and reassemble after taking steps to prevent foreign material from getting in.
• The numbers “2-10” and “2-12” appearing in above illustrations are consistent with lead line numbers shown in illustration of hydraulic pump assembly in “2-2. Hydraulic Component Specifications” (P.4-007).
9-012
INSPECTION AND ADJUSTMENT
8. MEASUREMENT AND INSPECTION OF STEERING CIRCUIT PRESSURE 8-1. Measurement
WARNING Make sure that there is no person around the articulated portion of the machine before operating the steering wheel. • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① D isconnect the hose (1) or (2) from steering cylinder. Attach pressure gauge through adapter ⓝ . • Adapter ⓝ : G3/8 • Pressure gauge : 0 to 25 MPa (0 to 3,625 psi) ② Confirm that F-R lever is “N”. ③ Apply parking brake by pressing parking brake switch button. ④ Start the engine and set throttle lever to “Full”. ⑤ Turn steering wheel to operate relief valve. ⑥ Read pressure indicated by pressure gauge.
1
2
★ Standard maximum circuit pressure (orbitroll relief pressure + charge relief pressure) : 18.1 ± 1.0 MPa (2,625 ± 145 psi)
SW654-09025
n
PG002003
9-013
INSPECTION AND ADJUSTMENT
8-2. Inspection • If measurement results indicate the pressure deviating from standard maximum circuit pressure range, make an adjustment in accordance with procedure described below. ① Remove relief valve (2) from orbitrol. ② Check removed relief valve for trapped dirt, scratches on its seat and other abnormalities. ③ If trapped dirt is present, disassemble and clean relief valve. ④ If a scratch or any other abnormality is found on seat, replace relief valve. ⑤ After inspection, measure pressure again and check that pressure reaches standard maximum circuit pressure range. (NOTICE) • Carefully disassemble and reassemble after taking steps to prevent foreign material from getting in.
9-014
2 GW751-09010
INSPECTION AND ADJUSTMENT
9. MEASUREMENT OF HYDRAULIC PUMP CASE PRESSURE 9-1. Measurement of Propulsion Pump Case Pressure • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Disconnect hose (2) from propulsion pump (1) drain port (1-16). Attach pressure gauge through adapter ⓟ . • Adapter ⓟ : G1/2 • Pressure gauge : 0 to 5 MPa (0 to 725 psi) ② Confirm that F-R lever is “N”. ③ Apply parking brake by pressing parking brake switch button. ”. ④ Set propulsion speed change switch to “ ⑤ Set shift lever to “1st”. ⑥ Start the engine and set throttle lever to “Full”. ⑦ Establish a condition in which machine propulsion load becomes maximum. (Pressure does not build up unless propulsion load is applied.) ⑧ With propulsion load at maximum, measure pressure when speed change switch is “ ” and “ F-R lever is “N”, “F”, and “R”, respectively.
” and
1
1-16
2
SW654-09020
1
★ Allowable pump case pressure : 0.4 MPa (58.0 psi) or less
1-16
2
SW654-09021
p
PG002004
• The number “1-10” appearing in above illustrations is consistent with lead line numbers shown in illustration of hydraulic pump assembly in “2-2. Hydraulic Component Specifications” (P.4-007).
9-015
INSPECTION AND ADJUSTMENT
9-2. Measurement of Vibrator Pump Case Pressure • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Disconnect hose (2) from vibrator pump (1) drain port (2-9). Attach pressure gauge through adapter ⓟ . • Adapter ⓟ : G1/2 • Pressure gauge : 0 to 5 MPa (0 to 725 psi) ② Confirm that F-R lever is “N”. ③ Apply parking brake by pressing parking brake switch button.
2
2-9
④ Set shift lever to “1st”. ”. ⑤ Set vibratory drum select switch to “ ”. ⑥ Set vibration mode change switch to “ ⑦ Start the engine and set throttle lever to “Full”. ⑧ Press F-R lever vibration switch ON. ⑨ Slowly move F-R lever to forward or reverse side. ⑩ Measure pressure when vibration switch is “
”/
“ ”and “ ”/“ ”, respectively. ⑪ Press F-R lever vibration switch OFF or move back F-R lever to “N” as soon as measurement is finished.
1
SW654-09022
1
★ Allowable pump case pressure : 0.4 MPa (58.0 psi) or less
2-9 SW654-09023
p
PG002004
• The number “2-9” appearing in above illustrations is consistent with lead line numbers shown in illustration of hydraulic pump assembly in “2-2. Hydraulic Component Specifications” (P.4-007).
9-016
INSPECTION AND ADJUSTMENT
10. MEASUREMENT OF PROPULSION MOTOR CASE PRESSURE 10-1. Measurement • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Remove plug from drain port (1). Attach pressure gauge with adapter ⓙ . • Adapter ⓙ : 7/8-14UNF • Pressure gauge : 0 to 5 MPa (0 to 725 psi) ② Confirm that F-R lever is “N”. ③ Apply parking brake by pressing parking brake switch button. ”. ④ Set propulsion speed change switch to “ ⑤ Set propulsion shift lever to “1st”. ⑥ Start the engine and set throttle lever to “Full”. ⑦ Establish a condition in which machine propulsion load becomes maximum. (Pressure does not build up unless propulsion load is applied.) ⑧ With propulsion load at maximum, measure pressure when speed change switch is “ ” and “ F-R lever is “N”, “F”, and “R”, respectively.
1 SW652-1-09019
” and j
★ Allowable motor case pressure : 0.4 MPa (58.0 psi) or less
PG001022
9-017
INSPECTION AND ADJUSTMENT
11. MEASUREMENT OF VIBRATOR MOTOR CASE PRESSURE 11-1. Measurement • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Remove plug from drain port (1). Attach pressure gauge with adapter ⓘ . • Adapter ⓘ : 3/4-16UNF • Pressure gauge : 0 to 5 MPa (0 to 725 psi) ② Confirm that F-R lever is “N”. ③ Apply parking brake by pressing parking brake switch button. ④ Set shift lever to “1st”. ”. ⑤ Set vibratory drum select switch to “ ”. ⑥ Set vibration mode change switch to “ ⑦ Start the engine and set throttle lever to “Full”. ⑧ Press F-R lever vibration switch ON. ⑨ Slowly move F-R lever to forward or reverse side. ⑩ Measure pressure when vibration switch is “
1
”/
“ ”and “ ”/“ ”, respectively. ⑪ Press F-R lever vibration switch OFF or move back F-R lever to “N” as soon as measurement is finished.
SW652-1-09020
i
★ Allowable motor case pressure : 0.2 MPa (29.0 psi) or less
PG001019
9-018
INSPECTION AND ADJUSTMENT
12. ADJUSTMENT OF THROTTLE LEVER 12-1. Adjustment of Potentiometer • If potentiometer (1) is replaced, make following adjustments. • Make adjustments after amply warmed engine. • Oil temperature during measurement : 50 ± 5°C (122 ± 9°F) ① Apply grease to shaft of potentiometer. ② Insert potentiometer shaft to the groove on throttle lever (3), and fix it with two screws (2).
1
(NOTICE) • When fixing potentiometer (1), turn potentiometer counterclockwise till it is stopped by screws (2) and tighten screws.
A
• Apply thread-locked liquid to screws (2).
2 3 SW654-09024
1
VIEW A SW654-09001
9-019
INSPECTION AND ADJUSTMENT ③ Set throttle lever (3) to “IDOL”. ④ Loosen lock nut (4), and adjust engine rotational speed to standard value with stopper bolt (5). IDOL
0 min-1 ★ Engine rotational speed : 1,000 - 50
• After adjustment, fix stopper bolt (5) with lock nut (4). ⑤ Set throttle lever to “FULL”. ⑥ Loosen lock nut (6), and adjust engine rotational speed to standard value with stopper bolt (7).
7
65
4
FULL 3
★ Engine rotational speed : 2,400 ± 50 min-1 • After adjustment, fix stopper bolt (7) with lock nut (6).
9-020
SW654-09009
INSPECTION AND ADJUSTMENT
12-2. Adjustment of Operating Force ① Tighten nut (8) and set operating force at center of throttle lever (3) knob to standard operating force. Do not turn nut to the loosening direction. ★ Standard operating force : 45 ± 10 N (10 ± 2 lbf) (NOTICE) • In case of loosen nut (8), replace it with a new one.
B
3
SW654-09010
8
VIEW B SW654-09011
9-021
INSPECTION AND ADJUSTMENT
13. ADJUSTMENT OF F-R LEVER AND SHIFT LEVER 13-1. Adjustment of Linkage • In cases such as propulsion pump is replaced, control cable is replaced, or F-R lever or shift lever does not move smoothly, make following adjustments. • “N”, maximum “F”, and maximum “R” positions of F-R lever are positioned by notches.
A
C
B D
A
SW654-09002
① Set F-R lever (1) to “N”. F N
1 R
SECTION A-A
SW654-09006
② Attach control cable (4) to shaft subassembly (2) and bracket (3).
a
★ Specified dimension a: 206 mm (8.1 in.)
2 3 4
VIEW B 9-022
SW654-09003
INSPECTION AND ADJUSTMENT • 1st, 2nd, 3rd, and 4th positions of shift lever (7) are positioned by notches. ③ Set shift lever to “1st”.
6
1ST 2ND 3RD 4TH
7
b
④ Align hole (8) in plate (7) with hole in base (6), and insert steel bar. ⑤ Attach control cables (4) and (9) to plate. ⑥ Attach control cables to bracket (10).
5
b
★ Specified dimension b: 209 mm (8.2 in.) 4 10
9
8
VIEW C
⑦ Fix propulsion pump control lever (11) at neutral position. ⑧ Attach control cable (9) to propulsion pump control lever and bracket (12).
SW654-09004
9
11
★ Specified dimension c: 207 mm (8.1 in.) ⑨ Confirm the strokes “d” of propulsion pump control lever in each direction. ★ Specified dimension d: 1st 11 mm (0.43 in.) 2nd 16 mm (0.63 in.) 3rd 22 mm (0.87 in.) 4th 31 mm (1.22 in.)
R
12
c
F
d d
VIEW D
SW654-09005
9-023
INSPECTION AND ADJUSTMENT
13-2. Adjustment of Operating Force 13-2-1. Adjustment of F-R lever ① Loosen lock nut (15), and adjust bolt (16) so that operating force at center of F-R lever (1) knob matches standard operating force.
1
★ Standard operating force : 40 ± 10 N (9 ± 2 lbf)
A
• After adjustment, fix bolt (16) with lock nut (15). ② Loosen lock nut (13), and adjust bolt (14) to match operating force of lever to standard operating force +5N, when getting over notch at center of F-R lever knob. ★ Operating force to move lever over notch : 45 ± 10 N (10 ± 2 lbf)
SW654-09016
• After adjustment, fix bolt (14) with lock nut (13). 13,14
15,16
B
B
VIEW A
14 13
SECTION B-B 9-024
SW654-09012
16 15 SW654-09013
INSPECTION AND ADJUSTMENT
13-2-2. Adjustment of shift lever ① Adjust nut (17) so that operating force at center of shift lever (5) knob matches standard operating force.
5
★ Standard operating force : 40 ± 10 N (9 ± 2 lbf) ② Loosen lock nut (19), and adjust bolt (18) to match operating force of lever to standard operating force +5N, when getting over notch at center of shift lever knob.
A
★ Operating force to move lever over notch : 45 ± 10 N (10 ± 2 lbf) • After adjustment, fix bolt (18) with lock nut (19). SW654-09017
F
N
1 R
1ST 2ND
4
3RD
2
a
3
SW652-1-09014
17
18 19
SECTION B-B SW654-09015
9-025
INSPECTION AND ADJUSTMENT
14. MOVABLE WEIGHT ADJUSTMENT (SW654ND) • When eccentric shaft is replaced, make adjustment as follows. • Be sure to replace bolts (1) and nuts (2) with new ones as these are not allowed to reuse.
14-1. Adjustment ① Tighten bolts (1) until gaps at both sides of movable weight (3) becomes 1mm (0.04 in.) each.
1
2
3
1 mm (0.04 in.)
1 mm (0.04 in.)
2 1
SW652-1-09029
② Put eccentric shaft (5) on wooden blocks (6) with stopper (4) placed at top. ③ Put movable weight (3) against stopper (4).
4
5 3
6 SW652-1-09030
④ Make sure that movable weight (3) starts to swing down by its own weight when movable weight is rotated away from stopper (4) by 15°. ⑤ If swinging does not start at 15°, adjust with bolts (1). ⑥ Securely lock with nuts (2).
15°
4 3
(NOTICE) • After adjustment is made, be sure to caulk bolts (1) and nuts (2) to prevent turning. 1,2
SW652-1-09031
9-026
TROUBLESHOOTING
TROUBLESHOOTING
1. TROUBLESHOOTING 1-1. Safety Precautions for Troubleshooting WARNING Unexpected machine movement may cause a serious accident. When inspecting the machine while the engine is running, always follow the instructions below. • Park the machine on level, flat ground. • Apply the parking brake. • Set chocks in front and behind each drum or tire. • Make sure that service personnel are given the appropriate information at the appropriate time. • Make sure that no one can enter any hazardous area.
CAUTION Do not work on the hydraulic system while the engine is running and the system is hot and under pressure. Do not disconnect hydraulic hoses or fittings until the system has cooled and pressure has been properly relieved. Before removing any plugs from the pressure measurement ports, always release any residual pressure from the piping and open the cap of the fluid tank to release and pressure.
WARNING Inadvertent starting the engine may cause a serious accident. When inspecting the engine, make sure to exchange the appropriate cues and hand signal with the person at the operator station to avoid any accidents.
CAUTION Before inspecting inside of the engine compartment, always stop the engine. Contact with the fan, V-belt or exhaust system parts while the engine is running may cause serious injury.
1-2. Important Information for Troubleshooting Before conducting troubleshooting, it is important to carefully read the operation manual and workshop manual and understand the electric circuits for each component as well as the structure and function of each system. Sufficient knowledge of the systems will enable you to identify a possible cause much faster. A fault or problem may seem to be related to many different factors. To identify the true cause, some experience is needed. To perform the appropriate troubleshooting, it is important to learn not only the normal operations of the systems but also the possible symptoms that may occur when an abnormal condition is present. This chapter explains the possible causes and remedies for likely incidents taken from past experience.
10-001
TROUBLESHOOTING
1-3. Before Starting The information in this section is provided to assist the troubleshooter in understanding the systems and quickly determine the causes when operating abnormalities occur. The following steps are recommended: 1. If not familiar with the machine, study the Operator’s Manual and this Shop Manual. 2. Check with the operator for 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 electrical system source. 5. Isolate the problem to a particular component or circuit. 6. Eliminate the simplest or easiest to check possibilities first to prevent unnecessary disassembly of components. 7. Following repair or replacement of any parts, perform operational tests to verify that the problem has been eliminated and the performance of all the systems is normal.
10-002
TROUBLESHOOTING
2. ELECTRICAL SYSTEM TROUBLESHOOTING 2-1. When Performing Electrical System Fault Diagnosis WARNING Be very careful because equipment can return to normal during an inspection and suddenly operate properly when a failure occurs due to a faulty contact or other such cause.
2-1-1. Precautions to take during electrical circuit fault diagnosis • When disconnecting or connecting a connector, be sure to turn the power supply OFF. (Electronic control parts such as the engine control unit, in particular, could be damaged internally.) • Since connectors are not numbered, be sure to affix alignment marks so that you can restore them to their original condition. • Before making a diagnosis, check related connectors for faulty connections. (Check by disconnecting and reconnecting related connectors several times.) • Before proceeding to the next step, be sure to return the disconnected connectors to their original condition. • When diagnosing a circuit (measuring the voltage, resistance, continuity and current), move related wiring and connectors several times, and check whether the tester’s numerical values change. (If values change, faulty contact in the circuit is possible.) • Do not ground the circuit of the control unit or apply voltage to it unless otherwise specified. • For information of wire number, wire size, and wire color used in the sample circuit diagrams, refer to "1-1. Wire Numbers, Wire Sizes, Wire Colors and Connectors Shown in Electrical Circuit Diagram, Wiring Harness Layout and Wiring Harnesses" (P.5-001).
10-003
TROUBLESHOOTING
2-1-2. Inspection procedures using a tester Some of the various inspection procedures are presented here for reference, using a sample circuit below.
Equipment A
1
5
Main power source of equipment B
1
2
3
2
3
4
Ground of equipment A
Power to equipment A
Signal from equipment A
Battery Equipment B
TS-10001
1) Measuring resistance using tester 1-1) Measuring resistance of equipment A (measuring resistance between terminals 1 and 3)
Equipment A Connector
Harness 1
Equipment A
2
3
1
2
3
2
3
4
Ohmmeter (tester) 1
2
3 1
5
Main power source of equipment B
Ground of equipment A
Signal from Power to equipment A equipment A
Equipment B TS-10002
Inspection procedure ① Disconnect the connector of equipment A. ② Connect the test probe (+) to connector terminal 1 of equipment A and the test probe (-) to connector terminal 3 of equipment A and measure the resistance. At this time, reversing the connector terminals between the probes (+) and (-) does not make any difference in the measurement.
10-004
TROUBLESHOOTING 1-2) Measuring resistance of harness (measuring resistance between terminal 1 of equipment A and terminal 2 of equipment B) Connector A
Harness
Connector B
Equipment A
Equipment A
Equipment B
3
2
1
5
4
3
2
Ohmmeter (tester)
1
2
3
1
2
3
2
3
4
1
1
5
Main power source of equipment B
Ground of equipment A
Signal from Power to equipment A equipment A
Equipment B
TS-10003
Inspection procedure ① Disconnect the connectors of equipment A and equipment B. ② Connect the test probe (+) to connector terminal 1 of equipment A and the test probe (-) to connector terminal 2 of equipment B and measure the resistance. At this time, reversing the connector terminals between the probes (+) and (-) does not make any difference in the measurement. Criteria for harness defects When there is no abnormality in the harness: Less than 10 Ω (measured value) If there is any abnormality in the harness such as broken wire: 10 Ω or higher (measured value) 1-3) Measuring resistance of grounding wire (measuring resistance between terminal 5 of equipment B and ground) Connector A Harness Equipment B
5
4
3
2
1
1
Battery
5
Ohmmeter (tester)
Main power source of equipment B
Equipment B TS-10004
Inspection procedure ① Disconnect the connector of equipment B. ② Connect the test probe (+) to connector terminal 5 of equipment B and the test probe (-) to a machine ground point (the bolt fastening the ground terminal or an unpainted portion on the body) and measure the resistance. At this time, reversing the connector terminals between the probes (+) and (-) does not make any difference in the measurement. (NOTICE) • When measuring the resistance, connect the test probes to both ends of the portion to be measured. Make also sure that no voltage is applied to the portion to be measured. • When measuring the internal resistance of equipment, be sure first to disconnect all harnesses from the equipment. • When measuring the resistance of a harness, disconnect the equipment connected to both ends of the harness. 10-005
TROUBLESHOOTING 2) Measuring voltage and current flowing using tester 2-1) Measuring voltage of equipment A (measuring voltage between terminals 1 and 3)
Equipment A
Equipment A
Equipment B
1
2
Voltmeter (tester)
1
2
3
2
3
4
3 1
5
Main power source of equipment B
Ground of equipment A
Signal from equipment A
Power to equipment A
Equipment B TS-10005
Inspection procedure ① Connect the connectors of equipment A and that of equipment B. ② Connect the test probe (+) to connector terminal 3 of equipment A and the test probe (-) to connector terminal 1 of equipment A and measure the voltage. Note that reversing the connector terminals between the probes (+) and (-) changes the result of the measurement. Be sure to connect the probe (+) to the power source side and the probe (-) to the ground side.
10-006
TROUBLESHOOTING Measurement using a test harness Test harness
Equipment A
Equipment B
1
2
3
Measurement from the backside of connector
Measurement on a lead cable
Test probe Connector
Wire
Needle
Lead cable
TS-10006
Measurement method For measurement of voltage, connect the tester probes in parallel to the portion to be measured. Because the voltage can be measured only when the connector is connected in position, contact the tester probes to the terminals without disconnecting the connector. The following methods are available: • Measurement using a test harness Prepare the test harness for the measurement. • Measurement from the backside of connector Insert a wire from the backside of the connector. • Measurement on a lead cable Remove the bundling tape from the harness to separate each cable, and stick the needle into the relevant cable. (NOTICE) • Except for preparing the test harness, proper protection must be made after the measurement to prevent corrosion in the connector terminals or harnesses. 10-007
TROUBLESHOOTING 2-2) Measuring current flowing from equipment B to equipment A (measuring current between terminal 2 of equipment B and terminal 1 of equipment A)
Test harness Equipment A Equipment A
Equipment B 1
Ammeter (tester) 1
2
3
3
2
3
1
2
3
2
3
4
Harness (connecting terminals)
1
1
The test harness connects the corresponding terminals other than those to be measured.
2
5
Main power source of equipment B
Ground of Signal from Power to equipment A equipment A equipment A
Equipment B TS-10007
Inspection procedure ① Disconnect the connector of equipment A and connect the test harness. ② Connect the test probe (+) to connector terminal 1 (harness side) of equipment A and the test probe (-) to connector terminal 1 (equipment side) of equipment A and measure the current. Note that reversing the connector terminals between the probes (+) and (-) changes the result of the measurement. Be sure to connect the probe (+) to the power source side and the probe (-) to the ground side. Measurement method When measuring the current, connect the tester in series to the portion to be measured. Because the current cannot be measured when the connector is connected in position, disconnect the connector to allow the test probe to connect between the terminals.
10-008
TROUBLESHOOTING
2-1-3. Inspection of electrical system Operate the applicable switches and turn the relays ON and OFF. Ultimately, if the solenoid valve operates (makes a sound) and the pump runs, the electrical system is OK. If there is a failure (fault), narrow the range of the inspection to the six broad steps described below. 1) Ground inspection • Check for disconnected or loose ground. If rust or corrosion is present (which can cause faulty contact), remove the rust. 2) Fuse inspection 2-1) Check for blown fuses, disconnections and corrosion. (A fatigue open circuit cannot be identified visually. Use a tester for checking.) 2-2) If a fuse is blown Check whether a pump or valve (that is supposed to be protected by a blown fuse) burned, and whether there is a burning odor. Especially if the pump and valve are not burned, check the harness for signs of burning. If it is burned, replace it. If a fuse is blown and a relay along the pathway has failed, replace it. And if there is a timer, replace the timer, too. If a switch visually appears to be unsatisfactory (burned, melted, etc.) even though it operates, replace it. • Simply replacing a fuse may not eliminate the true cause of a problem, and over current may flow again. Also, if over current secondarily causes an electrical path to fail (such as a wiring meltdown inside a solenoid valve), current will not flow. Thus, a fuse may not be blown out, but it also will not operate. If you do not know the location of burning or of an odor, investigate as described follows. 2-3) How to find cause of failure when fuse blown is reproduced ① Turn the starter switch OFF, and remove the connector from the load (valve, pump). ② Referring to the circuit diagram, remove electrical parts that are connected to the circuit, such as relays, timers and diodes. ③ Turn the starter switch ON, and see whether the conditions can be reproduced (fuse is blown). ④ If a fuse is blown, a part such as a relay may have caused a short between the previous harness and ground (vehicle body). (Replace the harness.) If the conditions are not reproduced, check for signs of burning (odor) on the removed electrical parts. ⑤ If there is no problem, turn the starter switch OFF and reattach the parts. ⑥ Turn the starter switch ON and try again. ⑦ If a fuse is blown with this action, the problem was caused by a short between the harness and ground (vehicle body) that followed the attached electrical part. (Replace the harness.) ⑧ If the conditions are not reproduced, turn the starter switch OFF, and connect the loads (valve and pump) one at a time. Turn the starter switch ON and try again to see whether the fuse blown is reproduced. ⑨ If the fuse blown is reproduced, whatever was added at that time (including a harness added electrically) will be the cause of the failure. • Even if the fuse is not blown and the valve or pump is not burned, the valve or pump may be damaged electrically and may not operate. There may simply be a disconnection in the interior or an abnormal heat-up. • Even if the fuse is not blown, abnormal heat-up (hot enough to cause burns if touched) may occur if a relay, timer, diode or other semiconductor fails.
10-009
TROUBLESHOOTING 3) Connector inspection • Is a connector disconnected or loose? • Check that pins are not snapped or corroded. • If faulty contact is suspected Turn the starter switch OFF. Then disconnect and check the connectors (including relay and switch sockets). If the terminal has no luster, faulty contact due to oxidation can be suspected. Therefore, polish the terminal by inserting and removing the connector (relay, switch) repeatedly at least five times. (Luster will return.) 4) Relay inspection (Check ON/OFF operation by sound.) • Conduct without running the engine. (If you run the engine, you cannot hear the sound of operation.) Sound heard : A relay failure occurred. No sound heard : Using a tester, check the harness. Sound heard : A relay failure occurred. Still no sound : Using a tester, check the harness. Continuity : Turn the starter switch OFF temporarily, disconnect the relay and check for continuity between the harness-side grounding terminal (color: black) and vehicle body ground. (If there is none, replace the harness.) Voltage : With the relay disconnected, turn the starter switch ON and turn the operating switch ON. 24 V (or 12 V) (between vehicle body ground) should not reach the relay coil input terminal. Confirm this. Identify the location (section) to which 24 V (or 12 V) reaches. Then replace the harness or take other action. 5) Solenoid valve inspection (Check ON/OFF operation by sound.) • Conduct without running the engine. (If you run the engine, you cannot hear the sound of operation.) Sound heard : The electrical system is normal. No sound heard : Check with a tester. Continuity : ① Turn the starter switch OFF temporarily, disconnect the connector and check for continuity between the harness-side grounding terminal (color: black) and vehicle body ground. (If there is none, replace the harness.) : ② Is the solenoid valve coil burnt? (Turn the starter switch OFF, disconnect the connector and check the resistance between the solenoid valve terminals.) Voltage : With the connector disconnected, turn the starter switch ON and check whether 24 V (or 12 V) exists between the harness-side connector and vehicle body ground. If YES : Replace the valve. If NO : Investigate and identify the location (section) to which 24 V (or 12 V) reaches. Then replace the harness or take other action. 6) Harness check • If an incomplete disconnection inside the harness is suspected, wiggle (move) the harness during the relay inspection and solenoid valve inspection to see whether the relay (valve) operates incorrectly. • Check for burned areas of the harness. • Turn the starter switch OFF, disconnect the connector and check the continuity, referring to the circuit diagram and wiring coloring.
10-010
TROUBLESHOOTING
2-2. Engine Diagnosis Trouble Code 2-2-1. Description of diagnostic trouble code (DTC) • When the engine warning lamp or engine stop lamp illuminates, the DPF meter is used to display a DTC (diagnostic trouble code). 10
30
20
0
ECO
60
0
MODE
(SEC)
PUMP 1
SPRAY PAUSE
AUTO
TIMER
SIDE MARKER LIGHT
CONT PUMP 2
TIMER
AUTO
OFF
WATER SPRAY MODE
ENGINE WARNING lamp
ENGINE WARNING
ENGINE STOP
OVER HEAT
ENGINE STOP lamp
DPF meter SW654-10001
1) DTC display procedure using the DPF meter • A current or past DTC stored in the engine control unit (ECU) is displayed on the DPF meter by switching its display as described in the diagram below. Button operation : Left button : Right button Left button
Right button
: Center button
Center button
: Center button press and hold
DTC not stored
DTC stored
Active DM1 : Current DTC Stored DM2 : Past DTC
*Pressing and holding the center button returns any display back to the DPF meter.
DPF-10010
10-011
TROUBLESHOOTING
2-2-2. Table of the diagnostic trouble code (DTC) J1939-73 SPN
FMI 3
29 4 2 91
3 4
100
1
Description
• Short circuit in sensor/harness power supply
Accelerator sensor-2 Low
• Open circuit in sensor/harness, ground fault
Accelerator pedal sensor property abnormal
• Sensor output of two systems excessively different
Accelerator sensor-1 High
• Short circuit in sensor/harness power supply
Accelerator sensor-1 Low
• Open circuit in sensor/harness, ground fault
Engine oil pressure decrease
• Engine oil pressure switch activated
Boost pressure sensor High
• Open circuit in sensor/harness, +B short-circuited • Sensor failure
Boost pressure sensor Low
• Short circuit in sensor/harness ground • Sensor failure
Atmospheric pressure sensor High
• Short circuit in sensor/ECU internal circuit +B
Atmospheric pressure sensor Low
• Short circuit in sensor/ECU internal circuit ground
Engine overheat
• Engine water temperature abnormally high
Water temperature sensor High
• Open circuit in sensor/harness, +B short-circuited
Water temperature sensor Low
• Short circuit in sensor/harness ground
Intake air shortage (Turbo Intake air shortage (Turbo blower IN hose disconnected) blower IN hose disconnected)
• Intake air shortage (Turbo blower IN hose disconnected)
Accelerator pedal or lever position sensor-2 abnormal Accelerator pedal or lever position sensor property abnormal Accelerator pedal or lever position sensor-1 abnormal Oil pressure decrease
Boost pressure sensor abnormal
102 4 3 108 4 0 3 4 1 3 132
4
15
0
157
Atmospheric pressure sensor abnormal Overheat Water temperature sensor abnormal
Mass air flow (MAF) sensor abnormal Turbo boost increase insufficient (Blow out: Hose between intake flanges disconnected) Rail pressure abnormally high
3
Mass air flow (MAF) sensor High • Short circuit in sensor/harness +B Mass air flow (MAF) sensor Low
• Open circuit in sensor/harness, ground fault
Turbo boost increase insufficient (Blow out: Hose between intake flanges disconnected)
• Turbo blow out: Hose between intake flanges disconnected (abnormal)
Rail pressure abnormally high
• Actual pressure exceeds command pressure. (When detected high pressure exceeding specified pressure range)
Rail pressure sensor High
• Open circuit in sensor/harness, +B short-circuited • Sensor failure
Rail pressure sensor Low
• Short circuit in sensor/harness ground • Sensor failure
Rail pressure sensor abnormal 4
10-012
Diagnosis
Accelerator sensor-2 High
3
110
DTC Description
TROUBLESHOOTING J1939-73 SPN
Description
FMI
• Open circuit, short circuit, or breakage in harness • Battery abnormal
4
Battery voltage Low
• Open circuit, short circuit, or breakage in harness • Battery abnormal
3
Intake air temperature sensor (with built-in mass air flow sensor) High
• Open circuit in sensor/harness, +B short-circuited
168
Battery voltage abnormal
171 4
0 3 4 0 174
Diagnosis
Battery voltage High
3
172
DTC Description
3 4
Intake air temperature sensor (with built-in mass air Intake air temperature sensor flow sensor) abnormal (with built-in mass air flow sensor) Low Intake air temperature abnormally high (Intercooler model only)
• Short circuit in sensor/harness ground
Intake air temperature abnormally high
• Intake air temperature abnormally high
Intake air temperature sensor High
• Open circuit in sensor/harness, +B short-circuited
Intake air temperature sensor Low
• Short circuit in sensor/harness ground
Fuel temperature abnormally Fuel temperature abnormally high high
• Fuel temperature abnormally high
Intake air temperature sensor abnormal
Fuel temperature sensor abnormal
Fuel temperature sensor High
• Open circuit in sensor/harness, +B short-circuited
Fuel temperature sensor Low
• Short circuit in sensor/harness ground
190
0
Overrun
Engine overrun
• Engine speed exceeds specified speed
628
2
ECU flash ROM and CPU abnormal
ECU flash ROM abnormal
• Monitoring of unauthorized alteration of internal flash ROM
633
7
Pressure limiter valve opening abnormal
Pressure limiter valve opening abnormal
• Pressure limiter valve opening abnormal
2
Crankshaft position sensor (NE sensor) abnormal
NE sensor pulse count abnormal
• Open circuit in sensor/harness, short-circuited • Sensor failure
7
NE-G phase shift
NE-G phase shift failure
• Phase shift between NE pulse and G pulse excessive
8
Crankshaft position sensor (NE sensor) abnormal
NE sensor pulse not inputted
• Open circuit in sensor/harness, short-circuited • Sensor failure
636
651
3
Injector of 1st engine cylinder (TWV1): Open circuit in harness/coil
652
3
Injector of 2nd engine cylinder (TWV4): Open circuit in harness/coil
Open circuit in TWV driving system 653
3
Injector of 3rd engine cylinder (TWV2): Open circuit in harness/coil
654
3
Injector of 4th engine cylinder (TWV3): Open circuit in harness/coil
• Open circuit in harness • Open circuit in injector coi
10-013
TROUBLESHOOTING J1939-73 SPN 723 1077
1239
FMI 2 8 2
1
3 4
Description
DTC Description
Camshaft position sensor (G sensor) abnormal
G sensor pulse count abnormal • Open circuit in sensor/harness, short-circuited G sensor pulse not inputted • Sensor failure
ECU flash ROM and CPU abnormal
ECU CPU abnormal (main IC abnormal)
• CPU failure
Fuel leakage (high pressure fuel system)
• Fuel leakage from high pressure fuel system (when detected excessive fuel consumption, calculating from difference of fuel rail pressure before and after fuel injection)
SCV +B short-circuit
• Short circuit in SCV +B
SCV driving system abnormal
• Open circuit in SCV, ground fault
Fuel leakage (high pressure fuel system)
SCV abnormal
7
SCV sticking
SCV sticking diagnosis
• SCV sticks while open (when detected condition that actual rail pressure constantly exceeds command rail pressure)
2
Main relay abnormal
Main relay abnormal
• Main relay failure
0
Exhaust temperature rise abnormal T1
Exhaust temperature rise abnormal T1
• DPF inlet temperature (T1) abnormally high
Exhaust temperature sensor 1 (T1: DOC outlet) High
• Open circuit in sensor/harness, +B short-circuited
Exhaust temperature sensor 1 (T1: DOC outlet) Low
• Short circuit in sensor/harness ground
Exhaust temperature rise abnormal T2
• DPF outlet temperature (T2) abnormally high
Exhaust temperature sensor 2 (T2: DPF outlet) High
• Open circuit in sensor/harness, +B short-circuited
Exhaust temperature sensor 2 (T2: DPF outlet) Low
• Short circuit in sensor/harness ground
Differential pressure sensor abnormal High
• Open circuit in sensor/harness, +B short-circuited
Differential pressure sensor abnormal Low
• Short circuit in sensor/harness ground
DOC reaction abnormal (exhaust gas abnormal)
• DOC temperature abnormally high due to unburned gas
Sensor supply voltage 1 High
• Sensor supply voltage 1 abnormal or recognition abnormal
1347
1485
3242
3 4 0
3246
3 4 3
3251 4 3252 3509
3510
3701
10-014
Diagnosis
0 3 4 3 4
Exhaust temperature sensor 1 (T1: DOC outlet) abnormal Exhaust temperature rise abnormal T2 Exhaust temperature sensor 2 (T2: DPF outlet) abnormal Differential pressure sensor abnormal DOC reaction abnormal (exhaust gas abnormal) Sensor voltage 1 abnormal Sensor supply voltage 2 abnormal
Sensor supply voltage 1 Low Sensor supply voltage 2 High Sensor supply voltage 2 Low
• Sensor supply voltage 2 abnormal or recognition abnormal
0
PM accumulation abnormal level 5
PM accumulation abnormal level 5
• PM (estimated) accumulation quantity excessive level 5
15
PM accumulation abnormal level 3
PM accumulation abnormal level 3
• PM (estimated) accumulation quantity excessive level 3
16
PM accumulation abnormal level 4
PM accumulation abnormal level 4
• PM (estimated) accumulation quantity excessive level 4
TROUBLESHOOTING J1939-73 SPN
FMI 0
4765
3 4
2
523523
Description Exhaust temperature rise abnormal T0 Exhaust temperature sensor 0 (T0 : DOC inlet) abnormal Open circuit in common 1 system
3 Short circuit in common 1 TWV driving system 4
2
523524
Open circuit in common 2 system
3 Short circuit in common 2 TWV driving system 4
DTC Description
Diagnosis
Exhaust temperature rise abnormal T0
• DOC inlet temperature (T0) abnormally high
Exhaust temperature sensor 0 (T0 : DOC inlet) High
• Open circuit in sensor/harness, +B short-circuited
Exhaust temperature sensor 0 (T0 : DOC inlet) Low
• Short circuit in sensor/harness ground
Open circuit in injector driving circuit: Common 1 system, or TWV 1 and 3 (1st and 4th cylinders) simultaneously
• Open circuit in harness
Short circuit in battery: Injector driving circuit at ECU side (Common 1 system), or 1st and 4th cylinders at INJ side simultaneously
• Short circuit in harness +B
Short circuit in GND: Injector driving circuit at ECU side (Common 1 system), or 1st and 4th cylinders at INJ side simultaneously
• Short circuit in harness ground
Open circuit in injector driving circuit: Common 2 system, or TWV 2 and 4 (3rd and 2nd cylinders) simultaneously
• Open circuit in harness
Short circuit in battery: Injector driving circuit at ECU side (Common 2 system), or 2nd and 3rd cylinders at INJ side simultaneously
• Short circuit in harness +B
Short circuit in GND: Injector driving circuit at ECU side (Common 2 system), or 2nd and 3rd cylinders at INJ side simultaneously
• Short circuit in harness ground
523525
1
Injector charge voltage abnormal
ECU injector charge voltage insufficient
• Injector charge voltage insufficient • ECU charge circuit failure
523527
2
ECU flash ROM and CPU abnormal
ECU CPU abnormal (watching IC abnormal)
• CPU-watching IC failure
523535
0
Overcharge
ECU injector charge voltage excessively high
• ECU injector charge voltage excessively high (ECU charge circuit failure)
QR data abnormal
• QR code correction data abnormal
QR data writing abnormal
• QR code correction data unwritten
Pump seizure 1
• Pressure abnormally high 1
Pump seizure 2
• Pressure abnormally high 2
Accelerator sensor at machine body abnormal
• Abnormal message from machine body received
2 523538
QR abnormal 7
523539
2
523540
2
523543
2
Pump seizure Accelerator pedal or lever position sensor abnormal (via CAN)
10-015
TROUBLESHOOTING J1939-73 SPN
FMI 3
523544 4
Description Air heater relay drive abnormal
DTC Description
Diagnosis
Short circuit in air heater relay driving circuit +B
• Short circuit in air heater relay driving circuit +B
Short circuit in air heater relay driving circuit GND
• Open circuit in air heater relay driving circuit, ground fault
523547
2
CAN2 bus off
CAN2 bus off
• Short circuit in CAN2 +B/GND or traffic abnormally high
523548
2
Open circuit in CAN2 frame
Open circuit in CAN_KBT original frame
• Open circuit in CAN_KBT original frame
523572
4 EGR motor abnormal
Open circuit in EGR motor
• Open circuit in EGR motor coil
4
Short circuit in EGR motor
• Short circuit in EGR motor coil
523575
7
EGR valve sticking (FB abnormal)
• EGR valve sticking
523576
2
EGR motor ambient temperature abnormal
• EGR motor temperature abnormally high
523577
2
EGR thermistor sensor with built-in valve abnormal
• EGR motor temperature sensor abnormal
523578
2
Open circuit in CAN_ EGR control line
Disconnection (open circuit) in EGR control line communication
• CAN communication with EGR
523580
2
Intake throttle FB (feed back) abnormal
Intake throttle FB (feed back) abnormal
• Intake throttle DC motor feed back abnormal
Intake throttle lift sensor abnormal (High)
• Intake throttle lift sensor High
Intake throttle lift sensor abnormal (Low)
• Intake throttle lift sensor Low
17
Water temperature rise during manual regeneration insufficient
Water temperature rise during manual regeneration insufficient
• While regenerating, conditions required for warming up the engine not established (Insufficient water temperature rise)
523590
16
Manual regeneration process time-up abnormal
Manual regeneration process time-up abnormal
• Regeneration process not end due to insufficient DPF temperature rise (Regeneration time)
523591
2
CAN_CCVS communication disruption
• CAN_CCVS communication disruption
523592
2
CAN_CM1 communication disruption
• CAN_CM1 communication disruption
523593
2
CAN_DDC1 communication disruption
• CAN_DDC1 communication disruption
523594
2
CAN_ETC2 communication disruption
• CAN_ETC2 communication disruption
523595
2
CAN_ETC5 communication disruption
• CAN_ETC5 communication disruption
523596
2
CAN_TSC1 communication disruption
• CAN_TSC1 communication disruption
523598
2
CAN_EBC1 communication disruption
• CAN_EBC1 communication disruption
523574
3
EGR position sensor abnormal • EGR position sensor abnormal
3 523582 4
523589
10-016
EGR (DC motor) abnormal
Intake throttle lift sensor abnormal
Open circuit in CAN2 frame
TROUBLESHOOTING J1939-73
Description
DTC Description
Diagnosis
SPN
FMI
523599
0
Simultaneous open circuit in all exhaust temperature sensors
Simultaneous open circuit in all • Simultaneous open circuit in all exhaust temperature sensors exhaust temperature sensors
523600
0
Warning on incomplete learning of individual difference of pumps
Warning on incomplete learning of individual difference of • Pump learning history pumps
523601
0
Exhaust temperature continuously abnormal (Starter relay drive prohibit warning)
Exhaust temperature • Exhaust temperature when continuously abnormal (Starter abnormally high temperature relay drive prohibit warning) generated
523602
0
Regeneration frequency abnormally high
Regeneration frequency abnormally high
• Abnormal interval between end of regeneration process and trigger for next regeneration
523603
15
Warning on High. Temp_AECD operation
Warning on High.Temp_AECD operation
• High Temperature AECD_EGR valve limiting state warning
523604
2
CAN1 bus off
CAN1 bus off
• Short circuit in CAN1 +B/GND or traffic abnormally high
523700
13
KBT area EEPROM checksum not coincident
• KBT area EEPROM checksum not coincident
523701
13
523702
13
EEPROM checksum not coincident
DST1 area EEPROM checksum • DST1 area EEPROM checksum not coincident not coincident DST2 area EEPROM checksum • DST2 area EEPROM checksum not coincident not coincident
10-017
TROUBLESHOOTING
Fig.: 2-3-1
1
TO COMBINATION METER
L12 LB 4
TO PARKING BRAKE SOLENOID, SERVO BYPASS SOLENOID
L13 GrB
3
L11 O
V75 BrR
2 6
IG-SW V13/V33 +BF V01/V21 MAIN V03/V23
R
L10 GY
W
5
TO STOP LAMP
VIBRATION AUTO SWITCH
V013WB
V03 LgY
V03LgY
G10 YG
R
G09 Br
W
P18 RL
B
TO VIBRATION MODE CHANGE SWITCH, WATER SPRAY CHANGE RELAY
V01 WB V01 WB
P16 WB
B
N B
PARKING BRAKE SWITCH +BP V18/V58/V38/V78
FOOT BRAKE SWITCH
L11 O
R G10 YG CAN2-L V17
B
G11 BW
W
F-R LEVER SWITCH
CAN2-H V37
CAN1-L V16 CAN1-H V36 A-VCC11(+5V) V51 APS1(SIG) V47 A-GND12 V46 A-VCC10 V50 APS2(SIG) V67 A-GND13 V66
POTENTIOMETER
V51 0.5R
+V1
V47 0.5W
+V2
V67 0.5W
GND2
TACHMETER PULSE V34
N B
SPEED SENSOR V14
ECU PARKING SW. V75 N-SW. V30
N B
2
PARKING INTERLOCK RELAY
OUT2
V66 0.5B
K06 RG
5
V75 BrR
GND1
V50 0.5R
4 3 1
G11 BW
OUT1
V46 0.5B
V75 BrR
V01 3WB 4 5
3
2
1
S22 3R
V03 LgY
V75 BrR
V30 LB
S22 R
ECU MAIN RELAY
DPF SW. V56 OIL PRE.LAMP V06 HEATER LAMP V07 V01 WB
DPF REQUEST LAMP V28 DPF ACTIVE LAMP V26 OVERHEAT LAMP V27
V30 LB
STOP LAMP V08
G11 BW
WARNING LAMP V09 STOP-SW. V32
4
N B
3
5
N B
1
2
N B
P
FUEL PUMP
NEUTRAL RELAY
DPF INHIBIT SW. V74
ECU
V01 3WB S22 3R K06 RG P18 RL
P16 WB
P18 RL
FUSE BOX (1)
TO COMBINATION METER
P09 5WR
P25 3BY
P09 5WR
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
V12 YG
P10 3BR
S22 3R P04 5W
V01 3WB
FUSE BOX (2)
K05 GY
N/A 24 N/A 23 N/A 22 N/A 21 5A 20 5A 19 20A 18 5A 17 5A 16 15A 15 5A 14 20A 13
K06 RG
P16 WB
K03 WY P11 LgR P24 15B
L R E
B
ALTERNATOR K02 3BW
ACC
BR
C ST-SW V12
OFF
STARTER V05
HT
HEATER RLY V24
STARTER SWITCH
P04 5W
V12 YG V05 YB V24 BR
ACC B R
COM
BR
E
BATTERY RELAY
ECU
STARTER SWITCH B
NO P11 LgR
P11 LgR
C
N B
OFF ON
P02 5R
ST
V24 BR
K01 5BY B
G
g
e
N
P02 5R
AV60 B(HEB 60)
R2
P01 5BR
R1
E
STARTER MOTOR
65A
B
ON
B (30) AV60 B(HEB 60)
P04 5W
P11 LgR
P10 3BR
STARTER RELAY
ST
S1(50)
65A
V05 YB
P03 5W
E
P09 5WR
S
65A
C
P08 5WR
P25 3BY K05 GY B
B AV60 B(HEB 60)
GLOW RELAY GLOW HEATER
+ 12V 115D31R BATTERY
SW654-10002
10-018
TROUBLESHOOTING
2-3. Engine Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. • Check any ground circuit which belongs to components to be checked. • Engine warning lamp or engine stop lamp must not be lighting. If engine warning lamp or engine stop lamp lights, refer to troubleshooting of engine manufacturer.
2-3-1. Engine will not start (Starter motor does not run) 1/3 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be OFF (Brake pedal is not depressed). Reference Fig.: 2-3-1 Check point
Check/Cause
Action
1. Battery
• Measure battery voltage or specific gravity. Standard voltage : 12 V or more Standard gravity : 1.26 or more • If value is below standard, battery capacity is insufficient.
Charge or replace battery.
2. Starter Switch
• Check continuity between O-O according to starter switch Replace starter switch. connection table. Switch is OK if there is continuity between connection O-O. • If there is no continuity, starter switch is faulty.
3. Starter Motor
(1) W hen starter switch is ON, measure voltage between starter motor terminal B and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is START, measure voltage between starter motor terminal S1 and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and starter motor does not run, starter motor is faulty.
Replace starter motor.
4. Starter Relay
(1) W hen starter switch is ON, measure voltage between starter relay terminal S inlet wire GY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is START, measure voltage between starter relay terminal B inlet wire BY and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is START, measure voltage between starter relay terminal C outlet wire BW and chassis ground Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, starter relay is faulty.
Replace starter relay.
10-019
TROUBLESHOOTING
Fig.: 2-3-1
1
TO COMBINATION METER
L12 LB 4
TO PARKING BRAKE SOLENOID, SERVO BYPASS SOLENOID
L13 GrB
3
L11 O
V75 BrR
2 6
IG-SW V13/V33 +BF V01/V21 MAIN V03/V23
R
L10 GY
W
5
TO STOP LAMP
VIBRATION AUTO SWITCH
V013WB
V03 LgY
V03LgY
G10 YG
R
G09 Br
W
P18 RL
B
TO VIBRATION MODE CHANGE SWITCH, WATER SPRAY CHANGE RELAY
V01 WB V01 WB
P16 WB
B
N B
PARKING BRAKE SWITCH +BP V18/V58/V38/V78
FOOT BRAKE SWITCH
L11 O
R G10 YG CAN2-L V17
B
G11 BW
W
F-R LEVER SWITCH
CAN2-H V37
CAN1-L V16 CAN1-H V36 A-VCC11(+5V) V51 APS1(SIG) V47 A-GND12 V46 A-VCC10 V50 APS2(SIG) V67 A-GND13 V66
POTENTIOMETER
V51 0.5R
+V1
V47 0.5W
+V2
V67 0.5W
GND2
TACHMETER PULSE V34
N B
SPEED SENSOR V14
ECU PARKING SW. V75 N-SW. V30
N B
2
PARKING INTERLOCK RELAY
OUT2
V66 0.5B
K06 RG
5
V75 BrR
GND1
V50 0.5R
4 3 1
G11 BW
OUT1
V46 0.5B
V75 BrR
V01 3WB 4 5
3
2
1
S22 3R
V03 LgY
V75 BrR
V30 LB
S22 R
ECU MAIN RELAY
DPF SW. V56 OIL PRE.LAMP V06 HEATER LAMP V07 V01 WB
DPF REQUEST LAMP V28 DPF ACTIVE LAMP V26 OVERHEAT LAMP V27
V30 LB
STOP LAMP V08
G11 BW
WARNING LAMP V09 STOP-SW. V32
4
N B
3
5
N B
1
2
N B
P
FUEL PUMP
NEUTRAL RELAY
DPF INHIBIT SW. V74
ECU
V01 3WB S22 3R K06 RG P18 RL
P16 WB
P18 RL
FUSE BOX (1)
TO COMBINATION METER
P09 5WR
P25 3BY
P09 5WR
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
V12 YG
P10 3BR
S22 3R P04 5W
V01 3WB
FUSE BOX (2)
K05 GY
N/A 24 N/A 23 N/A 22 N/A 21 5A 20 5A 19 20A 18 5A 17 5A 16 15A 15 5A 14 20A 13
K06 RG
P16 WB
K03 WY P11 LgR P24 15B
L R E
B
ALTERNATOR K02 3BW
ACC
BR
C ST-SW V12
OFF
STARTER V05
HT
HEATER RLY V24
STARTER SWITCH
P04 5W
V12 YG V05 YB V24 BR
ACC B R
COM
BR
E
BATTERY RELAY
ECU
STARTER SWITCH B
NO P11 LgR
P11 LgR
C
N B
OFF ON
P02 5R
ST
V24 BR
K01 5BY B
G
g
e
N
P02 5R
AV60 B(HEB 60)
R2
P01 5BR
R1
E
STARTER MOTOR
65A
B
ON
B (30) AV60 B(HEB 60)
P04 5W
P11 LgR
P10 3BR
STARTER RELAY
ST
S1(50)
65A
V05 YB
P03 5W
E
P09 5WR
S
65A
C
P08 5WR
P25 3BY K05 GY B
B AV60 B(HEB 60)
GLOW RELAY GLOW HEATER
+ 12V 115D31R BATTERY
SW654-10002
10-020
TROUBLESHOOTING
2-3-1. Engine will not start (Starter motor does not run) 2/3 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be OFF (Brake pedal is not depressed). Reference Fig.: 2-3-1 Check point 5. Battery Relay
Check/Cause
Action
(1) W hen starter switch is OFF, measure voltage between Replace battery relay. battery relay primary terminal COM and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between battery relay coil terminal BR inlet wire LgR and coil ground terminal E. Standard voltage : 12 V or more (3) W hen starter switch is ON, measure voltage between battery relay secondary terminal NO and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, battery relay is faulty.
6. Vibration AUTO Switch (1) W hen starter switch is ON, measure voltage between Replace vibration AUTO vibration AUTO switch terminal inlet wire RL and switch. chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between vibration AUTO switch terminal outlet wire YG and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, vibration AUTO switch is faulty. 7. F-R Lever Switch
(1) W hen starter switch is ON, measure voltage between F-R lever switch terminal inlet wire YG and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between F-R lever switch terminal outlet wire BW and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, F-R lever switch is faulty.
8. Parking Interlock Relay (1) W hen starter switch is ON, measure voltage between parking interlock relay terminal 1 inlet wire BrR and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between parking interlock relay terminal 3 inlet wire BW and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON, measure voltage between parking interlock relay terminal 5 outlet wire RG and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, parking interlock relay is faulty.
Replace F-R lever switch.
Replace parking interlock relay.
10-021
TROUBLESHOOTING
Fig.: 2-3-1
1
TO COMBINATION METER
L12 LB 4
TO PARKING BRAKE SOLENOID, SERVO BYPASS SOLENOID
L13 GrB
3
L11 O
V75 BrR
2 6
IG-SW V13/V33 +BF V01/V21 MAIN V03/V23
R
L10 GY
W
5
TO STOP LAMP
VIBRATION AUTO SWITCH
V013WB
V03 LgY
V03LgY
G10 YG
R
G09 Br
W
P18 RL
B
TO VIBRATION MODE CHANGE SWITCH, WATER SPRAY CHANGE RELAY
V01 WB V01 WB
P16 WB
B
N B
PARKING BRAKE SWITCH +BP V18/V58/V38/V78
FOOT BRAKE SWITCH
L11 O
R G10 YG CAN2-L V17
B
G11 BW
W
F-R LEVER SWITCH
CAN2-H V37
CAN1-L V16 CAN1-H V36 A-VCC11(+5V) V51 APS1(SIG) V47 A-GND12 V46 A-VCC10 V50 APS2(SIG) V67 A-GND13 V66
POTENTIOMETER
V51 0.5R
+V1
V47 0.5W
+V2
V67 0.5W
GND2
TACHMETER PULSE V34
N B
SPEED SENSOR V14
ECU PARKING SW. V75 N-SW. V30
N B
2
PARKING INTERLOCK RELAY
OUT2
V66 0.5B
K06 RG
5
V75 BrR
GND1
V50 0.5R
4 3 1
G11 BW
OUT1
V46 0.5B
V75 BrR
V01 3WB 4 5
3
2
1
S22 3R
V03 LgY
V75 BrR
V30 LB
S22 R
ECU MAIN RELAY
DPF SW. V56 OIL PRE.LAMP V06 HEATER LAMP V07 V01 WB
DPF REQUEST LAMP V28 DPF ACTIVE LAMP V26 OVERHEAT LAMP V27
V30 LB
STOP LAMP V08
G11 BW
WARNING LAMP V09 STOP-SW. V32
4
N B
3
5
N B
1
2
N B
P
FUEL PUMP
NEUTRAL RELAY
DPF INHIBIT SW. V74
ECU
V01 3WB S22 3R K06 RG P18 RL
P16 WB
P18 RL
FUSE BOX (1)
TO COMBINATION METER
P09 5WR
P25 3BY
P09 5WR
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
V12 YG
P10 3BR
S22 3R P04 5W
V01 3WB
FUSE BOX (2)
K05 GY
N/A 24 N/A 23 N/A 22 N/A 21 5A 20 5A 19 20A 18 5A 17 5A 16 15A 15 5A 14 20A 13
K06 RG
P16 WB
K03 WY P11 LgR P24 15B
L R E
B
ALTERNATOR K02 3BW
ACC
BR
C ST-SW V12
OFF
STARTER V05
HT
HEATER RLY V24
STARTER SWITCH
P04 5W
V12 YG V05 YB V24 BR
ACC B R
COM
BR
E
BATTERY RELAY
ECU
STARTER SWITCH B
NO P11 LgR
P11 LgR
C
N B
OFF ON
P02 5R
ST
V24 BR
K01 5BY B
G
g
e
N
P02 5R
AV60 B(HEB 60)
R2
P01 5BR
R1
E
STARTER MOTOR
65A
B
ON
B (30) AV60 B(HEB 60)
P04 5W
P11 LgR
P10 3BR
STARTER RELAY
ST
S1(50)
65A
V05 YB
P03 5W
E
P09 5WR
S
65A
C
P08 5WR
P25 3BY K05 GY B
B AV60 B(HEB 60)
GLOW RELAY GLOW HEATER
+ 12V 115D31R BATTERY
SW654-10002
10-022
TROUBLESHOOTING
2-3-1. Engine will not start (Starter motor does not run) 3/3 • F-R lever must be in “N”. • Parking brake switch must be applied. • Foot brake switch must be OFF (Brake pedal is not depressed). Reference Fig.: 2-3-1 Check point
Check/Cause
Action
9. Neutral Relay
(1) W hen starter switch is ON, measure voltage between neutral relay terminal 1 inlet wire BW and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, check continuity between neutral relay terminal 5 outlet wire B and chassis ground. There is continuity in normal condition. (3) W hen starter switch is ON, check continuity between neutral relay terminal 3 inlet wire LB and chassis ground. There is continuity in normal condition. • If above items (1) and (2) are OK and item (3) is NG, neutral relay is faulty.
Replace neutral relay.
10. Parking Brake Switch
(1) W hen starter switch is ON, measure voltage between Replace parking brake parking brake switch terminal 1 inlet wire O and chassis switch. ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between parking brake switch terminal 2 outlet wire BrR 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.
11. Foot Brake Switch
(1) W hen starter switch is ON, measure voltage between foot brake switch terminal inlet wire WB and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between foot brake switch terminal outlet wire O and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, foot brake switch is faulty.
Replace foot brake switch.
12. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-023
TROUBLESHOOTING
Fig.: 2-3-1
1
TO COMBINATION METER
L12 LB 4
TO PARKING BRAKE SOLENOID, SERVO BYPASS SOLENOID
L13 GrB
3
L11 O
V75 BrR
2 6
IG-SW V13/V33 +BF V01/V21 MAIN V03/V23
R
L10 GY
W
5
TO STOP LAMP
VIBRATION AUTO SWITCH
V013WB
V03 LgY
V03LgY
G10 YG
R
G09 Br
W
P18 RL
B
TO VIBRATION MODE CHANGE SWITCH, WATER SPRAY CHANGE RELAY
V01 WB V01 WB
P16 WB
B
N B
PARKING BRAKE SWITCH +BP V18/V58/V38/V78
FOOT BRAKE SWITCH
L11 O
R G10 YG CAN2-L V17
B
G11 BW
W
F-R LEVER SWITCH
CAN2-H V37
CAN1-L V16 CAN1-H V36 A-VCC11(+5V) V51 APS1(SIG) V47 A-GND12 V46 A-VCC10 V50 APS2(SIG) V67 A-GND13 V66
POTENTIOMETER
V51 0.5R
+V1
V47 0.5W
+V2
V67 0.5W
GND2
TACHMETER PULSE V34
N B
SPEED SENSOR V14
ECU PARKING SW. V75 N-SW. V30
N B
2
PARKING INTERLOCK RELAY
OUT2
V66 0.5B
K06 RG
5
V75 BrR
GND1
V50 0.5R
4 3 1
G11 BW
OUT1
V46 0.5B
V75 BrR
V01 3WB 4 5
3
2
1
S22 3R
V03 LgY
V75 BrR
V30 LB
S22 R
ECU MAIN RELAY
DPF SW. V56 OIL PRE.LAMP V06 HEATER LAMP V07 V01 WB
DPF REQUEST LAMP V28 DPF ACTIVE LAMP V26 OVERHEAT LAMP V27
V30 LB
STOP LAMP V08
G11 BW
WARNING LAMP V09 STOP-SW. V32
4
N B
3
5
N B
1
2
N B
P
FUEL PUMP
NEUTRAL RELAY
DPF INHIBIT SW. V74
ECU
V01 3WB S22 3R K06 RG P18 RL
P16 WB
P18 RL
FUSE BOX (1)
TO COMBINATION METER
P09 5WR
P25 3BY
P09 5WR
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
V12 YG
P10 3BR
S22 3R P04 5W
V01 3WB
FUSE BOX (2)
K05 GY
N/A 24 N/A 23 N/A 22 N/A 21 5A 20 5A 19 20A 18 5A 17 5A 16 15A 15 5A 14 20A 13
K06 RG
P16 WB
K03 WY P11 LgR P24 15B
L R E
B
ALTERNATOR K02 3BW
ACC
BR
C ST-SW V12
OFF
STARTER V05
HT
HEATER RLY V24
STARTER SWITCH
P04 5W
V12 YG V05 YB V24 BR
ACC B R
COM
BR
E
BATTERY RELAY
ECU
STARTER SWITCH B
NO P11 LgR
P11 LgR
C
N B
OFF ON
P02 5R
ST
V24 BR
K01 5BY B
G
g
e
N
P02 5R
AV60 B(HEB 60)
R2
P01 5BR
R1
E
STARTER MOTOR
65A
B
ON
B (30) AV60 B(HEB 60)
P04 5W
P11 LgR
P10 3BR
STARTER RELAY
ST
S1(50)
65A
V05 YB
P03 5W
E
P09 5WR
S
65A
C
P08 5WR
P25 3BY K05 GY B
B AV60 B(HEB 60)
GLOW RELAY GLOW HEATER
+ 12V 115D31R BATTERY
SW654-10002
10-024
TROUBLESHOOTING
2-3-2. Engine will not start (But starter motor runs) • In case of engine will not start while starter motor runs, generally trouble is caused by that fuel is not supplied, supply amount of fuel is extremely low, or selection of fuel is not appropriate. • Check that fuel is supplied to inlet of fuel pump. Reference Fig.: 2-3-1 Check point
Check/Cause
Action
1. Fuel Pump
• When starter switch is ON, measure voltage between fuel Repair or replace fuel pump terminal inlet wire WB and chassis ground. pump. Standard voltage : 12 V or more • If above item is OK and fuel pump does not operate, fuel pump is faulty.
2. ECU Main Relay
Replace ECU main relay. (1) M easure voltage between ECU main relay terminal 1 inlet wire R and chassis ground. Standard voltage : 12 V or more (2) M easure voltage between ECU main relay terminal 3 inlet wire R and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON, measure voltage between ECU main relay terminal 5 outlet wire WB and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, ECU main relay is faulty.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2-3-3. No charging Reference Fig.: 2-3-1 Check point 1. Alternator
Check/Cause
Action
• After starting engine, measure voltage between alternator Replace alternator or terminal B wire B and chassis ground. battery. Standard voltage : At least intermediate engine speed, 14 V or more • If voltage is lower than standard, alternator is faulty. • If voltage is normal and battery is not charged, battery is faulty.
10-025
TROUBLESHOOTING
Fig.: 2-3-1
1
TO COMBINATION METER
L12 LB 4
TO PARKING BRAKE SOLENOID, SERVO BYPASS SOLENOID
L13 GrB
3
L11 O
V75 BrR
2 6
IG-SW V13/V33 +BF V01/V21 MAIN V03/V23
R
L10 GY
W
5
TO STOP LAMP
VIBRATION AUTO SWITCH
V013WB
V03 LgY
V03LgY
G10 YG
R
G09 Br
W
P18 RL
B
TO VIBRATION MODE CHANGE SWITCH, WATER SPRAY CHANGE RELAY
V01 WB V01 WB
P16 WB
B
N B
PARKING BRAKE SWITCH +BP V18/V58/V38/V78
FOOT BRAKE SWITCH
L11 O
R G10 YG CAN2-L V17
B
G11 BW
W
F-R LEVER SWITCH
CAN2-H V37
CAN1-L V16 CAN1-H V36 A-VCC11(+5V) V51 APS1(SIG) V47 A-GND12 V46 A-VCC10 V50 APS2(SIG) V67 A-GND13 V66
POTENTIOMETER
V51 0.5R
+V1
V47 0.5W
+V2
V67 0.5W
GND2
TACHMETER PULSE V34
N B
SPEED SENSOR V14
ECU PARKING SW. V75 N-SW. V30
N B
2
PARKING INTERLOCK RELAY
OUT2
V66 0.5B
K06 RG
5
V75 BrR
GND1
V50 0.5R
4 3 1
G11 BW
OUT1
V46 0.5B
V75 BrR
V01 3WB 4 5
3
2
1
S22 3R
V03 LgY
V75 BrR
V30 LB
S22 R
ECU MAIN RELAY
DPF SW. V56 OIL PRE.LAMP V06 HEATER LAMP V07 V01 WB
DPF REQUEST LAMP V28 DPF ACTIVE LAMP V26 OVERHEAT LAMP V27
V30 LB
STOP LAMP V08
G11 BW
WARNING LAMP V09 STOP-SW. V32
4
N B
3
5
N B
1
2
N B
P
FUEL PUMP
NEUTRAL RELAY
DPF INHIBIT SW. V74
ECU
V01 3WB S22 3R K06 RG P18 RL
P16 WB
P18 RL
FUSE BOX (1)
TO COMBINATION METER
P09 5WR
P25 3BY
P09 5WR
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
V12 YG
P10 3BR
S22 3R P04 5W
V01 3WB
FUSE BOX (2)
K05 GY
N/A 24 N/A 23 N/A 22 N/A 21 5A 20 5A 19 20A 18 5A 17 5A 16 15A 15 5A 14 20A 13
K06 RG
P16 WB
K03 WY P11 LgR P24 15B
L R E
B
ALTERNATOR K02 3BW
ACC
BR
C ST-SW V12
OFF
STARTER V05
HT
HEATER RLY V24
STARTER SWITCH
P04 5W
V12 YG V05 YB V24 BR
ACC B R
COM
BR
E
BATTERY RELAY
ECU
STARTER SWITCH B
NO P11 LgR
P11 LgR
C
N B
OFF ON
P02 5R
ST
V24 BR
K01 5BY B
G
g
e
N
P02 5R
AV60 B(HEB 60)
R2
P01 5BR
R1
E
STARTER MOTOR
65A
B
ON
B (30) AV60 B(HEB 60)
P04 5W
P11 LgR
P10 3BR
STARTER RELAY
ST
S1(50)
65A
V05 YB
P03 5W
E
P09 5WR
S
65A
C
P08 5WR
P25 3BY K05 GY B
B AV60 B(HEB 60)
GLOW RELAY GLOW HEATER
+ 12V 115D31R BATTERY
SW654-10002
10-026
TROUBLESHOOTING
2-3-4. Glow heater is not heated (Engine starting performance is bad in cold weather) Reference Fig. : 2-3-1 Check point
Check/Cause
Action
1. Glow Heater
• When starter switch is ON, measure voltage between glow heater terminal inlet wire BY and chassis ground. Standard voltage : 12 V or more • If voltage is OK, glow heater is faulty.
Replace glow heater.
2. Glow Relay
Replace glow relay. (1) W hen starter switch is ON, measure voltage between glow relay terminal g inlet wire BR and chassis ground. Standard voltage : 12 V or more (2) M easure voltage between glow relay terminal B inlet wire R and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON, measure voltage between glow relay terminal G outlet wire BY and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, glow relay is faulty.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2-3-5. Starter motor runs even when F-R lever is not at “N” Reference Fig. : 2-3-1 Check point 1. F-R Lever Switch
Check/Cause • When starter switch is OFF and F-R lever is “F” or “R”, check continuity between F-R lever switch terminal wire YG and terminal wire BW. There is no continuity in normal condition. • If there is continuity, F-R lever switch is faulty.
Action Replace F-R lever switch.
10-027
TROUBLESHOOTING
Fig.: 2-3-1
1
TO COMBINATION METER
L12 LB 4
TO PARKING BRAKE SOLENOID, SERVO BYPASS SOLENOID
L13 GrB
3
L11 O
V75 BrR
2 6
IG-SW V13/V33 +BF V01/V21 MAIN V03/V23
R
L10 GY
W
5
TO STOP LAMP
VIBRATION AUTO SWITCH
V013WB
V03 LgY
V03LgY
G10 YG
R
G09 Br
W
P18 RL
B
TO VIBRATION MODE CHANGE SWITCH, WATER SPRAY CHANGE RELAY
V01 WB V01 WB
P16 WB
B
N B
PARKING BRAKE SWITCH +BP V18/V58/V38/V78
FOOT BRAKE SWITCH
L11 O
R G10 YG CAN2-L V17
B
G11 BW
W
F-R LEVER SWITCH
CAN2-H V37
CAN1-L V16 CAN1-H V36 A-VCC11(+5V) V51 APS1(SIG) V47 A-GND12 V46 A-VCC10 V50 APS2(SIG) V67 A-GND13 V66
POTENTIOMETER
V51 0.5R
+V1
V47 0.5W
+V2
V67 0.5W
GND2
TACHMETER PULSE V34
N B
SPEED SENSOR V14
ECU PARKING SW. V75 N-SW. V30
N B
2
PARKING INTERLOCK RELAY
OUT2
V66 0.5B
K06 RG
5
V75 BrR
GND1
V50 0.5R
4 3 1
G11 BW
OUT1
V46 0.5B
V75 BrR
V01 3WB 4 5
3
2
1
S22 3R
V03 LgY
V75 BrR
V30 LB
S22 R
ECU MAIN RELAY
DPF SW. V56 OIL PRE.LAMP V06 HEATER LAMP V07 V01 WB
DPF REQUEST LAMP V28 DPF ACTIVE LAMP V26 OVERHEAT LAMP V27
V30 LB
STOP LAMP V08
G11 BW
WARNING LAMP V09 STOP-SW. V32
4
N B
3
5
N B
1
2
N B
P
FUEL PUMP
NEUTRAL RELAY
DPF INHIBIT SW. V74
ECU
V01 3WB S22 3R K06 RG P18 RL
P16 WB
P18 RL
FUSE BOX (1)
TO COMBINATION METER
P09 5WR
P25 3BY
P09 5WR
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
V12 YG
P10 3BR
S22 3R P04 5W
V01 3WB
FUSE BOX (2)
K05 GY
N/A 24 N/A 23 N/A 22 N/A 21 5A 20 5A 19 20A 18 5A 17 5A 16 15A 15 5A 14 20A 13
K06 RG
P16 WB
K03 WY P11 LgR P24 15B
L R E
B
ALTERNATOR K02 3BW
ACC
BR
C ST-SW V12
OFF
STARTER V05
HT
HEATER RLY V24
STARTER SWITCH
P04 5W
V12 YG V05 YB V24 BR
ACC B R
COM
BR
E
BATTERY RELAY
ECU
STARTER SWITCH B
NO P11 LgR
P11 LgR
C
N B
OFF ON
P02 5R
ST
V24 BR
K01 5BY B
G
g
e
N
P02 5R
AV60 B(HEB 60)
R2
P01 5BR
R1
E
STARTER MOTOR
65A
B
ON
B (30) AV60 B(HEB 60)
P04 5W
P11 LgR
P10 3BR
STARTER RELAY
ST
S1(50)
65A
V05 YB
P03 5W
E
P09 5WR
S
65A
C
P08 5WR
P25 3BY K05 GY B
B AV60 B(HEB 60)
GLOW RELAY GLOW HEATER
+ 12V 115D31R BATTERY
SW654-10002
10-028
TROUBLESHOOTING
2-3-6. Engine speed does not change when operating throttle lever • Engine warning lamp must not be lighting. • Refer to voltage measurement method when voltage is to be measured without disconnecting connector. Reference Fig. : 2-3-1 Check point
Check/Cause
Action
1. Connector
• Check for corrosion, break, bend, or loosening on potentiometer connector terminals. • If there are any above mentioned abnormalities, the connector is faulty.
Replace connector or terminal.
2. Potentiometer
Replace potentiometer. (1) W hen starter switch is ON, measure voltage between potentiometer terminal +V1 wire R and potentiometer terminal GND1 wire B. Standard voltage : 5 ± 0.5 V (2) W hen starter switch is ON, measure voltage between potentiometer terminal +V2 wire R and potentiometer terminal GND2 wire B. Standard voltage : 5 ± 0.5 V (3) W hen starter switch is ON, measure voltage between potentiometer terminal OUT1 wire W and potentiometer terminal GND1 wire B. When throttle lever is at IDLE position Standard voltage : 0.5 to 1.0 V When throttle lever is at FULL position Standard voltage : 4.0 to 4.5 V (4) W hen starter switch is ON, measure voltage between potentiometer terminal OUT2 wire W and potentiometer terminal GND2 wire B. When throttle lever is at IDLE position Standard voltage : 4.0 to 4.5 V When throttle lever is at FULL position Standard voltage : 0.5 to 1.0 V • If above items (1) and (2) are OK and item (3) or (4) is NG, potentiometer is faulty.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
(NOTICE) • Because three-wire shield cable is used between potentiometer and ECU, it is impossible to repair it. It must be replaced.
10-029
TROUBLESHOOTING
Fig.: 2-4-1
L11 O
R
L10 GY
W
FOOT BRAKE SWITCH P16 WB
B
TO STOP LAMP
K12 PL
3 2
P17 WL 1
SPEED CHANGE SWITCH SPEED CHANGE SWITCH
N B
SPEED CHANGE SOLENOID
SPEED
CONNECTION 1-3 1-2
N B
N B
PARKING BRAKE SOLENOID
SERVO BYPASS SOLENOID
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
TO PARKING INTERLOCK RELAY, ECU, SPEED PULSE ON/OFF RELAY
B
R1
R2
ACC
ON OFF HT
STARTER SWITCH STARTER SWITCH B
ACC B R
BR
C
P04 5W
C
ST
COM
BR
E
BATTERY RELAY
OFF ON
NO
P11 LgR
P11 LgR N B
AV60 B(HEB 60)
ST
65A
P04 5W
P11 LgR
P09 5WR
FUSE BOX (1)
P03 5W
N B
P09 5WR
5
65A
4
PARKING BRAKE SWITCH
V75 BrR
P08 5WR
L12 LB
L13 GrB
P16 WB
TO COMBINATION METER
2 6
P09 5WR
1
P17 WL
3
L11 O
AV60 B(HEB 60)
+ 12V 115D31R BATTERY
SW654-10003
10-030
TROUBLESHOOTING
2-4. Propulsion System Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. • When measuring voltage and current without disconnecting connectors, refer to “Measuring voltage and current flowing using tester” (P.10-006 to P.10-008). • Check any ground circuit which belongs to components to be checked.
2-4-1. Machine moves neither forward nor backward • Parking brake switch must be released. • Foot brake switch must be OFF (Brake pedal is not depressed). Reference Fig.: 2-4-1 Check point
Check/Cause
Action
1. Parking Brake Solenoid • Disconnect harness and measure resistance of coil. Standard resistance : 7.5 Ω • If measured resistance is abnormal, parking brake solenoid is faulty.
Replace parking brake solenoid.
2. Servo Bypass Solenoid • Disconnect harness and measure resistance of coil. Standard resistance : 12.3 ± 1.2 Ω • If measured resistance is abnormal, servo bypass solenoid is faulty
Replace servo bypass solenoid.
3. Parking Brake Switch
(1) W hen starter switch is ON, measure voltage between Replace parking brake parking brake switch terminal 1 inlet wire O and chassis switch. ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between parking brake switch terminal 3 outlet wire GrB 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.
4. Foot Brake Switch
(1) W hen starter switch is ON, measure voltage between foot brake switch terminal inlet wire WB and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between foot brake switch terminal outlet wire O and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, foot brake switch is faulty.
Replace foot brake switch.
5. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-031
TROUBLESHOOTING
Fig.: 2-4-1
L11 O
R
L10 GY
W
FOOT BRAKE SWITCH P16 WB
B
TO STOP LAMP
K12 PL
3 2
P17 WL 1
SPEED CHANGE SWITCH SPEED CHANGE SWITCH
N B
SPEED CHANGE SOLENOID
SPEED
CONNECTION 1-3 1-2
N B
N B
PARKING BRAKE SOLENOID
SERVO BYPASS SOLENOID
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
TO PARKING INTERLOCK RELAY, ECU, SPEED PULSE ON/OFF RELAY
B
R1
R2
ACC
ON OFF HT
STARTER SWITCH STARTER SWITCH B
ACC B R
BR
C
P04 5W
C
ST
COM
BR
E
BATTERY RELAY
OFF ON
NO
P11 LgR
P11 LgR N B
AV60 B(HEB 60)
ST
65A
P04 5W
P11 LgR
P09 5WR
FUSE BOX (1)
P03 5W
N B
P09 5WR
5
65A
4
PARKING BRAKE SWITCH
V75 BrR
P08 5WR
L12 LB
L13 GrB
P16 WB
TO COMBINATION METER
2 6
P09 5WR
1
P17 WL
3
L11 O
AV60 B(HEB 60)
+ 12V 115D31R BATTERY
SW654-10003
10-032
TROUBLESHOOTING
2-4-2. Machine speed cannot be changed • Speed change switch must be “ Reference Fig.: 2-4-1 Check point
”. Check/Cause
Action
1. Speed Change Solenoid
• Disconnect harness and measure resistance of coil. Standard resistance : 7.5 Ω • If measured resistance is abnormal, speed change solenoid is faulty.
Replace speed change solenoid.
2. Speed Change Switch
(1) W hen starter switch is ON, measure voltage between speed change switch terminal 1 inlet wire WL and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between speed change switch terminal 2 outlet wire PL and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and (2) is NG, speed change switch is faulty.
Replace speed change switch.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-033
TROUBLESHOOTING
Fig.: 2-4-1
L11 O
R
L10 GY
W
FOOT BRAKE SWITCH P16 WB
B
TO STOP LAMP
K12 PL
3 2
P17 WL 1
SPEED CHANGE SWITCH SPEED CHANGE SWITCH
N B
SPEED CHANGE SOLENOID
SPEED
CONNECTION 1-3 1-2
N B
N B
PARKING BRAKE SOLENOID
SERVO BYPASS SOLENOID
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
TO PARKING INTERLOCK RELAY, ECU, SPEED PULSE ON/OFF RELAY
B
R1
R2
ACC
ON OFF HT
STARTER SWITCH STARTER SWITCH B
ACC B R
BR
C
P04 5W
C
ST
COM
BR
E
BATTERY RELAY
OFF ON
NO
P11 LgR
P11 LgR N B
AV60 B(HEB 60)
ST
65A
P04 5W
P11 LgR
P09 5WR
FUSE BOX (1)
P03 5W
N B
P09 5WR
5
65A
4
PARKING BRAKE SWITCH
V75 BrR
P08 5WR
L12 LB
L13 GrB
P16 WB
TO COMBINATION METER
2 6
P09 5WR
1
P17 WL
3
L11 O
AV60 B(HEB 60)
+ 12V 115D31R BATTERY
SW654-10003
10-034
TROUBLESHOOTING
2-4-3. Brake cannot be released • Parking brake switch must be released. • Foot brake switch must be OFF (Brake pedal is not depressed). Reference Fig.: 2-4-1 Check point
Check/Cause
1. Parking Brake Solenoid • Disconnect harness and measure resistance of coil. Standard voltage : 7.5 Ω • If measured resistance is abnormal, parking brake solenoid is faulty.
Action Replace parking brake solenoid.
2. Parking Brake Switch
(1) W hen starter switch is ON, measure voltage between Replace parking brake parking brake switch terminal 1 inlet wire O and chassis switch. ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between parking brake switch terminal 3 outlet wire GrB 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.
3. Foot Brake Switch
(1) W hen starter switch is ON, measure voltage between foot brake switch terminal inlet wire WB and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between foot brake switch terminal outlet wire O and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, foot brake switch is faulty.
Replace foot brake switch.
4. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-035
TROUBLESHOOTING
Fig.: 2-4-1
L11 O
R
L10 GY
W
FOOT BRAKE SWITCH P16 WB
B
TO STOP LAMP
K12 PL
3 2
P17 WL 1
SPEED CHANGE SWITCH SPEED CHANGE SWITCH
N B
SPEED CHANGE SOLENOID
SPEED
CONNECTION 1-3 1-2
N B
N B
PARKING BRAKE SOLENOID
SERVO BYPASS SOLENOID
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
TO PARKING INTERLOCK RELAY, ECU, SPEED PULSE ON/OFF RELAY
B
R1
R2
ACC
ON OFF HT
STARTER SWITCH STARTER SWITCH B
ACC B R
BR
C
P04 5W
C
ST
COM
BR
E
BATTERY RELAY
OFF ON
NO
P11 LgR
P11 LgR N B
AV60 B(HEB 60)
ST
65A
P04 5W
P11 LgR
P09 5WR
FUSE BOX (1)
P03 5W
N B
P09 5WR
5
65A
4
PARKING BRAKE SWITCH
V75 BrR
P08 5WR
L12 LB
L13 GrB
P16 WB
TO COMBINATION METER
2 6
P09 5WR
1
P17 WL
3
L11 O
AV60 B(HEB 60)
+ 12V 115D31R BATTERY
SW654-10003
10-036
TROUBLESHOOTING
2-4-4. Brake does not work • Parking brake switch must be applied. • Foot brake switch must be ON (Brake pedal is depressed). Reference Fig.: 2-4-1 Check point
Check/Cause
Action
1. Parking Brake Solenoid • Disconnect harness and measure resistance of coil. Standard voltage : 7.5 Ω • If measured resistance is abnormal, parking brake solenoid is faulty.
Replace parking brake solenoid.
2. Parking Brake Switch
• When starter switch is ON, measure voltage between parking brake switch terminal 3 outlet wire GrB and chassis ground. There is no electricity in normal condition. • If there is electricity, parking brake switch is faulty.
Replace parking brake switch.
3. Foot Brake Switch
• When starter switch is ON, measure voltage between foot Replace foot brake brake switch terminal outlet wire O and chassis ground. switch. There is no electricity in normal condition. • If there is electricity, foot brake switch is faulty.
4. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-037
TROUBLESHOOTING
Fig.: 2-5-1
TO F-R LEVER SWITCH
G10 YG
R
G09 Br
W
VIBRATION AUTO SWITCH P18 RL
B
G06 BR
2
G09 Br 1
G03 L
3
COM NO
VIBRATION MODE CHANGE SWITCH
W
G04 YW
G
G
G05 W
W
F-R LEVER VIBRATION SWITCH (R)
VIBRATION MODE CHANGE SWITCH VIBRATION MODE
NC
Br
NO
G06 BR
Br
NC COM
F-R LEVER VIBRATION SWITCH (L)
CONNECTION 1-3
AUTO
2
P18 RL 1
3 5
4
6
P18 RL
1-2
G01 BrW
G01 BrW
F
sol.b N B
G02 GW
R
G02 GW
VIBRATORY DRUM SELECT SWITCH
VIBRATORY DRUM VALVE SELECT SOLENOID
sol.a N B
VIBRATORY DRUM SELECT SWITCH POSITION
CONNECTION
G08 OW
1-2,4-6
G08 OW
(LOW) (OSCILLATION)
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
P18 RL
1-3,4-5
N B
sol.a N B
VIBRATOR SOLENOID
P09 5WR
P09 5WR
FUSE BOX (1)
sol.b
(HIGH) (NORMAL)
G07 LW
G07 LW
1-3,4-6
HT
STARTER SWITCH STARTER SWITCH B
ACC B R
ST
4
G06 BR
VIBRATION SWITCH
SW654ND
VIBRATION SWITCH POSITION (LOW)
VIBRATION SWITCH
CONNECTION
POSITION
1-2,4-6
CONNECTION 1-2,4-6
(OSCILLATION)
P04 5W
65A
1-3,4-6
1-3,4-5
DIODE UNIT A B
NO
COM
BR
E
TO COMBINATION METER
P11 LgR
C
1-3,4-5
(NORMAL)
C D
E F G H
I
A E
F
B C
G
D I
H
K13 OG G07 LW G08 OW
BATTERY RELAY
OFF ON
5
P11 LgR N B
AV60 B(HEB 60)
OFF
C
P03 5W
ON
BR
P09 5WR
ACC
65A
R2
1
1-3,4-6
P08 5WR
P11 LgR
P04 5W ST
R1
G06 BR
2 6
SW654
(HIGH)
B
3
AV60 B(HEB 60)
+ 12V 115D31R BATTERY
SW654-10004
10-038
TROUBLESHOOTING
2-5. Vibration Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. • Throttle switch must be “FULL”. • Check any ground circuit which belongs to components to be checked.
2-5-1. No vibration occurs 1/2 • F-R lever must be “F” or “R”. • Vibration mode change switch must be “AUTO” (automatic mode). • Vibration switch must not be “ Reference Fig.: 2-5-1
”.
Check point
Check/Cause
Action
1. Vibrator Solenoid
• Disconnect harness and measure resistance of coil. Standard voltage : 5.5 Ω • If measured resistance is abnormal, vibrator solenoid is faulty.
2. Vibration Switch
(1) When starter switch is ON, measure voltage between Replace vibration switch. vibration switch terminal 1 inlet wire BR, terminal 4 inlet wire BR and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and vibration switch is in below position, measure voltage between vibration switch terminal 2 outlet wire OW and chassis ground. SW654 :“ ” (LOW) SW654ND : “ ” (OSCILLATION) Standard voltage : 12 V or more (3) W hen starter switch is ON and vibration switch is in below position, measure voltage between vibration switch terminal 5 outlet wire LW and chassis ground. SW654 :“ SW654ND : “
Replace vibrator solenoid.
” (HIGH) ” (NORMAL)
Standard voltage : 12 V or more • If above item (1) is OK and item (2) or (3) is NG, vibration switch is faulty. 3. Vibration Mode Change (1) W hen starter switch is ON, measure voltage between Replace vibration mode Switch vibration mode change switch terminal 1 inlet wire Br change switch. and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between vibration mode change switch terminal 2 outlet wire BR and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, vibration mode change switch is faulty. 4. Vibration AUTO Switch (1) W hen starter switch is ON, measure voltage between Replace vibration AUTO vibration AUTO switch terminal inlet wire RL and switch. chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between vibration AUTO switch terminal outlet wire Br and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, vibration AUTO switch is faulty. 10-039
TROUBLESHOOTING
Fig.: 2-5-1
TO F-R LEVER SWITCH
G10 YG
R
G09 Br
W
VIBRATION AUTO SWITCH P18 RL
B
G06 BR
2
G09 Br 1
G03 L
3
COM NO
VIBRATION MODE CHANGE SWITCH
W
G04 YW
G
G
G05 W
W
F-R LEVER VIBRATION SWITCH (R)
VIBRATION MODE CHANGE SWITCH VIBRATION MODE
NC
Br
NO
G06 BR
Br
NC COM
F-R LEVER VIBRATION SWITCH (L)
CONNECTION 1-3
AUTO
2
P18 RL 1
3 5
4
6
P18 RL
1-2
G01 BrW
G01 BrW
F
sol.b N B
G02 GW
R
G02 GW
VIBRATORY DRUM SELECT SWITCH
VIBRATORY DRUM VALVE SELECT SOLENOID
sol.a N B
VIBRATORY DRUM SELECT SWITCH POSITION
CONNECTION
G08 OW
1-2,4-6
G08 OW
(LOW) (OSCILLATION)
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
P18 RL
1-3,4-5
N B
sol.a N B
VIBRATOR SOLENOID
P09 5WR
P09 5WR
FUSE BOX (1)
sol.b
(HIGH) (NORMAL)
G07 LW
G07 LW
1-3,4-6
HT
STARTER SWITCH STARTER SWITCH B
ACC B R
ST
4
G06 BR
VIBRATION SWITCH
SW654ND
VIBRATION SWITCH POSITION (LOW)
VIBRATION SWITCH
CONNECTION
POSITION
1-2,4-6
CONNECTION 1-2,4-6
(OSCILLATION)
P04 5W
65A
1-3,4-6
1-3,4-5
DIODE UNIT A B
NO
COM
BR
E
TO COMBINATION METER
P11 LgR
C
1-3,4-5
(NORMAL)
C D
E F G H
I
A E
F
B C
G
D I
H
K13 OG G07 LW G08 OW
BATTERY RELAY
OFF ON
5
P11 LgR N B
AV60 B(HEB 60)
OFF
C
P03 5W
ON
BR
P09 5WR
ACC
65A
R2
1
1-3,4-6
P08 5WR
P11 LgR
P04 5W ST
R1
G06 BR
2 6
SW654
(HIGH)
B
3
AV60 B(HEB 60)
+ 12V 115D31R BATTERY
SW654-10004
10-040
TROUBLESHOOTING
2-5-1. No vibration occurs 2/2 • F-R lever must be “F” or “R”. • Vibration mode change switch must be “AUTO” (automatic mode). • Vibration switch must not be “ Reference Fig.: 2-5-1 Check point 5. Harness Connecting Between Terminals
”. Check/Cause
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Action Repair or replace harness.
2-5-2. Amplitude does not change (Remains either low or high) : SW654 • Vibration mode change switch must be “AUTO” (automatic mode). Reference Fig.: 2-5-1 Check point
Check/Cause
Action
1. Vibrator Solenoid
• Disconnect harness and measure resistance of coil. Standard voltage : 5.5 Ω • If measured resistance is abnormal, amplitude cylinder solenoid is faulty.
Replace amplitude cylinder solenoid.
2. Vibration Switch
(1) W hen starter switch is ON, measure voltage between vibration switch terminal 1 inlet wire BR terminal 4 inlet wire BR and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and vibration switch is “ ”, measure voltage vibration switch terminal wires and chassis ground. • Vibration switch terminal 2 outlet wire OW and chassis ground. • Vibration switch terminal 5 outlet wire LW and chassis ground. There is no electricity in normal condition. (3) When starter switch is ON and vibration switch is “ ”, measure voltage between vibration switch terminal 2 outlet wire OW and chassis ground. Standard voltage : 12 V or more. (4) W hen starter switch is ON and vibration switch is “ ”, measure voltage between vibration switch terminal 5 outlet wire LW and chassis ground. Standard voltage : 12 V or more. • If above item (1) is OK and item (2), (3) or (4) is NG, vibration switch is faulty.
Replace vibration switch.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-041
TROUBLESHOOTING
Fig.: 2-5-1
TO F-R LEVER SWITCH
G10 YG
R
G09 Br
W
VIBRATION AUTO SWITCH P18 RL
B
G06 BR
2
G09 Br 1
G03 L
3
COM NO
VIBRATION MODE CHANGE SWITCH
W
G04 YW
G
G
G05 W
W
F-R LEVER VIBRATION SWITCH (R)
VIBRATION MODE CHANGE SWITCH VIBRATION MODE
NC
Br
NO
G06 BR
Br
NC COM
F-R LEVER VIBRATION SWITCH (L)
CONNECTION 1-3
AUTO
2
P18 RL 1
3 5
4
6
P18 RL
1-2
G01 BrW
G01 BrW
F
sol.b N B
G02 GW
R
G02 GW
VIBRATORY DRUM SELECT SWITCH
VIBRATORY DRUM VALVE SELECT SOLENOID
sol.a N B
VIBRATORY DRUM SELECT SWITCH POSITION
CONNECTION
G08 OW
1-2,4-6
G08 OW
(LOW) (OSCILLATION)
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
P18 RL
1-3,4-5
N B
sol.a N B
VIBRATOR SOLENOID
P09 5WR
P09 5WR
FUSE BOX (1)
sol.b
(HIGH) (NORMAL)
G07 LW
G07 LW
1-3,4-6
HT
STARTER SWITCH STARTER SWITCH B
ACC B R
ST
4
G06 BR
VIBRATION SWITCH
SW654ND
VIBRATION SWITCH POSITION (LOW)
VIBRATION SWITCH
CONNECTION
POSITION
1-2,4-6
CONNECTION 1-2,4-6
(OSCILLATION)
P04 5W
65A
1-3,4-6
1-3,4-5
DIODE UNIT A B
NO
COM
BR
E
TO COMBINATION METER
P11 LgR
C
1-3,4-5
(NORMAL)
C D
E F G H
I
A E
F
B C
G
D I
H
K13 OG G07 LW G08 OW
BATTERY RELAY
OFF ON
5
P11 LgR N B
AV60 B(HEB 60)
OFF
C
P03 5W
ON
BR
P09 5WR
ACC
65A
R2
1
1-3,4-6
P08 5WR
P11 LgR
P04 5W ST
R1
G06 BR
2 6
SW654
(HIGH)
B
3
AV60 B(HEB 60)
+ 12V 115D31R BATTERY
SW654-10004
10-042
TROUBLESHOOTING
2-5-3. Vibration does not change (Remains normal or oscillation vibration) : SW654ND • Vibration mode change switch must be “AUTO” (automatic mode). Reference Fig.: 2-5-1 Check point
Check/Cause
Action
1. Vibrator Solenoid
• Disconnect harness and measure resistance of coil. Standard voltage : 5.5 Ω • If measured resistance is abnormal, amplitude cylinder solenoid is faulty.
Replace amplitude cylinder solenoid.
2. Vibration Switch
Replace vibration (1) W hen starter switch is ON, measure voltage between vibration switch terminal 1 inlet wire BR, terminal 4 inlet switch. wire BR and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and vibration switch is “ ”, measure voltage vibration switch terminal wires and chassis ground. • Vibration switch terminal 2 outlet wire OW and chassis ground. • Vibration switch terminal 5 outlet wire LW and chassis ground. There is no electricity in normal condition. (3) W hen starter switch is ON and vibration switch is “ ”, measure voltage between vibration switch terminal 2 outlet wire OW and chassis ground. Standard voltage : 12 V or more. (4) W hen starter switch is ON and vibration switch is “ ”, measure voltage between vibration switch terminal 5 outlet wire LW and chassis ground. Standard voltage : 12 V or more. • If above item (1) is OK and item (2), (3) or (4) is NG, vibration switch is faulty.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-043
TROUBLESHOOTING
Fig.: 2-5-1
TO F-R LEVER SWITCH
G10 YG
R
G09 Br
W
VIBRATION AUTO SWITCH P18 RL
B
G06 BR
2
G09 Br 1
G03 L
3
COM NO
VIBRATION MODE CHANGE SWITCH
W
G04 YW
G
G
G05 W
W
F-R LEVER VIBRATION SWITCH (R)
VIBRATION MODE CHANGE SWITCH VIBRATION MODE
NC
Br
NO
G06 BR
Br
NC COM
F-R LEVER VIBRATION SWITCH (L)
CONNECTION 1-3
AUTO
2
P18 RL 1
3 5
4
6
P18 RL
1-2
G01 BrW
G01 BrW
F
sol.b N B
G02 GW
R
G02 GW
VIBRATORY DRUM SELECT SWITCH
VIBRATORY DRUM VALVE SELECT SOLENOID
sol.a N B
VIBRATORY DRUM SELECT SWITCH POSITION
CONNECTION
G08 OW
1-2,4-6
G08 OW
(LOW) (OSCILLATION)
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
P18 RL
1-3,4-5
N B
sol.a N B
VIBRATOR SOLENOID
P09 5WR
P09 5WR
FUSE BOX (1)
sol.b
(HIGH) (NORMAL)
G07 LW
G07 LW
1-3,4-6
HT
STARTER SWITCH STARTER SWITCH B
ACC B R
ST
4
G06 BR
VIBRATION SWITCH
SW654ND
VIBRATION SWITCH POSITION (LOW)
VIBRATION SWITCH
CONNECTION
POSITION
1-2,4-6
CONNECTION 1-2,4-6
(OSCILLATION)
P04 5W
65A
1-3,4-6
1-3,4-5
DIODE UNIT A B
NO
COM
BR
E
TO COMBINATION METER
P11 LgR
C
1-3,4-5
(NORMAL)
C D
E F G H
I
A E
F
B C
G
D I
H
K13 OG G07 LW G08 OW
BATTERY RELAY
OFF ON
5
P11 LgR N B
AV60 B(HEB 60)
OFF
C
P03 5W
ON
BR
P09 5WR
ACC
65A
R2
1
1-3,4-6
P08 5WR
P11 LgR
P04 5W ST
R1
G06 BR
2 6
SW654
(HIGH)
B
3
AV60 B(HEB 60)
+ 12V 115D31R BATTERY
SW654-10004
10-044
TROUBLESHOOTING
2-5-4. Vibration mode cannot be switched (F-R lever vibration switch does not work) • Vibration mode change switch must be “ • Vibration switch must not be “OFF”.
” (manual mode).
Reference Fig.: 2-5-1 Check point
Check/Cause
Action
hen starter switch is ON, measure voltage between Replace vibration mode 1. Vibration Mode Change (1) W Switch vibration mode change switch terminal 1 inlet wire Br change switch. and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between vibration mode change switch terminal 2 outlet wire BR and chassis ground. There is no electricity in normal condition. • If above item (1) is OK and item (2) is NG, vibration mode change switch is faulty. 2. F-R Lever Vibration Switch (L)
• Check continuity between F-R lever vibration switch (L) terminals. • Terminal NC and terminal COM • Terminal NO and terminal COM • If continuity is made and broken when switch is operated, it is normal. If not, switch is faulty.
Replace F-R lever vibration switch (L).
3. F-R Lever Vibration Switch (R)
• Check continuity between F-R lever vibration switch (R) terminals. • Terminal NC and terminal COM • Terminal NO and terminal COM • If continuity is made and broken when switch is operated, it is normal. If not, switch is faulty.
Replace F-R lever vibration switch (R).
4. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-045
TROUBLESHOOTING
Fig.: 2-5-1
TO F-R LEVER SWITCH
G10 YG
R
G09 Br
W
VIBRATION AUTO SWITCH P18 RL
B
G06 BR
2
G09 Br 1
G03 L
3
COM NO
VIBRATION MODE CHANGE SWITCH
W
G04 YW
G
G
G05 W
W
F-R LEVER VIBRATION SWITCH (R)
VIBRATION MODE CHANGE SWITCH VIBRATION MODE
NC
Br
NO
G06 BR
Br
NC COM
F-R LEVER VIBRATION SWITCH (L)
CONNECTION 1-3
AUTO
2
P18 RL 1
3 5
4
6
P18 RL
1-2
G01 BrW
G01 BrW
F
sol.b N B
G02 GW
R
G02 GW
VIBRATORY DRUM SELECT SWITCH
VIBRATORY DRUM VALVE SELECT SOLENOID
sol.a N B
VIBRATORY DRUM SELECT SWITCH POSITION
CONNECTION
G08 OW
1-2,4-6
G08 OW
(LOW) (OSCILLATION)
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
P18 RL
1-3,4-5
N B
sol.a N B
VIBRATOR SOLENOID
P09 5WR
P09 5WR
FUSE BOX (1)
sol.b
(HIGH) (NORMAL)
G07 LW
G07 LW
1-3,4-6
HT
STARTER SWITCH STARTER SWITCH B
ACC B R
ST
4
G06 BR
VIBRATION SWITCH
SW654ND
VIBRATION SWITCH POSITION (LOW)
VIBRATION SWITCH
CONNECTION
POSITION
1-2,4-6
CONNECTION 1-2,4-6
(OSCILLATION)
P04 5W
65A
1-3,4-6
1-3,4-5
DIODE UNIT A B
NO
COM
BR
E
TO COMBINATION METER
P11 LgR
C
1-3,4-5
(NORMAL)
C D
E F G H
I
A E
F
B C
G
D I
H
K13 OG G07 LW G08 OW
BATTERY RELAY
OFF ON
5
P11 LgR N B
AV60 B(HEB 60)
OFF
C
P03 5W
ON
BR
P09 5WR
ACC
65A
R2
1
1-3,4-6
P08 5WR
P11 LgR
P04 5W ST
R1
G06 BR
2 6
SW654
(HIGH)
B
3
AV60 B(HEB 60)
+ 12V 115D31R BATTERY
SW654-10004
10-046
TROUBLESHOOTING
2-5-5. Vibratory drum cannot be switched Reference Fig.: 2-5-1 Check point
Check/Cause
Action
1. Vibratory Drum Select Solenoid Valve (a), (b)
• Disconnect harness and measure resistance of coil. Replace vibratory drum Standard voltage : 12.3 ± 1.2 Ω select solenoid valve • If measured resistance is abnormal, vibratory drum select (a) or (b). solenoid valve is faulty.
2. Vibratory Drum Select Switch
(1) W hen starter switch is ON, measure voltage between vibratory drum select switch terminal 1 inlet wire RL, terminal 4 inlet wire RL and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and vibratory drum select switch is in “ ”, measure voltage between vibratory drum select switch terminal 2 outlet wire BrW and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON and vibratory drum select switch is in “ ”, measure voltage between vibratory drum select switch terminal 2 outlet wire BrW, terminal 5 outlet wire GW and chassis ground. There is no electricity in normal condition. (4) W hen starter switch is ON and vibratory drum select switch is in “ ”, measure voltage between vibratory drum select switch terminal 5 outlet wire GW and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2), (3) or (4) is NG, vibratory drum select switch is faulty.
Replace vibratory drum select switch.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-047
TROUBLESHOOTING
Fig.: 2-6-1
P18 RL
B
R
G10 YG
W
G09 Br
TO F-R LEVER SWITCH
4
3
2
1
WATER SPRAY TIMER N B
2
1
4
3
W08 Lg
VIBRATION AUTO SWITCH
W07 LgY W07 LgY W08 Lg
2
P12 WY 1
3 5
4
6
P12 WY
G09 Br
4
N B
5
3
W10 Gr
2
1
W09 GrW
WATER SPRAY CHANGE RELAY
W07 LgY W08 Lg W09 GrW
WATER SPRAY MODE SELECT SWITCH
WATER SPRAY MODE SELECT SWITCH POSITION CONNECTION TIMER 1-2,4-6 CONT 1-3,4-6 AUTO 1-3,4-5
4
W04 2LR
3
5
N
1
2
P12 2WY W06 LgB
B
WATER SPRAY RELAY (R)
DIODE UNIT A B
C D
E F G H
TO COMBINATION METER
I
A E
F
B C
G
D I
H
4
W01 2LW
3
5
N
1
2
P12 2WY W03 GrY
K04 PG
B
WATER SPRAY RELAY (F)
W03 GrY
3
W03 GrY
2
W10 Gr 1
WATER SPRAY SWITCH (F)
P12 2WY
W01 2LW
W10 Gr 1
P07 3WL
W05 2W
P09 5WR
FUSE BOX (1)
W02 2WR
P09 5WR
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
W04 2LR
2
WATER SPRAY SWITCH (R)
W06 LgB
P18 RL
3
W06 LgB
WATER SPRAY PUMP (R) W05 2W
P
N 2B
WATER SPRAY PUMP (F)
P09 5WR
45A 65A
N 2B
P06 3WL
P03 5W
P08 5WR NO
COM
65A
P04 5W P11 LgR
P07 3WL
P
P04 5W
W02 2WR
ST
B
R1
R2
ACC
BR
C
ON
P11 LgR
OFF
E
P11 LgR N B
HT AV60 B(HEB 60)
BR
BATTERY RELAY
AV60 B(HEB 60)
STARTER SWITCH STARTER SWITCH B
ACC B R
C
OFF ON ST
+ 12V 115D31R BATTERY
SW654-10005
10-048
TROUBLESHOOTING
2-6. Water Spray Check following items before troubleshooting. • No blown fuses and power is applied up to fuses. • Water spray switch (F) and (R) must be ON. • Check any ground circuit which belongs to components to be checked..
2-6-1. Continuous water spray does not operate 1/2 • Water spray mode select switch must be “CONT”. Reference Fig.: 2-6-1 Check point
Check/Cause
Action
1. W ater Spray Pump (F)
(1) W hen starter switch is ON, measure voltage between Replace water spray water spray pump (F) terminal inlet wire WR and pump (F). chassis ground. Standard voltage : 12 V or more (2) C heck that no abnormality is found in water spray pump (F) ground terminal. • If above items (1) and (2) are OK and water spray pump (F) does not operate, water spray pump (F) is faulty.
2. W ater Spray Pump (R)
(1) W hen starter switch is ON, measure voltage between Replace water spray water spray pump (R) terminal inlet wire W and pump (R). chassis ground. Standard voltage : 12 V or more (2) C heck that no abnormality is found in water spray pump (R) ground terminal. • If above items (1) and (2) are OK and water spray pump (R) does not operate, water spray pump (R) is faulty.
3. W ater Spray Relay (F)
(1) W hen starter switch is ON, measure voltage between water spray relay (F) terminal 1 inlet wire GrY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between water spray relay (F) terminal 3 inlet wire WY and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON, measure voltage between water spray relay (F) terminal 5 outlet wire LW and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, water spray relay (F) is faulty.
Replace water spray relay (F).
4. W ater Spray Relay (R)
(1) W hen starter switch is ON, measure voltage between water spray relay (R) terminal 1 inlet wire LgB and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between water spray relay (R) terminal 3 inlet wire WY and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON, measure voltage between water spray relay (R) terminal 5 outlet wire LR and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, water spray relay (R) is faulty.
Replace water spray relay (R).
10-049
TROUBLESHOOTING
Fig.: 2-6-1
P18 RL
B
R
G10 YG
W
G09 Br
TO F-R LEVER SWITCH
4
3
2
1
WATER SPRAY TIMER N B
2
1
4
3
W08 Lg
VIBRATION AUTO SWITCH
W07 LgY W07 LgY W08 Lg
2
P12 WY 1
3 5
4
6
P12 WY
G09 Br
4
N B
5
3
W10 Gr
2
1
W09 GrW
WATER SPRAY CHANGE RELAY
W07 LgY W08 Lg W09 GrW
WATER SPRAY MODE SELECT SWITCH
WATER SPRAY MODE SELECT SWITCH POSITION CONNECTION TIMER 1-2,4-6 CONT 1-3,4-6 AUTO 1-3,4-5
4
W04 2LR
3
5
N
1
2
P12 2WY W06 LgB
B
WATER SPRAY RELAY (R)
DIODE UNIT A B
C D
E F G H
TO COMBINATION METER
I
A E
F
B C
G
D I
H
4
W01 2LW
3
5
N
1
2
P12 2WY W03 GrY
K04 PG
B
WATER SPRAY RELAY (F)
W03 GrY
3
W03 GrY
2
W10 Gr 1
WATER SPRAY SWITCH (F)
P12 2WY
W01 2LW
W10 Gr 1
P07 3WL
W05 2W
P09 5WR
FUSE BOX (1)
W02 2WR
P09 5WR
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
W04 2LR
2
WATER SPRAY SWITCH (R)
W06 LgB
P18 RL
3
W06 LgB
WATER SPRAY PUMP (R) W05 2W
P
N 2B
WATER SPRAY PUMP (F)
P09 5WR
45A 65A
N 2B
P06 3WL
P03 5W
P08 5WR NO
COM
65A
P04 5W P11 LgR
P07 3WL
P
P04 5W
W02 2WR
ST
B
R1
R2
ACC
BR
C
ON
P11 LgR
OFF
E
P11 LgR N B
HT AV60 B(HEB 60)
BR
BATTERY RELAY
AV60 B(HEB 60)
STARTER SWITCH STARTER SWITCH B
ACC B R
C
OFF ON ST
+ 12V 115D31R BATTERY
SW654-10005
10-050
TROUBLESHOOTING
2-6-1. Continuous water spray does not operate 2/2 • Water spray mode select switch must be “CONT”. Reference Fig.: 2-6-1 Check point
Check/Cause
Action
5. Water Spray Switch (F) (1) W hen starter switch is ON, measure voltage between water spray switch (F) terminal 1 inlet wire Gr and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between water spray switch (F) terminal 2 outlet wire GrY and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, water spray switch (F) is faulty.
Replace water spray switch (F).
6. Water Spray Switch (R) (1) W hen starter switch is ON, measure voltage between water spray switch (R) terminal 1 inlet wire Gr and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between water spray switch (R) terminal 2 outlet wire LgB and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, water spray switch (R) is faulty.
Replace water spray switch (R).
7. W ater Spray Change Relay
(1) W hen starter switch is ON, measure voltage between water spray change relay terminal 4 inlet wire Lg and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between water spray change relay terminal 3 outlet wire Gr and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, water spray change relay is faulty.
Replace water spray change relay.
8. Water Spray Mode Select Switch
(1) W hen starter switch is ON, measure voltage between water spray mode select switch terminal 1 inlet wire WY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between water spray mode select switch terminal 3 outlet wire Lg and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, water spray mode select switch is faulty.
Replace water spray mode select switch.
9. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-051
TROUBLESHOOTING
Fig.: 2-6-1
P18 RL
B
R
G10 YG
W
G09 Br
TO F-R LEVER SWITCH
4
3
2
1
WATER SPRAY TIMER N B
2
1
4
3
W08 Lg
VIBRATION AUTO SWITCH
W07 LgY W07 LgY W08 Lg
2
P12 WY 1
3 5
4
6
P12 WY
G09 Br
4
N B
5
3
W10 Gr
2
1
W09 GrW
WATER SPRAY CHANGE RELAY
W07 LgY W08 Lg W09 GrW
WATER SPRAY MODE SELECT SWITCH
WATER SPRAY MODE SELECT SWITCH POSITION CONNECTION TIMER 1-2,4-6 CONT 1-3,4-6 AUTO 1-3,4-5
4
W04 2LR
3
5
N
1
2
P12 2WY W06 LgB
B
WATER SPRAY RELAY (R)
DIODE UNIT A B
C D
E F G H
TO COMBINATION METER
I
A E
F
B C
G
D I
H
4
W01 2LW
3
5
N
1
2
P12 2WY W03 GrY
K04 PG
B
WATER SPRAY RELAY (F)
W03 GrY
3
W03 GrY
2
W10 Gr 1
WATER SPRAY SWITCH (F)
P12 2WY
W01 2LW
W10 Gr 1
P07 3WL
W05 2W
P09 5WR
FUSE BOX (1)
W02 2WR
P09 5WR
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
W04 2LR
2
WATER SPRAY SWITCH (R)
W06 LgB
P18 RL
3
W06 LgB
WATER SPRAY PUMP (R) W05 2W
P
N 2B
WATER SPRAY PUMP (F)
P09 5WR
45A 65A
N 2B
P06 3WL
P03 5W
P08 5WR NO
COM
65A
P04 5W P11 LgR
P07 3WL
P
P04 5W
W02 2WR
ST
B
R1
R2
ACC
BR
C
ON
P11 LgR
OFF
E
P11 LgR N B
HT AV60 B(HEB 60)
BR
BATTERY RELAY
AV60 B(HEB 60)
STARTER SWITCH STARTER SWITCH B
ACC B R
C
OFF ON ST
+ 12V 115D31R BATTERY
SW654-10005
10-052
TROUBLESHOOTING
2-6-2. Continuous water spray works, but auto water spray does not operate • Water spray mode select switch must be “AUTO”. • F-R lever must be “F” or “R”. Reference Fig.: 2-6-1 Check point
Check/Cause
1. W ater Spray Change Relay
(1) W hen starter switch is ON, measure voltage between water spray change relay terminal 1 inlet wire GrW and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between water spray change relay terminal 5 inlet wire Br and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON, measure voltage between water spray change relay terminal 3 outlet wire Gr and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, water spray change relay is faulty.
Action Replace water spray change relay.
2. Vibration AUTO Switch (1) W hen starter switch is ON, measure voltage between Replace vibration AUTO vibration AUTO switch terminal inlet wire RL and switch. chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between vibration AUTO switch terminal outlet wire Br and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, vibration AUTO switch is faulty. 3. Water Spray Mode Select Switch
(1) W hen starter switch is ON, measure voltage between Replace water spray water spray mode select switch terminal 4 inlet wire WY mode select switch. and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between water spray mode select switch terminal 5 outlet wire GrW and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, water spray mode select switch is faulty.
4. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-053
TROUBLESHOOTING
Fig.: 2-6-1
P18 RL
B
R
G10 YG
W
G09 Br
TO F-R LEVER SWITCH
4
3
2
1
WATER SPRAY TIMER N B
2
1
4
3
W08 Lg
VIBRATION AUTO SWITCH
W07 LgY W07 LgY W08 Lg
2
P12 WY 1
3 5
4
6
P12 WY
G09 Br
4
N B
5
3
W10 Gr
2
1
W09 GrW
WATER SPRAY CHANGE RELAY
W07 LgY W08 Lg W09 GrW
WATER SPRAY MODE SELECT SWITCH
WATER SPRAY MODE SELECT SWITCH POSITION CONNECTION TIMER 1-2,4-6 CONT 1-3,4-6 AUTO 1-3,4-5
4
W04 2LR
3
5
N
1
2
P12 2WY W06 LgB
B
WATER SPRAY RELAY (R)
DIODE UNIT A B
C D
E F G H
TO COMBINATION METER
I
A E
F
B C
G
D I
H
4
W01 2LW
3
5
N
1
2
P12 2WY W03 GrY
K04 PG
B
WATER SPRAY RELAY (F)
W03 GrY
3
W03 GrY
2
W10 Gr 1
WATER SPRAY SWITCH (F)
P12 2WY
W01 2LW
W10 Gr 1
P07 3WL
W05 2W
P09 5WR
FUSE BOX (1)
W02 2WR
P09 5WR
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
W04 2LR
2
WATER SPRAY SWITCH (R)
W06 LgB
P18 RL
3
W06 LgB
WATER SPRAY PUMP (R) W05 2W
P
N 2B
WATER SPRAY PUMP (F)
P09 5WR
45A 65A
N 2B
P06 3WL
P03 5W
P08 5WR NO
COM
65A
P04 5W P11 LgR
P07 3WL
P
P04 5W
W02 2WR
ST
B
R1
R2
ACC
BR
C
ON
P11 LgR
OFF
E
P11 LgR N B
HT AV60 B(HEB 60)
BR
BATTERY RELAY
AV60 B(HEB 60)
STARTER SWITCH STARTER SWITCH B
ACC B R
C
OFF ON ST
+ 12V 115D31R BATTERY
SW654-10005
10-054
TROUBLESHOOTING
2-6-3. Continuous water spray works, but intermittent water spray does not operate • Water spray mode select switch must be “TIMER”. Reference Fig. : 2-6-1 Check point
Check/Cause
Action
1. Water Spray Timer
(1) W hen starter switch is ON, measure voltage between Replace water spray water spray timer terminal 1 and 3 inlet wire LgY and timer. chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between water spray timer terminal 4 outlet wire Lg and chassis ground. Standard voltage : 12 V or more (Electricity flows for a definite time.) • If above item (1) is OK and item (2) is NG, water spray timer is faulty.
2. Water Spray mode Select Switch
(1) W hen starter switch is ON, measure voltage between Replace water spray water spray mode select switch terminal 1 inlet wire WY mode select switch. and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between water spray mode select switch terminal 2 outlet wire LgY and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, water spray mode select switch is faulty.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-055
TROUBLESHOOTING
Fig.: 2-7-1 COMBINATION LAMP (F,R) TURN SIGNAL LAMP (R) 21W SIDE MARKER LAMP (R) 5W
COMBINATION LAMP (R,R)
G
L07 GR
L07 GR
G
Y
L01 BY
L10 GY
GR
L01 BY
GY
L09 WR
R
N B
HEAD LAMP (R) 60/55W
R(Hi)
L04 1.25RW
W(Lo)
L03 1.25RB
TURN SIGNAL LAMP (R) 21W STOP LAMP (R) 21W TAIL LAMP (R) 5W BACKUP LAMP (R) 21W
N B L05 1.25RG
R
HEAD LAMP (L) 60/55W
FLOOD LAMP (R) 55W
B
N B R(Hi)
L04 1.25RW
W(Lo)
L03 1.25RB
L05 1.25RG
R
FLOOD LAMP (L) 55W
B
N B L09 WR
COMBINATION LAMP (F,L) TURN SIGNAL LAMP (L) 21W SIDE MARKER LAMP (L) 5W
L08 G
Y
L01 BY
GY G GR TURN SIGNAL SWITCH
R B
COMBINATION LAMP (R,L)
G(R)
L07 GR
GR(L)
N
L16 W
Y
BACKUP BUZZER
N B
TURN SIGNAL SWITCH L
G
L08 G
GY
L06 LY
R
L09 WR
R
L01 BY
RY
L10 GY
GR
L08 G
G
BACKUP LAMP (L) 21W TAIL LAMP (L) 5W STOP LAMP (L) 21W TURN SIGNAL LAMP (L) 21W
N B L08 G L07 GR L04 2RW L03 2RB L01 BY
L10 GY
L05 2RG
L09 WR P15 2RY
BACKUP BUZZER SWITCH
FLASHER UNIT L07 GR L08 G
3
FLOOD LAMP SWITCH POSITION CONNECTION
L06 LY
2 6
1
5
4
L L06 LY
E
B
L06 LY
2-3,5-6
P15 RY
OFF
HAZARD SWITCH L05 2RG
LIGHTING SWITCH POSITION CONNECTION 2-3,5-6
B
P16 WB
FUSE BOX (2)
1-2,4-5
ST
P19 LR B
R1
R2
ACC
ON
BR
C
P13 2WG
P15 2RY
P16 WB
FUSE BOX (1)
NO
COM
BR
E
P11 LgR
OFF HT
BATTERY RELAY
STARTER SWITCH STARTER SWITCH B
ACC B R
C
P11 LgR N B
OFF ON
AV60 B(HEB 60)
N B
P04 5W
LIGHTING LO-HI SWITCH
2-3,5-6
P09 5WR
7
W
P04 5W
6
CONNECTION
65A
5
POSITION
P03 5W
3 4
L02 2Y
65A
2
P14 YR
N B
LIGHTING LO-HI SWITCH
1
L10 GY
FOOT BRAKE SWITCH
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
L04 2RW
R
P22 Y
P13 2WG
LIGHTING SWITCH L03 2RB
L11 O
B
N B
P09 5WR
7
W
FLOOD LAMP SWITCH
P09 5WR
6
1-2,4-5
P14 YR
P08 5WR
5
2-3,4-5
OFF
5 7
P22 Y
3 4
SIDE MARKER LIGHT
6
TO PARKING BRAKE SWITCH
P15 2RY
P11 LgR
L02 2Y
P13 2WG
2
3 4
P19 LR
L01 BY
2
1
N/A 24 N/A 23 N/A 22 N/A 21 5A 20 5A 19 20A 18 5A 17 5A 16 15A 15 5A 14 20A 13
1
L09 WR
1-2,4-5
AV60 B(HEB 60)
ST
+ 12V 115D31R BATTERY
SW654-10006
10-056
TROUBLESHOOTING
2-7. Lighting Check following items before troubleshooting. • No blown fuse and power is applied up to fuses.
2-7-1. Head lamp, side marker lamp and tail lamp do not light Reference Fig. : 2-7-1 Check point
Check/Cause
Action
1. Battery
• Measure battery voltage or specific gravity. Standard voltage : 12 V or more Standard gravity : 1.26 or more • If value is below standard, battery capacity is insufficient.
Charge or replace battery.
2. Each Bulb
• Check that none of lamp bulbs is burned out or has a contact failure. • Bulb is faulty or poorly connected.
Replace each bulb.
3. Lighting Switch
(1) W hen starter switch is ON, measure voltage between lighting switch terminal 2 and 5 inlet wire WG and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and lighting switch is “SIDE MARKER LIGHT”, measure voltage between lighting switch terminal 3 outlet wire BY and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON and lighting switch is “ ”, measure voltage between lighting switch terminal 6 outlet wire Y and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) or (3) is NG, lighting switch is faulty.
Replace lighting switch.
4. Lighting Lo-Hi Switch
Replace lighting Lo-Hi (1) W hen starter switch is ON and lighting switch is “ ”, measure voltage between ighting Lo-Hi switch switch. terminal 2 inlet wire Y and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, lighting switch is “ ” and lighting Lo-Hi switch is “ ”, measure voltage between lighting Lo-Hi switch terminal 1 outlet wire RB and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, lighting Lo-Hi switch is faulty.
5. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-057
TROUBLESHOOTING
Fig.: 2-7-1 COMBINATION LAMP (F,R) TURN SIGNAL LAMP (R) 21W SIDE MARKER LAMP (R) 5W
COMBINATION LAMP (R,R)
G
L07 GR
L07 GR
G
Y
L01 BY
L10 GY
GR
L01 BY
GY
L09 WR
R
N B
HEAD LAMP (R) 60/55W
R(Hi)
L04 1.25RW
W(Lo)
L03 1.25RB
TURN SIGNAL LAMP (R) 21W STOP LAMP (R) 21W TAIL LAMP (R) 5W BACKUP LAMP (R) 21W
N B L05 1.25RG
R
HEAD LAMP (L) 60/55W
FLOOD LAMP (R) 55W
B
N B R(Hi)
L04 1.25RW
W(Lo)
L03 1.25RB
L05 1.25RG
R
FLOOD LAMP (L) 55W
B
N B L09 WR
COMBINATION LAMP (F,L) TURN SIGNAL LAMP (L) 21W SIDE MARKER LAMP (L) 5W
L08 G
Y
L01 BY
GY G GR TURN SIGNAL SWITCH
R B
COMBINATION LAMP (R,L)
G(R)
L07 GR
GR(L)
N
L16 W
Y
BACKUP BUZZER
N B
TURN SIGNAL SWITCH L
G
L08 G
GY
L06 LY
R
L09 WR
R
L01 BY
RY
L10 GY
GR
L08 G
G
BACKUP LAMP (L) 21W TAIL LAMP (L) 5W STOP LAMP (L) 21W TURN SIGNAL LAMP (L) 21W
N B L08 G L07 GR L04 2RW L03 2RB L01 BY
L10 GY
L05 2RG
L09 WR P15 2RY
BACKUP BUZZER SWITCH
FLASHER UNIT L07 GR L08 G
3
FLOOD LAMP SWITCH POSITION CONNECTION
L06 LY
2 6
1
5
4
L L06 LY
E
B
L06 LY
2-3,5-6
P15 RY
OFF
HAZARD SWITCH L05 2RG
LIGHTING SWITCH POSITION CONNECTION 2-3,5-6
B
P16 WB
FUSE BOX (2)
1-2,4-5
ST
P19 LR B
R1
R2
ACC
ON
BR
C
P13 2WG
P15 2RY
P16 WB
FUSE BOX (1)
NO
COM
BR
E
P11 LgR
OFF HT
BATTERY RELAY
STARTER SWITCH STARTER SWITCH B
ACC B R
C
P11 LgR N B
OFF ON
AV60 B(HEB 60)
N B
P04 5W
LIGHTING LO-HI SWITCH
2-3,5-6
P09 5WR
7
W
P04 5W
6
CONNECTION
65A
5
POSITION
P03 5W
3 4
L02 2Y
65A
2
P14 YR
N B
LIGHTING LO-HI SWITCH
1
L10 GY
FOOT BRAKE SWITCH
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
L04 2RW
R
P22 Y
P13 2WG
LIGHTING SWITCH L03 2RB
L11 O
B
N B
P09 5WR
7
W
FLOOD LAMP SWITCH
P09 5WR
6
1-2,4-5
P14 YR
P08 5WR
5
2-3,4-5
OFF
5 7
P22 Y
3 4
SIDE MARKER LIGHT
6
TO PARKING BRAKE SWITCH
P15 2RY
P11 LgR
L02 2Y
P13 2WG
2
3 4
P19 LR
L01 BY
2
1
N/A 24 N/A 23 N/A 22 N/A 21 5A 20 5A 19 20A 18 5A 17 5A 16 15A 15 5A 14 20A 13
1
L09 WR
1-2,4-5
AV60 B(HEB 60)
ST
+ 12V 115D31R BATTERY
SW654-10006
10-058
TROUBLESHOOTING
2-7-2. Flood lamp does not light Reference Fig. : 2-7-1 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.
Replace each bulb.
2. Flood Lamp Switch
(1) W hen starter switch is ON, measure voltage between flood lamp switch terminal 2 inlet wire RY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and flood lamp switch is “ ”, measure voltage between flood lamp switch terminal 3 outlet wire RG and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, flood lamp switch is faulty.
Replace flood lamp switch.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2-7-3. High-beam of head lamp does not light Reference Fig. : 2-7-1 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.
Replace each bulb.
2. Lighting Lo-Hi Switch
Replace lighting Lo-Hi (1) W hen starter switch is ON and lighting switch is “ ”, measure voltage between lighting Lo-Hi switch switch. terminal 2 inlet wire Y and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, lighting switch is “ ” and lighting Lo-Hi switch is “ ”, measure voltage between lighting Lo-Hi switch terminal 3 outlet 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.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-059
TROUBLESHOOTING
Fig.: 2-7-1 COMBINATION LAMP (F,R) TURN SIGNAL LAMP (R) 21W SIDE MARKER LAMP (R) 5W
COMBINATION LAMP (R,R)
G
L07 GR
L07 GR
G
Y
L01 BY
L10 GY
GR
L01 BY
GY
L09 WR
R
N B
HEAD LAMP (R) 60/55W
R(Hi)
L04 1.25RW
W(Lo)
L03 1.25RB
TURN SIGNAL LAMP (R) 21W STOP LAMP (R) 21W TAIL LAMP (R) 5W BACKUP LAMP (R) 21W
N B L05 1.25RG
R
HEAD LAMP (L) 60/55W
FLOOD LAMP (R) 55W
B
N B R(Hi)
L04 1.25RW
W(Lo)
L03 1.25RB
L05 1.25RG
R
FLOOD LAMP (L) 55W
B
N B L09 WR
COMBINATION LAMP (F,L) TURN SIGNAL LAMP (L) 21W SIDE MARKER LAMP (L) 5W
L08 G
Y
L01 BY
GY G GR TURN SIGNAL SWITCH
R B
COMBINATION LAMP (R,L)
G(R)
L07 GR
GR(L)
N
L16 W
Y
BACKUP BUZZER
N B
TURN SIGNAL SWITCH L
G
L08 G
GY
L06 LY
R
L09 WR
R
L01 BY
RY
L10 GY
GR
L08 G
G
BACKUP LAMP (L) 21W TAIL LAMP (L) 5W STOP LAMP (L) 21W TURN SIGNAL LAMP (L) 21W
N B L08 G L07 GR L04 2RW L03 2RB L01 BY
L10 GY
L05 2RG
L09 WR P15 2RY
BACKUP BUZZER SWITCH
FLASHER UNIT L07 GR L08 G
3
FLOOD LAMP SWITCH POSITION CONNECTION
L06 LY
2 6
1
5
4
L L06 LY
E
B
L06 LY
2-3,5-6
P15 RY
OFF
HAZARD SWITCH L05 2RG
LIGHTING SWITCH POSITION CONNECTION 2-3,5-6
B
P16 WB
FUSE BOX (2)
1-2,4-5
ST
P19 LR B
R1
R2
ACC
ON
BR
C
P13 2WG
P15 2RY
P16 WB
FUSE BOX (1)
NO
COM
BR
E
P11 LgR
OFF HT
BATTERY RELAY
STARTER SWITCH STARTER SWITCH B
ACC B R
C
P11 LgR N B
OFF ON
AV60 B(HEB 60)
N B
P04 5W
LIGHTING LO-HI SWITCH
2-3,5-6
P09 5WR
7
W
P04 5W
6
CONNECTION
65A
5
POSITION
P03 5W
3 4
L02 2Y
65A
2
P14 YR
N B
LIGHTING LO-HI SWITCH
1
L10 GY
FOOT BRAKE SWITCH
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
L04 2RW
R
P22 Y
P13 2WG
LIGHTING SWITCH L03 2RB
L11 O
B
N B
P09 5WR
7
W
FLOOD LAMP SWITCH
P09 5WR
6
1-2,4-5
P14 YR
P08 5WR
5
2-3,4-5
OFF
5 7
P22 Y
3 4
SIDE MARKER LIGHT
6
TO PARKING BRAKE SWITCH
P15 2RY
P11 LgR
L02 2Y
P13 2WG
2
3 4
P19 LR
L01 BY
2
1
N/A 24 N/A 23 N/A 22 N/A 21 5A 20 5A 19 20A 18 5A 17 5A 16 15A 15 5A 14 20A 13
1
L09 WR
1-2,4-5
AV60 B(HEB 60)
ST
+ 12V 115D31R BATTERY
SW654-10006
10-060
TROUBLESHOOTING
2-7-4. Turn signal lamp does not blink Reference Fig. : 2-7-1 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.
Replace each bulb.
2. Flasher Unit
(1) W hen starter switch is ON, measure voltage between Replace flasher unit. flasher unit terminal B inlet wire RY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and turn signal switch lever is moved, measure voltage between flasher unit terminal L outlet wire LY and chassis ground. Standard voltage : 12 V or more with constant intervals • If above item (1) is OK and item (2) is NG, flasher unit is faulty.
3. Turn Signal Switch
(1) W hen starter switch is ON and turn signal switch lever is moved, measure voltage between turn signal switch terminal inlet wire LY and chassis ground. Standard voltage : 12 V or more with constant intervals (2) W hen starter switch is ON and turn signal switch lever is moved, measure voltage between turn signal switch terminals and chassis ground. Turn signal (L) : Wire No.L08 outlet wire G Turn signal (R) : Wire No.L07 outlet wire GR Standard voltage : 12 V or more with constant intervals • If above item (1) is OK and item (2) is NG, turn signal switch is faulty.
Replace turn signal switch.
4. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-061
TROUBLESHOOTING
Fig.: 2-7-1 COMBINATION LAMP (F,R) TURN SIGNAL LAMP (R) 21W SIDE MARKER LAMP (R) 5W
COMBINATION LAMP (R,R)
G
L07 GR
L07 GR
G
Y
L01 BY
L10 GY
GR
L01 BY
GY
L09 WR
R
N B
HEAD LAMP (R) 60/55W
R(Hi)
L04 1.25RW
W(Lo)
L03 1.25RB
TURN SIGNAL LAMP (R) 21W STOP LAMP (R) 21W TAIL LAMP (R) 5W BACKUP LAMP (R) 21W
N B L05 1.25RG
R
HEAD LAMP (L) 60/55W
FLOOD LAMP (R) 55W
B
N B R(Hi)
L04 1.25RW
W(Lo)
L03 1.25RB
L05 1.25RG
R
FLOOD LAMP (L) 55W
B
N B L09 WR
COMBINATION LAMP (F,L) TURN SIGNAL LAMP (L) 21W SIDE MARKER LAMP (L) 5W
L08 G
Y
L01 BY
GY G GR TURN SIGNAL SWITCH
R B
COMBINATION LAMP (R,L)
G(R)
L07 GR
GR(L)
N
L16 W
Y
BACKUP BUZZER
N B
TURN SIGNAL SWITCH L
G
L08 G
GY
L06 LY
R
L09 WR
R
L01 BY
RY
L10 GY
GR
L08 G
G
BACKUP LAMP (L) 21W TAIL LAMP (L) 5W STOP LAMP (L) 21W TURN SIGNAL LAMP (L) 21W
N B L08 G L07 GR L04 2RW L03 2RB L01 BY
L10 GY
L05 2RG
L09 WR P15 2RY
BACKUP BUZZER SWITCH
FLASHER UNIT L07 GR L08 G
3
FLOOD LAMP SWITCH POSITION CONNECTION
L06 LY
2 6
1
5
4
L L06 LY
E
B
L06 LY
2-3,5-6
P15 RY
OFF
HAZARD SWITCH L05 2RG
LIGHTING SWITCH POSITION CONNECTION 2-3,5-6
B
P16 WB
FUSE BOX (2)
1-2,4-5
ST
P19 LR B
R1
R2
ACC
ON
BR
C
P13 2WG
P15 2RY
P16 WB
FUSE BOX (1)
NO
COM
BR
E
P11 LgR
OFF HT
BATTERY RELAY
STARTER SWITCH STARTER SWITCH B
ACC B R
C
P11 LgR N B
OFF ON
AV60 B(HEB 60)
N B
P04 5W
LIGHTING LO-HI SWITCH
2-3,5-6
P09 5WR
7
W
P04 5W
6
CONNECTION
65A
5
POSITION
P03 5W
3 4
L02 2Y
65A
2
P14 YR
N B
LIGHTING LO-HI SWITCH
1
L10 GY
FOOT BRAKE SWITCH
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
L04 2RW
R
P22 Y
P13 2WG
LIGHTING SWITCH L03 2RB
L11 O
B
N B
P09 5WR
7
W
FLOOD LAMP SWITCH
P09 5WR
6
1-2,4-5
P14 YR
P08 5WR
5
2-3,4-5
OFF
5 7
P22 Y
3 4
SIDE MARKER LIGHT
6
TO PARKING BRAKE SWITCH
P15 2RY
P11 LgR
L02 2Y
P13 2WG
2
3 4
P19 LR
L01 BY
2
1
N/A 24 N/A 23 N/A 22 N/A 21 5A 20 5A 19 20A 18 5A 17 5A 16 15A 15 5A 14 20A 13
1
L09 WR
1-2,4-5
AV60 B(HEB 60)
ST
+ 12V 115D31R BATTERY
SW654-10006
10-062
TROUBLESHOOTING
2-7-5. Hazard lamp does not light (Turn signal blinks) • Hazard switch must be ON. Reference Fig. : 2-7-1 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.
Replace each bulb.
2. Hazard Switch
Replace hazard switch. (1) W hen starter switch is ON, measure voltage between hazard switch terminal 1 and 4 inlet wire LY and chassis ground. Standard voltage : 12 V or more with constant intervals (2) W hen starter switch is ON, measure voltage between hazard switch terminal 5 outlet wire G and chassis ground. Standard voltage : 12 V or more with constant intervals (3) W hen starter switch is ON, measure voltage between hazard switch terminal 2 outlet wire GR and chassis ground. Standard voltage : 12 V or more with constant intervals • If above item (1) is OK and item (2) or (3) is NG, hazard switch is faulty.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2-7-6. Backup lamp does not light Reference Fig. : 2-7-1 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.
Replace each bulb.
2. Backup Buzzer Switch
Replace backup buzzer (1) W hen starter switch is ON, measure voltage between backup buzzer switch terminal inlet wire Y and chassis switch. ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and F-R lever is “R” , measure voltage between backup buzzer switch terminal outlet wire WR and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, backup buzzer switch is faulty.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-063
TROUBLESHOOTING
Fig.: 2-7-1 COMBINATION LAMP (F,R) TURN SIGNAL LAMP (R) 21W SIDE MARKER LAMP (R) 5W
COMBINATION LAMP (R,R)
G
L07 GR
L07 GR
G
Y
L01 BY
L10 GY
GR
L01 BY
GY
L09 WR
R
N B
HEAD LAMP (R) 60/55W
R(Hi)
L04 1.25RW
W(Lo)
L03 1.25RB
TURN SIGNAL LAMP (R) 21W STOP LAMP (R) 21W TAIL LAMP (R) 5W BACKUP LAMP (R) 21W
N B L05 1.25RG
R
HEAD LAMP (L) 60/55W
FLOOD LAMP (R) 55W
B
N B R(Hi)
L04 1.25RW
W(Lo)
L03 1.25RB
L05 1.25RG
R
FLOOD LAMP (L) 55W
B
N B L09 WR
COMBINATION LAMP (F,L) TURN SIGNAL LAMP (L) 21W SIDE MARKER LAMP (L) 5W
L08 G
Y
L01 BY
GY G GR TURN SIGNAL SWITCH
R B
COMBINATION LAMP (R,L)
G(R)
L07 GR
GR(L)
N
L16 W
Y
BACKUP BUZZER
N B
TURN SIGNAL SWITCH L
G
L08 G
GY
L06 LY
R
L09 WR
R
L01 BY
RY
L10 GY
GR
L08 G
G
BACKUP LAMP (L) 21W TAIL LAMP (L) 5W STOP LAMP (L) 21W TURN SIGNAL LAMP (L) 21W
N B L08 G L07 GR L04 2RW L03 2RB L01 BY
L10 GY
L05 2RG
L09 WR P15 2RY
BACKUP BUZZER SWITCH
FLASHER UNIT L07 GR L08 G
3
FLOOD LAMP SWITCH POSITION CONNECTION
L06 LY
2 6
1
5
4
L L06 LY
E
B
L06 LY
2-3,5-6
P15 RY
OFF
HAZARD SWITCH L05 2RG
LIGHTING SWITCH POSITION CONNECTION 2-3,5-6
B
P16 WB
FUSE BOX (2)
1-2,4-5
ST
P19 LR B
R1
R2
ACC
ON
BR
C
P13 2WG
P15 2RY
P16 WB
FUSE BOX (1)
NO
COM
BR
E
P11 LgR
OFF HT
BATTERY RELAY
STARTER SWITCH STARTER SWITCH B
ACC B R
C
P11 LgR N B
OFF ON
AV60 B(HEB 60)
N B
P04 5W
LIGHTING LO-HI SWITCH
2-3,5-6
P09 5WR
7
W
P04 5W
6
CONNECTION
65A
5
POSITION
P03 5W
3 4
L02 2Y
65A
2
P14 YR
N B
LIGHTING LO-HI SWITCH
1
L10 GY
FOOT BRAKE SWITCH
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
L04 2RW
R
P22 Y
P13 2WG
LIGHTING SWITCH L03 2RB
L11 O
B
N B
P09 5WR
7
W
FLOOD LAMP SWITCH
P09 5WR
6
1-2,4-5
P14 YR
P08 5WR
5
2-3,4-5
OFF
5 7
P22 Y
3 4
SIDE MARKER LIGHT
6
TO PARKING BRAKE SWITCH
P15 2RY
P11 LgR
L02 2Y
P13 2WG
2
3 4
P19 LR
L01 BY
2
1
N/A 24 N/A 23 N/A 22 N/A 21 5A 20 5A 19 20A 18 5A 17 5A 16 15A 15 5A 14 20A 13
1
L09 WR
1-2,4-5
AV60 B(HEB 60)
ST
+ 12V 115D31R BATTERY
SW654-10006
10-064
TROUBLESHOOTING
2-7-7. Stop lamp does not light Reference Fig. : 2-7-1 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.
Replace each bulb.
2. Foot Brake Switch
Replace foot brake (1) W hen starter switch is ON, measure voltage between foot brake switch terminal inlet wire WB and chassis switch. ground. Standard voltage : 12 V or more (2) W hen starter switch is ON while foot brake is depressed, measure voltage between foot brake switch terminal outlet wire GY and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, foot brake switch is faulty.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-065
TROUBLESHOOTING
Fig.: 2-7-2
3
4
6 10
7 11
8 12
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
12V BATT (12V)
12V
KEY SW
TA pulse (square wave)
Temperature sensor
Engine speed 2 Engine speed 3 Engine speed 4
2-3,5-6 2-3,4-5
OFF
1-2,4-5
12V
Tachometer
Movement
Fuel meter
Movement
Temperature meter
LCD
Hour meter
EEPROM
Input interface
Engine speed 1
Frequency divider selector
TA pulse (pickup)
LIGHTING SWITCH POSITION CONNECTION
Movement
Input interface
Fuel sensor
SIDE MARKER LIGHT
5V power supply
Power excitation circuit
CPU
2
5 9
GROUND REV. PULSE INPUT 2 FUEL METER TEMPERATURE METER LAMP CHECK PARKING BRAKE HYD. OIL FILTER WARNING ENGINE OIL PRESS. WARNING CHARGE WARNING PREHEATING REV. RATIO SEL.1 (OPEN) REV. RATIO SEL.2 (GND) REV. RATIO SEL.3 (OPEN) REV. RATIO SEL.4 (OPEN) COOLANT TEMP. SEL.1 (OPEN) COOLANT TEMP. SEL.2 (OPEN)
Output interface
1
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
CAN interface
BATTERY 12V (+) BATTERY 24V (+) STARTER SWITCH (ACC) REV. PULSE INPUT 1 COMBI. METER ILLUMI. TURN SIGNAL (R) TURN SIGNAL (L) SIDE MARKER LAMP FLOOD LAMP WATER SPRAY LIQUID SPRAY VIBRATOR COMBINATION METER SWP12M SWP16F
AD input interface TA input interface
1 2 3 4 5 6 7 8 9 10 11 12
Illumination LED
Position lamp
Water spray indicator Liquid spray indicator Position lamp indicator Flood lamp indicator
Backlight Turn signal (R)
L02 2Y
2
P13 2WG
3 4
5
P13 2WG
6
7
Vibration Liquid spray Water spray
N B
LIGHTING SWITCH
Flood lamp Glow plug Parking brake
16_16M
15_16M
14_16M
13_16M
12_16M
9_16M
10_16M
11_16M
8_16M
7_16M
Engine charge warning Engine oil pressure Hydraulic filter Lamp check
N B
K03 WY
5_16M
6_16M
K10 LR
3_16M
4_16M
K03 WY
K08 GB
1_16M
2_16M
V34 BrY
N B B
K09 P
12_12F
9_12F
10_12F
11_12F
8_12F
7_12F
6_12F
L01 BY
5_12F
3_12F
1_12F
4_12F
L01 BY
V13 LgR
P05 BW
2_12F
COMBINATION METER
Vibration indicator Turn signal indicator (L) Turn signal indicator (R) Parking brake indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator
Output interface
TO LIGHTING LO-HI SWITCH
Turn signal (L)
1
Input interface
L01 BY
Coolant temperature 1 Coolant temperature 2
Y
System configuration diagram
N B K10 LR
FUEL GAUGE UNIT THERMO UNIT
Note:
G
The circuit in the dashed box is not mounted.
HYDRAULIC FILTER SWITCH
V13 LgR
N B
4
V34 BrY
5
3 V75 BrR
2
1
K03 WY P11 LgR
TO STARTER MOTOR
L12 LB 4
2 6 5
L R B
E
P13 2WG
ALTERNATOR
L13 GrB V75 BrR N B
FUSE BOX (1)
P09 5WR
1
P09 5WR
3
L11 O
P24 15B
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
TO FOOT BRAKE SWITCH TO COMBINATION METER
FUSE BOX (2)
P19 LR
TO PARKING BRAKE SOLENOID, SERVO BYPASS SOLENOID
P04 5W
N/A 24 N/A 23 N/A 22 N/A 21 5A 20 5A 19 20A 18 5A 17 5A 16 15A 15 5A 14 20A 13
P05 BW
SPEED PULSE ON/OFF RELAY
PARKING BRAKE SWITCH
P09 5WR
ST
P11 LgR
P19 LR
P04 5W
P04 5W
B
R1
R2
ACC
65A 65A
P08 5WR
P03 5W NO
COM
BR
E
P11 LgR BR
C
BATTERY RELAY
ON
AV60 B(HEB 60)
TO ECU
V13 LgR
P05 BW
P11 LgR
OFF
N B
HT
STARTER SWITCH STARTER SWITCH B
ACC B R
AV60 B(HEB 60)
C
ON
+ 12V 115D31R
ST
BATTERY
OFF
SW654-10007
10-066
TROUBLESHOOTING
2-7-8. Illumination of combination meter does not light Reference Fig. : 2-7-2 Check point
Check/Cause
Action
1. Harness
• Measure resistance between lighting switch terminal 3 wire BY and combination meter connector terminal wire No.L01 wire BY. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2. Combination Meter (Combination meter illumination)
(1) W hen starter switch is ON, measure voltage between combination meter terminal wires and ground terminal wire. • Battery 12 V (+) terminal wire No.P05 inlet wire BW and ground terminal wire No.N wire B • Starter switch (ACC) terminal wire No.V13 inlet wire LgR and ground terminal wire No.N wire B Standard voltage : 12 V or more (2) W hen starter switch is ON and lighting switch is “SIDE MARKER LIGHT”, measure voltage between combination meter illumination terminal wire No.L01 inlet wire BY and chassis 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.
2-7-9. Combination meter warning lamp or indicator lamp is abnormal Reference Fig. : 2-7-2 Check point 1. Combination Meter (Lamp check)
Check/Cause (1) W hen starter switch is ON, measure voltage between combination meter terminal wires and ground terminal wire. • Battery 12 V (+) terminal wire No.P05 inlet wire BW and ground terminal wire No.N wire B • Starter switch (ACC) terminal wire No.V13 inlet wire LgR and ground terminal wire No.N wire B Standard voltage : 12 V or more (2) W hen starter switch is ON, check that parking brake indicator lamp, hydraulic oil filter warning lamp, engine oil pressure warning lamp and charge warning lamp illuminate and then go out after starting engine. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, combination meter is faulty.
Action Replace combination meter.
(NOTICE) • Since engine cannot start unless parking brake switch is applied, parking brake indicator lamp does not go out even after starting engine.
10-067
TROUBLESHOOTING
Fig.: 2-7-2
3
4
6 10
7 11
8 12
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
12V BATT (12V)
12V
KEY SW
TA pulse (square wave)
Temperature sensor
Engine speed 2 Engine speed 3 Engine speed 4
2-3,5-6 2-3,4-5
OFF
1-2,4-5
12V
Tachometer
Movement
Fuel meter
Movement
Temperature meter
LCD
Hour meter
EEPROM
Input interface
Engine speed 1
Frequency divider selector
TA pulse (pickup)
LIGHTING SWITCH POSITION CONNECTION
Movement
Input interface
Fuel sensor
SIDE MARKER LIGHT
5V power supply
Power excitation circuit
CPU
2
5 9
GROUND REV. PULSE INPUT 2 FUEL METER TEMPERATURE METER LAMP CHECK PARKING BRAKE HYD. OIL FILTER WARNING ENGINE OIL PRESS. WARNING CHARGE WARNING PREHEATING REV. RATIO SEL.1 (OPEN) REV. RATIO SEL.2 (GND) REV. RATIO SEL.3 (OPEN) REV. RATIO SEL.4 (OPEN) COOLANT TEMP. SEL.1 (OPEN) COOLANT TEMP. SEL.2 (OPEN)
Output interface
1
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
CAN interface
BATTERY 12V (+) BATTERY 24V (+) STARTER SWITCH (ACC) REV. PULSE INPUT 1 COMBI. METER ILLUMI. TURN SIGNAL (R) TURN SIGNAL (L) SIDE MARKER LAMP FLOOD LAMP WATER SPRAY LIQUID SPRAY VIBRATOR COMBINATION METER SWP12M SWP16F
AD input interface TA input interface
1 2 3 4 5 6 7 8 9 10 11 12
Illumination LED
Position lamp
Water spray indicator Liquid spray indicator Position lamp indicator Flood lamp indicator
Backlight Turn signal (R)
L02 2Y
2
P13 2WG
3 4
5
P13 2WG
6
7
Vibration Liquid spray Water spray
N B
LIGHTING SWITCH
Flood lamp Glow plug Parking brake
16_16M
15_16M
14_16M
13_16M
12_16M
9_16M
10_16M
11_16M
8_16M
7_16M
Engine charge warning Engine oil pressure Hydraulic filter Lamp check
N B
K03 WY
5_16M
6_16M
K10 LR
3_16M
4_16M
K03 WY
K08 GB
1_16M
2_16M
V34 BrY
N B B
K09 P
12_12F
9_12F
10_12F
11_12F
8_12F
7_12F
6_12F
L01 BY
5_12F
3_12F
1_12F
4_12F
L01 BY
V13 LgR
P05 BW
2_12F
COMBINATION METER
Vibration indicator Turn signal indicator (L) Turn signal indicator (R) Parking brake indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator
Output interface
TO LIGHTING LO-HI SWITCH
Turn signal (L)
1
Input interface
L01 BY
Coolant temperature 1 Coolant temperature 2
Y
System configuration diagram
N B K10 LR
FUEL GAUGE UNIT THERMO UNIT
Note:
G
The circuit in the dashed box is not mounted.
HYDRAULIC FILTER SWITCH
V13 LgR
N B
4
V34 BrY
5
3 V75 BrR
2
1
K03 WY P11 LgR
TO STARTER MOTOR
L12 LB 4
2 6 5
L R B
E
P13 2WG
ALTERNATOR
L13 GrB V75 BrR N B
FUSE BOX (1)
P09 5WR
1
P09 5WR
3
L11 O
P24 15B
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
TO FOOT BRAKE SWITCH TO COMBINATION METER
FUSE BOX (2)
P19 LR
TO PARKING BRAKE SOLENOID, SERVO BYPASS SOLENOID
P04 5W
N/A 24 N/A 23 N/A 22 N/A 21 5A 20 5A 19 20A 18 5A 17 5A 16 15A 15 5A 14 20A 13
P05 BW
SPEED PULSE ON/OFF RELAY
PARKING BRAKE SWITCH
P09 5WR
ST
P11 LgR
P19 LR
P04 5W
P04 5W
B
R1
R2
ACC
65A 65A
P08 5WR
P03 5W NO
COM
BR
E
P11 LgR BR
C
BATTERY RELAY
ON
AV60 B(HEB 60)
TO ECU
V13 LgR
P05 BW
P11 LgR
OFF
N B
HT
STARTER SWITCH STARTER SWITCH B
ACC B R
AV60 B(HEB 60)
C
ON
+ 12V 115D31R
ST
BATTERY
OFF
SW654-10007
10-068
TROUBLESHOOTING
2-7-10. Tachometer reading is abnormal Reference Fig. : 2-7-2 Check point
Check/Cause
Action
1. C ombination Meter (Tachometer)
(1) W hen starter switch is ON, measure voltage between Replace combination combination meter terminal wires and ground terminal meter. wire. • Battery 12 V (+) terminal wire No.P05 inlet wire BW and ground terminal wire No.N wire B • Starter switch (ACC) terminal wire No.V13 inlet wire LgR and ground terminal wire No.N wire B Standard voltage : 12 V or more (2) C heck that combination meter REV. ratio SEL.2 terminal wire No.N wire B is grounded. (3) S tart engine and measure pulse between combination meter REV. pulse input.2 terminal wire No.V34 wire BrY and chassis ground. Standard pulse : 3 pulses/rotation of engine • If above item is OK and tachometer reading is NG, combination meter is faulty.
2. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2-7-11. Hour meter is abnormal Reference Fig. : 2-7-2 Check point 1. C ombination Meter (Hour meter)
Check/Cause • When starter switch is ON, measure voltage between combination meter terminal wires and ground terminal wire. • Battery 12 V (+) terminal wire No.P05 inlet wire BW and ground terminal wire No.N wire B • Starter switch (ACC) terminal wire No.V13 inlet wire LgR and ground terminal wire No.N wire B Standard voltage : 12 V or more • If no abnormality is found, combination meter is faulty.
Action Replace combination meter.
10-069
TROUBLESHOOTING
Fig.: 2-7-2
3
4
6 10
7 11
8 12
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
12V BATT (12V)
12V
KEY SW
TA pulse (square wave)
Temperature sensor
Engine speed 2 Engine speed 3 Engine speed 4
2-3,5-6 2-3,4-5
OFF
1-2,4-5
12V
Tachometer
Movement
Fuel meter
Movement
Temperature meter
LCD
Hour meter
EEPROM
Input interface
Engine speed 1
Frequency divider selector
TA pulse (pickup)
LIGHTING SWITCH POSITION CONNECTION
Movement
Input interface
Fuel sensor
SIDE MARKER LIGHT
5V power supply
Power excitation circuit
CPU
2
5 9
GROUND REV. PULSE INPUT 2 FUEL METER TEMPERATURE METER LAMP CHECK PARKING BRAKE HYD. OIL FILTER WARNING ENGINE OIL PRESS. WARNING CHARGE WARNING PREHEATING REV. RATIO SEL.1 (OPEN) REV. RATIO SEL.2 (GND) REV. RATIO SEL.3 (OPEN) REV. RATIO SEL.4 (OPEN) COOLANT TEMP. SEL.1 (OPEN) COOLANT TEMP. SEL.2 (OPEN)
Output interface
1
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
CAN interface
BATTERY 12V (+) BATTERY 24V (+) STARTER SWITCH (ACC) REV. PULSE INPUT 1 COMBI. METER ILLUMI. TURN SIGNAL (R) TURN SIGNAL (L) SIDE MARKER LAMP FLOOD LAMP WATER SPRAY LIQUID SPRAY VIBRATOR COMBINATION METER SWP12M SWP16F
AD input interface TA input interface
1 2 3 4 5 6 7 8 9 10 11 12
Illumination LED
Position lamp
Water spray indicator Liquid spray indicator Position lamp indicator Flood lamp indicator
Backlight Turn signal (R)
L02 2Y
2
P13 2WG
3 4
5
P13 2WG
6
7
Vibration Liquid spray Water spray
N B
LIGHTING SWITCH
Flood lamp Glow plug Parking brake
16_16M
15_16M
14_16M
13_16M
12_16M
9_16M
10_16M
11_16M
8_16M
7_16M
Engine charge warning Engine oil pressure Hydraulic filter Lamp check
N B
K03 WY
5_16M
6_16M
K10 LR
3_16M
4_16M
K03 WY
K08 GB
1_16M
2_16M
V34 BrY
N B B
K09 P
12_12F
9_12F
10_12F
11_12F
8_12F
7_12F
6_12F
L01 BY
5_12F
3_12F
1_12F
4_12F
L01 BY
V13 LgR
P05 BW
2_12F
COMBINATION METER
Vibration indicator Turn signal indicator (L) Turn signal indicator (R) Parking brake indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator
Output interface
TO LIGHTING LO-HI SWITCH
Turn signal (L)
1
Input interface
L01 BY
Coolant temperature 1 Coolant temperature 2
Y
System configuration diagram
N B K10 LR
FUEL GAUGE UNIT THERMO UNIT
Note:
G
The circuit in the dashed box is not mounted.
HYDRAULIC FILTER SWITCH
V13 LgR
N B
4
V34 BrY
5
3 V75 BrR
2
1
K03 WY P11 LgR
TO STARTER MOTOR
L12 LB 4
2 6 5
L R B
E
P13 2WG
ALTERNATOR
L13 GrB V75 BrR N B
FUSE BOX (1)
P09 5WR
1
P09 5WR
3
L11 O
P24 15B
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
TO FOOT BRAKE SWITCH TO COMBINATION METER
FUSE BOX (2)
P19 LR
TO PARKING BRAKE SOLENOID, SERVO BYPASS SOLENOID
P04 5W
N/A 24 N/A 23 N/A 22 N/A 21 5A 20 5A 19 20A 18 5A 17 5A 16 15A 15 5A 14 20A 13
P05 BW
SPEED PULSE ON/OFF RELAY
PARKING BRAKE SWITCH
P09 5WR
ST
P11 LgR
P19 LR
P04 5W
P04 5W
B
R1
R2
ACC
65A 65A
P08 5WR
P03 5W NO
COM
BR
E
P11 LgR BR
C
BATTERY RELAY
ON
AV60 B(HEB 60)
TO ECU
V13 LgR
P05 BW
P11 LgR
OFF
N B
HT
STARTER SWITCH STARTER SWITCH B
ACC B R
AV60 B(HEB 60)
C
ON
+ 12V 115D31R
ST
BATTERY
OFF
SW654-10007
10-070
TROUBLESHOOTING
2-7-12. Temperature meter is abnormal Reference Fig. : 2-7-2 Check point
Check/Cause
Action
1. Thermo Unit
• Disconnect harness and measure resistance of thermo unit. Standard resistance : 164.6 Ω (at unit temperature of 50℃) 26.44 Ω (at unit temperature of 103℃) • If resistance is abnormal, thermo unit is faulty.
Replace thermo unit.
2. Combination Meter (Temperature meter)
• When starter switch is ON, measure voltage between combination meter terminal wires and ground terminal wire. • Battery 12 V (+) terminal wire No.P05 inlet wire BW and ground terminal wire No.N wire B • Starter switch (ACC) terminal wire No.V13 inlet wire LgR and ground terminal wire No.N wire B Standard voltage : 12 V or more • If no abnormality is found, combination meter is faulty.
Replace combination meter.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2-7-13. Fuel meter is abnormal Reference Fig. : 2-7-2 Check point
Check/Cause
Action
1. Fuel Gauge Unit
• Disconnect harness and measure resistance of fuel gauge Replace fuel gauge unit. unit. Standard resistance : 13.5 Ω (with float in “F”) 80.0 Ω (with float in “E”) • If resistance is abnormal, fuel gauge unit is faulty.
2. Combination Meter (Fuel meter)
• When starter switch is ON, measure voltage between combination meter terminal wires and ground terminal wire. • Battery 12 V (+) terminal wire No.P05 inlet wire BW and ground terminal wire No.N wire B • Starter switch (ACC) terminal wire No.V13 inlet wire LgR and ground terminal wire No.N wire B Standard voltage : 12 V or more • If no abnormality is found, combination meter is faulty.
Replace combination meter.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-071
TROUBLESHOOTING
Fig.: 2-7-2
3
4
6 10
7 11
8 12
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
12V BATT (12V)
12V
KEY SW
TA pulse (square wave)
Temperature sensor
Engine speed 2 Engine speed 3 Engine speed 4
2-3,5-6 2-3,4-5
OFF
1-2,4-5
12V
Tachometer
Movement
Fuel meter
Movement
Temperature meter
LCD
Hour meter
EEPROM
Input interface
Engine speed 1
Frequency divider selector
TA pulse (pickup)
LIGHTING SWITCH POSITION CONNECTION
Movement
Input interface
Fuel sensor
SIDE MARKER LIGHT
5V power supply
Power excitation circuit
CPU
2
5 9
GROUND REV. PULSE INPUT 2 FUEL METER TEMPERATURE METER LAMP CHECK PARKING BRAKE HYD. OIL FILTER WARNING ENGINE OIL PRESS. WARNING CHARGE WARNING PREHEATING REV. RATIO SEL.1 (OPEN) REV. RATIO SEL.2 (GND) REV. RATIO SEL.3 (OPEN) REV. RATIO SEL.4 (OPEN) COOLANT TEMP. SEL.1 (OPEN) COOLANT TEMP. SEL.2 (OPEN)
Output interface
1
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
CAN interface
BATTERY 12V (+) BATTERY 24V (+) STARTER SWITCH (ACC) REV. PULSE INPUT 1 COMBI. METER ILLUMI. TURN SIGNAL (R) TURN SIGNAL (L) SIDE MARKER LAMP FLOOD LAMP WATER SPRAY LIQUID SPRAY VIBRATOR COMBINATION METER SWP12M SWP16F
AD input interface TA input interface
1 2 3 4 5 6 7 8 9 10 11 12
Illumination LED
Position lamp
Water spray indicator Liquid spray indicator Position lamp indicator Flood lamp indicator
Backlight Turn signal (R)
L02 2Y
2
P13 2WG
3 4
5
P13 2WG
6
7
Vibration Liquid spray Water spray
N B
LIGHTING SWITCH
Flood lamp Glow plug Parking brake
16_16M
15_16M
14_16M
13_16M
12_16M
9_16M
10_16M
11_16M
8_16M
7_16M
Engine charge warning Engine oil pressure Hydraulic filter Lamp check
N B
K03 WY
5_16M
6_16M
K10 LR
3_16M
4_16M
K03 WY
K08 GB
1_16M
2_16M
V34 BrY
N B B
K09 P
12_12F
9_12F
10_12F
11_12F
8_12F
7_12F
6_12F
L01 BY
5_12F
3_12F
1_12F
4_12F
L01 BY
V13 LgR
P05 BW
2_12F
COMBINATION METER
Vibration indicator Turn signal indicator (L) Turn signal indicator (R) Parking brake indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator
Output interface
TO LIGHTING LO-HI SWITCH
Turn signal (L)
1
Input interface
L01 BY
Coolant temperature 1 Coolant temperature 2
Y
System configuration diagram
N B K10 LR
FUEL GAUGE UNIT THERMO UNIT
Note:
G
The circuit in the dashed box is not mounted.
HYDRAULIC FILTER SWITCH
V13 LgR
N B
4
V34 BrY
5
3 V75 BrR
2
1
K03 WY P11 LgR
TO STARTER MOTOR
L12 LB 4
2 6 5
L R B
E
P13 2WG
ALTERNATOR
L13 GrB V75 BrR N B
FUSE BOX (1)
P09 5WR
1
P09 5WR
3
L11 O
P24 15B
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
TO FOOT BRAKE SWITCH TO COMBINATION METER
FUSE BOX (2)
P19 LR
TO PARKING BRAKE SOLENOID, SERVO BYPASS SOLENOID
P04 5W
N/A 24 N/A 23 N/A 22 N/A 21 5A 20 5A 19 20A 18 5A 17 5A 16 15A 15 5A 14 20A 13
P05 BW
SPEED PULSE ON/OFF RELAY
PARKING BRAKE SWITCH
P09 5WR
ST
P11 LgR
P19 LR
P04 5W
P04 5W
B
R1
R2
ACC
65A 65A
P08 5WR
P03 5W NO
COM
BR
E
P11 LgR BR
C
BATTERY RELAY
ON
AV60 B(HEB 60)
TO ECU
V13 LgR
P05 BW
P11 LgR
OFF
N B
HT
STARTER SWITCH STARTER SWITCH B
ACC B R
AV60 B(HEB 60)
C
ON
+ 12V 115D31R
ST
BATTERY
OFF
SW654-10007
10-072
TROUBLESHOOTING
2-7-14. Hydraulic oil filter warning lamp remains ON Reference Fig. : 2-7-2 Check point
Check/Cause
Action
1. Harness
• Disconnect connectors between combination meter and Repair or replace hydraulic oil filter switch. harness. • Measure resistance between terminals and chassis ground. • Hydraulic oil filter switch terminal wire LR and chassis ground. • Combination meter connector terminal wire No.K10 wire LR and chassis ground. Standard resistance : 100k Ω or more • If resistance is abnormal, harness is faulty.
2. Hydraulic Oil Filter Switch
• When starter switch is OFF, check continuity between Replace hydraulic oil hydraulic oil filter switch inlet terminal wire LR and chassis filter switch. ground. There is no continuity in normal condition. • If there is continuity, hydraulic oil filter switch is faulty.
3. Combination Meter (Hydraulic oil filter warning)
(1) W hen starter switch is ON, measure voltage between combination meter terminal wires and ground terminal wire. • Battery terminal wire No.P05 inlet wire BW and ground terminal wire No.N wire B. • Starter switch (ACC) terminal wire No.V13 inlet wire LgR and ground terminal wire No.N wire B. Standard voltage : 12 V or more (2) W hen starter switch is ON, measure voltage between combination meter hydraulic oil filter warning terminal outlet wire No.K10 wire LR and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK but hydraulic oil filter warning lamp remains on after starting engine, combination meter is faulty.
Replace combination meter.
2-7-15. Charge warning lamp remains ON • Check with engine running. Reference Fig. : 2-7-2 Check point 1. Harness
Check/Cause • Disconnect connectors between combination meter and alternator terminal L. • Measure resistance between terminals and chassis ground. • Combination meter connector terminal wire No.K03 wire WY and chassis ground. • Alternator terminal L wire WY and chassis ground Standard resistance : 100k Ω or more • If resistance is abnormal, harness is faulty.
• Measure voltage between combination meter charge 2. Combination Meter (Charge warning lamp) warning terminal wire No.K03 outlet wire WY and chassis ground. Standard voltage : 12 V or more • If no abnormality is found, combination meter is faulty.
Action Repair or replace harness.
Replace combination meter.
10-073
TROUBLESHOOTING
Fig.: 2-7-3
1
1
2
3
4
5
6
7
8
9
10
11
12
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
GROUND REV. PULSE INPUT 2 FUEL METER TEMPERATURE METER LAMP CHECK PARKING BRAKE HYD. OIL FILTER WARNING ENGINE OIL PRESS. WARNING CHARGE WARNING PREHEATING REV. RATIO SEL.1 (OPEN) REV. RATIO SEL.2 (GND) REV. RATIO SEL.3 (OPEN) REV. RATIO SEL.4 (OPEN) COOLANT TEMP. SEL.1 (OPEN) COOLANT TEMP. SEL.2 (OPEN)
16_16M
15_16M
14_16M
13_16M
12_16M
11_16M
9_16M
10_16M
8_16M
7_16M
6_16M
5_16M
4_16M
3_16M
1_16M N B
K13 OG
2_16M
12_12F
11_12F
9_12F
10_12F
8_12F
7_12F
6_12F
5_12F
4_12F
3_12F
1_12F
COMBINATION METER 2_12F
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
V13 LgR
BATTERY 12V (+) BATTERY 24V (+) STARTER SWITCH (ACC) REV. PULSE INPUT 1 COMBI. METER ILLUMI. TURN SIGNAL (R) TURN SIGNAL (L) SIDE MARKER LAMP FLOOD LAMP WATER SPRAY LIQUID SPRAY VIBRATOR COMBINATION METER SWP12M SWP16F
P05 BW
1 2 3 4 5 6 7 8 9 10 11 12
TO F-R LEVER SWITCH
G10 YG
R
G09 Br
W
VIBRATION AUTO SWITCH P18 RL
B
12V BATT (12V)
Tachometer
Movement
Fuel meter
Frequency divider selector
Fuel sensor Temperature sensor
Engine speed 4
VIBRATION MODE
AUTO
Turn signal (L)
Input interface
Engine charge warning Engine oil pressure Hydraulic filter
(LOW) (OSCILLATION)
sol.b
Br
G06 BR
NC COM
F-R LEVER VIBRATION SWITCH (L)
(HIGH) (NORMAL)
3
G06 BR
2 6
1
5
4
G06 BR
VIBRATION SWITCH
sol.a
N B
Vibration indicator Turn signal indicator (L) Turn signal indicator (R) Parking brake indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator
Output interface
Vibration Liquid spray
Parking brake
NO
1-2
G07 LW
Water spray indicator Liquid spray indicator Position lamp indicator Flood lamp indicator
Backlight
Glow plug
W
CONNECTION
Illumination LED
Turn signal (R)
Flood lamp
G
G05 W
G08 OW
Position lamp
Water spray
G04 YW
F-R LEVER VIBRATION SWITCH (R)
VIBRATION MODE CHANGE SWITCH
Hour meter
W G
1-3
Output interface
Engine speed 3
COM NO
CPU
Engine speed 2
Temperature meter
NC
Br
VIBRATION MODE CHANGE SWITCH
EEPROM
Input interface
Engine speed 1
LCD
G03 L
3
G07 LW
TA pulse (square wave)
Movement
G06 BR
2
G09 Br 1
AD input interface TA input interface
TA pulse (pickup)
12V
Movement
Input interface
G08 OW
KEY SW
CAN interface
12V
5V power supply
Power excitation circuit
N B
SW654
VIBRATOR SOLENOID
VIBRATION SWITCH POSITION
CONNECTION 1-2,4-6
(LOW)
SW654ND
VIBRATION SWITCH POSITION
CONNECTION 1-2,4-6
(OSCILLATION)
1-3,4-6 1-3,4-5
(HIGH)
1-3,4-6 1-3,4-5
(NORMAL)
Lamp check Coolant temperature 1
DIODE UNIT
Coolant temperature 2 System configuration diagram Note:
A B
The circuit in the dashed box is not mounted.
C D
E F G H
I
A E
F
B C
G
D I
H
K13 OG G07 LW
P18 RL
V13 LgR
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
B OFF ON ST
ACC B R
ST
B
R1
R2
P11 LgR
P19 LR
C
ACC
N B
65A 65A
P03 5W
AV60 B(HEB 60)
P08 5WR
+ 12V 115D31R BATTERY
ON OFF HT
STARTER SWITCH
10-074
C
E
P11 LgR
P09 5WR
BR
BR
BATTERY RELAY
P04 5W
STARTER SWITCH
COM
AV60 B(HEB 60)
FUSE BOX (1)
NO P11 LgR
P09 5WR
P09 5WR
P19 LR
FUSE BOX (2)
P04 5W
N/A 24 N/A 23 N/A 22 N/A 21 5A 20 5A 19 20A 18 5A 17 5A 16 15A 15 5A 14 20A 13
P05 BW
G08 OW
SW654-10008
TROUBLESHOOTING
2-7-16. Vibration indicator lamp does not light • Check that vibrator can be operated. Reference Fig. : 2-7-3 Check point
Check/Cause
Action
1. Harness
(1) M easure resistance between vibration switch terminal 5 Repair or replace wire LW and diode unit terminal E wire LW. harness. Standard resistance : 10 Ω or less (2) M easure resistance between vibration switch terminal 2 wire OW and diode unit terminal A wire OW. Standard resistance : 10 Ω or less (3) M easure resistance between diode unit terminal F wire OG and combination meter connector terminal wire No. K13 wire OG. Standard resistance : 10 Ω or less • If above item (1), (2) or (3) is NG, harness is faulty.
2. Diode Unit
(1) W hen starter switch is ON and vibration switch is in below position, measure voltage between diode unit terminal A inlet wire OW and chassis ground. SW654 :“ ” (LOW) SW654ND : “ ” (OSCILLATION) Standard voltage : 12 V or more (2) When starter switch is ON and vibration switch is in below position, measure voltage between diode unit terminal E inlet wire LW and chassis ground. SW654 :“ SW654ND : “
Replace diode unit.
” (HIGH) ” (NORMAL)
Standard voltage : 12 V or more (3) W hen starter switch is ON, measure voltage between diode unit terminal F outlet wire OG and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, diode unit is faulty. 3. Combination Meter (Vibration indicator lamp)
(1) W hen starter switch is ON, measure voltage between combination meter terminal wires and ground terminal wire. • Battery 12 V (+) terminal wire No.P05 inlet wire BW and ground terminal wire No.N wire B • Starter switch (ACC) terminal wire No.V13 inlet wire LgR and ground terminal wire No.N wire B Standard voltage : 12 V or more (2) W hen starter switch is ON, F-R lever and vibration mode change switch and vibration switch in below position, measure voltage between combination meter vibration terminal wire No. K13 inlet wire OG and chassis ground. F-R lever : “F” or “R” Vibration mode change switch : “AUTO” Vibration switch : Must not be “ ” Standard voltage : 12 V or more • If above items (1) and (2) are OK and vibration indicator lamp does not light, combination meter is faulty.
Replace combination meter.
10-075
TROUBLESHOOTING
Fig.: 2-7-4
4
7 11
8 12
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
N B 12V
KEY SW
Movement
Frequency divider selector
AD input interface TA input interface
TA pulse (pickup) TA pulse (square wave)
Fuel sensor Temperature sensor
2
1
4
3
Engine speed 4
Fuel meter
Movement
Temperature meter
LCD
Hour meter
G09 Br
G09 Br
4
N B
5
3
2
1
WATER SPRAY MODE SELECT SWITCH POSITION CONNECTION TIMER 1-2,4-6 CONT 1-3,4-6 AUTO 1-3,4-5
2 1
3 5
4
6
W07 LgY W08 Lg W09 GrW
WATER SPRAY MODE SELECT SWITCH Illumination LED Water spray indicator Liquid spray indicator Position lamp indicator Flood lamp indicator
Backlight
Turn signal (L)
Input interface
Water spray Flood lamp Glow plug Parking brake
Vibration indicator Turn signal indicator (L) Turn signal indicator (R) Parking brake indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator
Output interface
Vibration Liquid spray
Engine charge warning Engine oil pressure Hydraulic filter
4
W04 2LR
3
5
N
1
2
P12 2WY W06 LgB
DIODE UNIT A B
C D
E F G H
Lamp check
I
A E
F
B C
G
D I
H
W03 GrY
W06 LgB
W01 2LW
3
5
N
1
2
W03 GrY
W06 LgB
ON ST
C
B
R2
ACC
ON
W10 Gr 1
W01 2LW
P12 2WY P07 3WL
W05 2W
P09 5WR
W05 2W
BR
C
P04 5W P07 3WL
OFF P09 5WR
HT
STARTER SWITCH
10-076
FUSE BOX (1)
W02 2WR
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1 P09 5WR
R1
2
NO
COM
BR
E
P11 LgR
W02 2WR
P11 LgR
P19 LR ST
W04 2LR
P18 RL
V13 LgR
P05 BW P04 5W
P19 LR
STARTER SWITCH
3
The circuit in the dashed box is not mounted.
N/A 24 N/A 23 N/A 22 N/A 21 5A 20 5A 19 20A 18 5A 17 5A 16 15A 15 5A 14 20A 13 FUSE BOX (2)
W10 Gr 1
WATER SPRAY SWITCH (F )
System configuration diagram Note:
2
B
WATER SPRAY RELAY (F)
W03 GrY
3
WATER SPRAY SWITCH (R)
4
P12 2WY
K04 PG
Coolant temperature 2
B
WATER SPRAY RELAY (R)
Coolant temperature 1
OFF
W10 Gr W09 GrW
WATER SPRAY CHANGE RELAY
P12 WY
Turn signal (R)
ACC B R
16_16M
W08 Lg
W
P12 WY
Position lamp
B
15_16M
14_16M
13_16M
12_16M
G10 YG
VIBRATION AUTO SWITCH
Movement
Output interface
Engine speed 3
W07 LgY
R
CPU
Engine speed 2
B
W07 LgY
EEPROM
Input interface
Engine speed 1
12V
P18 RL
Tachometer
Input interface
CAN interface
12V
5V power supply
Power excitation circuit
9_16M
WATER SPRAY TIMER W08 Lg
BATT (12V)
10_16M
1
11_16M
3
2
8_16M
5_16M
4_16M
3_16M
1_16M
4
N B
2_16M
12_12F
9_12F
10_12F
K04 PG
11_12F
8_12F
7_12F
6_12F
5_12F
4_12F
3_12F
1_12F
2_12F
TO F-R LEVER SWITCH
WATER SPRAY PUMP (R) P
N 2B
WATER SPRAY PUMP (F) P
65A 45A 65A
N 2B P03 5W P06 3WL
BATTERY RELAY P11 LgR N B AV60 B(HEB 60)
AV60 B(HEB 60)
3
6 10
COMBINATION METER 7_16M
2
5 9
GROUND REV. PULSE INPUT 2 FUEL METER TEMPERATURE METER LAMP CHECK PARKING BRAKE HYD. OIL FILTER WARNING ENGINE OIL PRESS. WARNING CHARGE WARNING PREHEATING REV. RATIO SEL.1 (OPEN) REV. RATIO SEL.2 (GND) REV. RATIO SEL.3 (OPEN) REV. RATIO SEL.4 (OPEN) COOLANT TEMP. SEL.1 (OPEN) COOLANT TEMP. SEL.2 (OPEN)
6_16M
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
V13 LgR
BATTERY 12V (+) BATTERY 24V (+) STARTER SWITCH (ACC) REV. PULSE INPUT 1 COMBI. METER ILLUMI. TURN SIGNAL (R) TURN SIGNAL (L) SIDE MARKER LAMP FLOOD LAMP WATER SPRAY LIQUID SPRAY VIBRATOR COMBINATION METER SWP12M SWP16F
P05 BW
1 2 3 4 5 6 7 8 9 10 11 12
+ 12V 115D31R BATTERY
P08 5WR
SW654-10009
TROUBLESHOOTING
2-7-17. Water spray indicator lamp does not light • Check that water spray pump can be activated. Reference Fig. : 2-7-4 Check point
Check/Cause
Action
1. Harness
(1) M easure resistance between water spray switch (F) terminal 2 wire GrY and diode unit terminal I wire GrY. Standard resistance : 10 Ω or less (2) M easure resistance between water spray switch (R) terminal 2 wire LgB and diode unit terminal D wire LgB. Standard resistance : 10 Ω or less (3) M easure resistance between diode unit terminal H wire PG and combination meter connector terminal wire No. K04 wire PG. Standard resistance : 10 Ω or less • If above item (1) , (2) or (3) is NG, harness is faulty.
Repair or replace harness.
2. Diode Unit
(1) W hen starter switch is ON, water spray switch (F) is ON Replace diode unit. and water spray mode select switch is “CONT”, measure voltage between diode unit terminal I inlet wire GrY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON, water spray switch (R) is ON and water spray mode select switch is “CONT”, measure voltage between diode unit terminal D inlet wire LgB and chassis ground. Standard voltage : 12 V or more (3) W hen starter switch is ON, water spray switch (F) or (R) is ON and water spray mode select switch is “CONT” , measure voltage between diode unit terminal H outlet wire PG and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and item (3) is NG, diode unit is faulty.
3. Combination Meter (Water spray indicator lamp)
(1) W hen starter switch is ON, measure voltage between combination meter terminal wires and ground terminal wire. • Battery 12 V (+) terminal wire No.P05 inlet wire BW and ground terminal wire No.N wire B • Starter switch (ACC) terminal wire No.V13 inlet wire LgR and ground terminal wire No.N wire B Standard voltage : 12 V or more (2) W hen starter switch is ON, water spray switch (F) or (R) is ON and water spray mode select switch is “CONT”, measure voltage between combination meter water spray terminal wire No.K04 inlet wire PG and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and water spray indicator lamp does not light, combination meter is faulty.
Replace combination meter.
10-077
TROUBLESHOOTING
Fig.: 2-7-5
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
TO STOP LAMP
1 4
L10 GY
W
N B
5
Frequency divider selector
AD input interface TA input interface
TA pulse (pickup) TA pulse (square wave)
Fuel sensor Temperature sensor
Tachometer
Movement
Fuel meter
Movement
Temperature meter
LCD
Hour meter
L01 BY
TO LIGHTING LO-HI SWITCH
Engine speed 4
16_16M
15_16M
N B
LIGHTING SWITCH POSITION CONNECTION
SIDE MARKER LIGHT
2-3,4-5
OFF
1-2,4-5
FLASHER UNIT L
Turn signal (L)
Liquid spray Input interface
L
Engine charge warning Engine oil pressure Hydraulic filter
R
L08 G
TURN SIGNAL SWITCH
G(R)
L07 GR
GR(L)
L08 G
GY
L06 LY
3 1
5
4
L06 LY
1 3 4
P15 2RY
5
P14 YR
7
N B
FLOOD LAMP SWITCH POSITION CONNECTION
TO TURN SIGNAL LAMP (F,L)(R,L)
System configuration diagram
2
FLOOD LAMP SWITCH
TO TURN SIGNAL LAMP (F,R)(R,R)
Coolant temperature 2
P15 RY
HAZARD SWITCH
6
Lamp check
B
L06 LY
2 6
L05 2RG
Coolant temperature 1
Note:
L07 GR
N
Vibration indicator Turn signal indicator (L) Turn signal indicator (R) Parking brake indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator
Output interface
Vibration
E
L06 LY
GY G GR
Illumination LED
Backlight
Glow plug
P13 2WG
7
P05 BW
Turn signal (R)
Parking brake
5
6
LIGHTING SWITCH
TURN SIGNAL SWITCH
Water spray indicator Liquid spray indicator Position lamp indicator Flood lamp indicator
Flood lamp
P13 2WG
L05 RG
Position lamp
Water spray
2
3 4
V13 LgR
Output interface
Engine speed 3
L02 2Y
EEPROM
CPU
Engine speed 2
1
2-3,5-6
Input interface
Engine speed 1
12V
Movement
Input interface
KEY SW
CAN interface
12V
5V power supply
P16 WB
B
TO PARKING INTERLOCK RELAY, ECU, SPEED PULSE ON/OFF RELAY
12V Power excitation circuit
FOOT BRAKE SWITCH
TO PARKING BRAKE SOLENOID, SERVO BYPASS SOLENOID
V75 BrR
2 6
L12 LB
R
L13 GrB
3
L11 O
L11 O
PARKING BRAKE SWITCH BATT (12V)
14_16M
13_16M
12_16M
9_16M
10_16M
11_16M
8_16M
7_16M
6_16M
5_16M
4_16M
N B
L12 LB
3_16M
1_16M
2_16M
12_12F
9_12F
11_12F
8_12F
7_12F
6_12F
5_12F
4_12F
10_12F
L05 RG
L01 BY
L08 G
L07 GR
L01 BY
1_12F
3_12F
COMBINATION METER
GROUND REV. PULSE INPUT 2 FUEL METER TEMPERATURE METER LAMP CHECK PARKING BRAKE HYD. OIL FILTER WARNING ENGINE OIL PRESS. WARNING CHARGE WARNING PREHEATING REV. RATIO SEL.1 (OPEN) REV. RATIO SEL.2 (GND) REV. RATIO SEL.3 (OPEN) REV. RATIO SEL.4 (OPEN) COOLANT TEMP. SEL.1 (OPEN) COOLANT TEMP. SEL.2 (OPEN)
2_12F
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
V13 LgR
BATTERY 12V (+) BATTERY 24V (+) STARTER SWITCH (ACC) REV. PULSE INPUT 1 COMBI. METER ILLUMI. TURN SIGNAL (R) TURN SIGNAL (L) SIDE MARKER LAMP FLOOD LAMP WATER SPRAY LIQUID SPRAY VIBRATOR COMBINATION METER SWP12M SWP16F
P05 BW
1 2 3 4 5 6 7 8 9 10 11 12
2-3,5-6 OFF
1-2,4-5
TO FLOOD LAMP
The circuit in the dashed box is not mounted.
P05 BW V13 LgR P14 YR P16 WB P15 2RY
P13 2WG
OFF ON ST
ST
B
R1
R2
P11 LgR
C
P19 LR
ACC B R
P04 5W
B
ACC
ON OFF
BR
E
P09 5WR
65A 65A
P08 5WR
P11 LgR N B
P03 5W
AV60 B(HEB 60) BR
C
+ 12V 115D31R BATTERY
HT
STARTER SWITCH
10-078
COM
BATTERY RELAY
P04 5W
STARTER SWITCH
NO P11 LgR
AV60 B(HEB 60)
P15 2RY
P16 WB
FUSE BOX (1)
P09 5WR
P09 5WR
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
P14 YR
V13 LgR P19 LR
FUSE BOX (2)
P04 5W
N/A 24 N/A 23 N/A 22 N/A 21 5A 20 5A 19 20A 18 5A 17 5A 16 15A 15 5A 14 20A 13
P05 BW
P13 2WG
SW654-10010
TROUBLESHOOTING
2-7-18. Flood lamp indicator lamp does not light • Check that flood lamp lights. Reference Fig. : 2-7-5 Check point
Check/Cause
Action
1. Harness
• Measure resistance between flood lamp switch terminal 3 Repair or replace wire RG and combination meter connector terminal wire harness. No.L05 wire RG. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
2. Combination Meter (Flood lamp indicator lamp)
(1) W hen starter switch is ON, measure voltage between Replace combination combination meter terminal wires and ground terminal meter. wire. • Battery 12 V (+) terminal wire No.P05 inlet wire BW and ground terminal wire No.N wire B • Starter switch (ACC) terminal wire No.V13 inlet wire LgR and ground terminal wire No.N wire B Standard voltage : 12 V or more (2) W hen starter switch is ON and flood lamp switch is “ ”, measure voltage between combination meter flood lamp terminal wire No.L05 inlet wire RG and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and flood lamp indicator lamp does not light, combination meter is faulty.
2-7-19. Side marker lamp indicator lamp does not light • Check that side marker lamp and tail lamp light. Reference Fig. : 2-7-5 Check point
Check/Cause
Action
1. Harness
• Measure resistance between lighting switch terminal 3 wire BY and combination meter connector terminal wire No.L01 wire BY. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2. Combination Meter (Side marker lamp indicator lamp)
(1) W hen starter switch is ON, measure voltage between combination meter terminal wires and ground terminal wire. • Battery 12 V (+) terminal wire No.P05 inlet wire BW and ground terminal wire No.N wire B • Starter switch (ACC) terminal wire No.V13 inlet wire LgR and ground terminal wire No.N wire B Standard voltage : 12 V or more (2) W hen starter switch is ON and lighting switch is “SIDE MARKER LIGHT”, measure voltage between combination meter side marker lamp terminal wire No.L01 inlet wire BY and chassis ground. Standard voltage : 12 V or more • If above items (1) and (2) are OK and side marker lamp indicator lamp does not light, combination meter is faulty.
Replace combination meter.
10-079
TROUBLESHOOTING
Fig.: 2-7-5
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
TO STOP LAMP
1 4
L10 GY
W
N B
5
Frequency divider selector
AD input interface TA input interface
TA pulse (pickup) TA pulse (square wave)
Fuel sensor Temperature sensor
Tachometer
Movement
Fuel meter
Movement
Temperature meter
LCD
Hour meter
L01 BY
TO LIGHTING LO-HI SWITCH
Engine speed 4
16_16M
15_16M
N B
LIGHTING SWITCH POSITION CONNECTION
SIDE MARKER LIGHT
2-3,4-5
OFF
1-2,4-5
FLASHER UNIT L
Turn signal (L)
Liquid spray Input interface
L
Engine charge warning Engine oil pressure Hydraulic filter
R
L08 G
TURN SIGNAL SWITCH
G(R)
L07 GR
GR(L)
L08 G
GY
L06 LY
3 1
5
4
L06 LY
1 3 4
P15 2RY
5
P14 YR
7
N B
FLOOD LAMP SWITCH POSITION CONNECTION
TO TURN SIGNAL LAMP (F,L)(R,L)
System configuration diagram
2
FLOOD LAMP SWITCH
TO TURN SIGNAL LAMP (F,R)(R,R)
Coolant temperature 2
P15 RY
HAZARD SWITCH
6
Lamp check
B
L06 LY
2 6
L05 2RG
Coolant temperature 1
Note:
L07 GR
N
Vibration indicator Turn signal indicator (L) Turn signal indicator (R) Parking brake indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator
Output interface
Vibration
E
L06 LY
GY G GR
Illumination LED
Backlight
Glow plug
P13 2WG
7
P05 BW
Turn signal (R)
Parking brake
5
6
LIGHTING SWITCH
TURN SIGNAL SWITCH
Water spray indicator Liquid spray indicator Position lamp indicator Flood lamp indicator
Flood lamp
P13 2WG
L05 RG
Position lamp
Water spray
2
3 4
V13 LgR
Output interface
Engine speed 3
L02 2Y
EEPROM
CPU
Engine speed 2
1
2-3,5-6
Input interface
Engine speed 1
12V
Movement
Input interface
KEY SW
CAN interface
12V
5V power supply
P16 WB
B
TO PARKING INTERLOCK RELAY, ECU, SPEED PULSE ON/OFF RELAY
12V Power excitation circuit
FOOT BRAKE SWITCH
TO PARKING BRAKE SOLENOID, SERVO BYPASS SOLENOID
V75 BrR
2 6
L12 LB
R
L13 GrB
3
L11 O
L11 O
PARKING BRAKE SWITCH BATT (12V)
14_16M
13_16M
12_16M
9_16M
10_16M
11_16M
8_16M
7_16M
6_16M
5_16M
4_16M
N B
L12 LB
3_16M
1_16M
2_16M
12_12F
9_12F
11_12F
8_12F
7_12F
6_12F
5_12F
4_12F
10_12F
L05 RG
L01 BY
L08 G
L07 GR
L01 BY
1_12F
3_12F
COMBINATION METER
GROUND REV. PULSE INPUT 2 FUEL METER TEMPERATURE METER LAMP CHECK PARKING BRAKE HYD. OIL FILTER WARNING ENGINE OIL PRESS. WARNING CHARGE WARNING PREHEATING REV. RATIO SEL.1 (OPEN) REV. RATIO SEL.2 (GND) REV. RATIO SEL.3 (OPEN) REV. RATIO SEL.4 (OPEN) COOLANT TEMP. SEL.1 (OPEN) COOLANT TEMP. SEL.2 (OPEN)
2_12F
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
V13 LgR
BATTERY 12V (+) BATTERY 24V (+) STARTER SWITCH (ACC) REV. PULSE INPUT 1 COMBI. METER ILLUMI. TURN SIGNAL (R) TURN SIGNAL (L) SIDE MARKER LAMP FLOOD LAMP WATER SPRAY LIQUID SPRAY VIBRATOR COMBINATION METER SWP12M SWP16F
P05 BW
1 2 3 4 5 6 7 8 9 10 11 12
2-3,5-6 OFF
1-2,4-5
TO FLOOD LAMP
The circuit in the dashed box is not mounted.
P05 BW V13 LgR P14 YR P16 WB P15 2RY
P13 2WG
OFF ON ST
ST
B
R1
R2
P11 LgR
C
P19 LR
ACC B R
P04 5W
B
ACC
ON OFF
BR
E
P09 5WR
65A 65A
P08 5WR
P11 LgR N B
P03 5W
AV60 B(HEB 60) BR
C
+ 12V 115D31R BATTERY
HT
STARTER SWITCH
10-080
COM
BATTERY RELAY
P04 5W
STARTER SWITCH
NO P11 LgR
AV60 B(HEB 60)
P15 2RY
P16 WB
FUSE BOX (1)
P09 5WR
P09 5WR
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
P14 YR
V13 LgR P19 LR
FUSE BOX (2)
P04 5W
N/A 24 N/A 23 N/A 22 N/A 21 5A 20 5A 19 20A 18 5A 17 5A 16 15A 15 5A 14 20A 13
P05 BW
P13 2WG
SW654-10010
TROUBLESHOOTING
2-7-20. Parking brake indicator lamp does not light Reference Fig. : 2-7-5 Check point
Check/Cause
Action
1. Harness
• Measure resistance between parking brake switch terminal 4 wire LB and combination meter connector terminal wire No.L12 wire LB. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2. Parking Brake Switch
• When parking brake switch is applied, check continuity between parking brake switch terminal 4 wire LB and terminal 5 wire B. There is continuity in normal condition. • If there is no continuity, parking brake switch is faulty.
Replace parking brake switch.
3. Combination Meter (Parking brake indicator lamp)
(1) W hen starter switch is ON, measure voltage between Replace combination combination meter terminal wires and ground terminal meter. wire. • Battery 12 V (+) terminal wire No.P05 inlet wire BW and ground terminal wire No.N wire B • Starter switch (ACC) terminal wire No.V13 inlet wire LgR and ground terminal wire No.N wire B Standard voltage : 12 V or more (2) W hen parking brake switch is applied and starter switch is ON, check continuity between combination meter parking brake terminal wire No.L12 inlet wire LB and chassis ground. There is continuity in normal condition. • If above items (1) and (2) are OK and parking brake indicator lamp does not light, combination meter is faulty.
10-081
TROUBLESHOOTING
Fig.: 2-7-5
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
TO STOP LAMP
1 4
L10 GY
W
N B
5
Frequency divider selector
AD input interface TA input interface
TA pulse (pickup) TA pulse (square wave)
Fuel sensor Temperature sensor
Tachometer
Movement
Fuel meter
Movement
Temperature meter
LCD
Hour meter
L01 BY
TO LIGHTING LO-HI SWITCH
Engine speed 4
16_16M
15_16M
N B
LIGHTING SWITCH POSITION CONNECTION
SIDE MARKER LIGHT
2-3,4-5
OFF
1-2,4-5
FLASHER UNIT L
Turn signal (L)
Liquid spray Input interface
L
Engine charge warning Engine oil pressure Hydraulic filter
R
L08 G
TURN SIGNAL SWITCH
G(R)
L07 GR
GR(L)
L08 G
GY
L06 LY
3 1
5
4
L06 LY
1 3 4
P15 2RY
5
P14 YR
7
N B
FLOOD LAMP SWITCH POSITION CONNECTION
TO TURN SIGNAL LAMP (F,L)(R,L)
System configuration diagram
2
FLOOD LAMP SWITCH
TO TURN SIGNAL LAMP (F,R)(R,R)
Coolant temperature 2
P15 RY
HAZARD SWITCH
6
Lamp check
B
L06 LY
2 6
L05 2RG
Coolant temperature 1
Note:
L07 GR
N
Vibration indicator Turn signal indicator (L) Turn signal indicator (R) Parking brake indicator Engine oil pressure indicator Engine charge warning indicator Hydraulic filter indicator Glow plug indicator
Output interface
Vibration
E
L06 LY
GY G GR
Illumination LED
Backlight
Glow plug
P13 2WG
7
P05 BW
Turn signal (R)
Parking brake
5
6
LIGHTING SWITCH
TURN SIGNAL SWITCH
Water spray indicator Liquid spray indicator Position lamp indicator Flood lamp indicator
Flood lamp
P13 2WG
L05 RG
Position lamp
Water spray
2
3 4
V13 LgR
Output interface
Engine speed 3
L02 2Y
EEPROM
CPU
Engine speed 2
1
2-3,5-6
Input interface
Engine speed 1
12V
Movement
Input interface
KEY SW
CAN interface
12V
5V power supply
P16 WB
B
TO PARKING INTERLOCK RELAY, ECU, SPEED PULSE ON/OFF RELAY
12V Power excitation circuit
FOOT BRAKE SWITCH
TO PARKING BRAKE SOLENOID, SERVO BYPASS SOLENOID
V75 BrR
2 6
L12 LB
R
L13 GrB
3
L11 O
L11 O
PARKING BRAKE SWITCH BATT (12V)
14_16M
13_16M
12_16M
9_16M
10_16M
11_16M
8_16M
7_16M
6_16M
5_16M
4_16M
N B
L12 LB
3_16M
1_16M
2_16M
12_12F
9_12F
11_12F
8_12F
7_12F
6_12F
5_12F
4_12F
10_12F
L05 RG
L01 BY
L08 G
L07 GR
L01 BY
1_12F
3_12F
COMBINATION METER
GROUND REV. PULSE INPUT 2 FUEL METER TEMPERATURE METER LAMP CHECK PARKING BRAKE HYD. OIL FILTER WARNING ENGINE OIL PRESS. WARNING CHARGE WARNING PREHEATING REV. RATIO SEL.1 (OPEN) REV. RATIO SEL.2 (GND) REV. RATIO SEL.3 (OPEN) REV. RATIO SEL.4 (OPEN) COOLANT TEMP. SEL.1 (OPEN) COOLANT TEMP. SEL.2 (OPEN)
2_12F
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
V13 LgR
BATTERY 12V (+) BATTERY 24V (+) STARTER SWITCH (ACC) REV. PULSE INPUT 1 COMBI. METER ILLUMI. TURN SIGNAL (R) TURN SIGNAL (L) SIDE MARKER LAMP FLOOD LAMP WATER SPRAY LIQUID SPRAY VIBRATOR COMBINATION METER SWP12M SWP16F
P05 BW
1 2 3 4 5 6 7 8 9 10 11 12
2-3,5-6 OFF
1-2,4-5
TO FLOOD LAMP
The circuit in the dashed box is not mounted.
P05 BW V13 LgR P14 YR P16 WB P15 2RY
P13 2WG
OFF ON ST
ST
B
R1
R2
P11 LgR
C
P19 LR
ACC B R
P04 5W
B
ACC
ON OFF
BR
E
P09 5WR
65A 65A
P08 5WR
P11 LgR N B
P03 5W
AV60 B(HEB 60) BR
C
+ 12V 115D31R BATTERY
HT
STARTER SWITCH
10-082
COM
BATTERY RELAY
P04 5W
STARTER SWITCH
NO P11 LgR
AV60 B(HEB 60)
P15 2RY
P16 WB
FUSE BOX (1)
P09 5WR
P09 5WR
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
P14 YR
V13 LgR P19 LR
FUSE BOX (2)
P04 5W
N/A 24 N/A 23 N/A 22 N/A 21 5A 20 5A 19 20A 18 5A 17 5A 16 15A 15 5A 14 20A 13
P05 BW
P13 2WG
SW654-10010
TROUBLESHOOTING
2-7-21. Turn signal indicator lamp does not light • Check that turn signal lamp blinks. Reference Fig. : 2-7-5 Check point
Check/Cause
Action
1. Harness
(1) M easure resistance between turn signal switch terminal Repair or replace wire No.L08 wire G and combination meter connector harness. terminal wire No.L08 wire G. Standard resistance : 10 Ω or less (2) M easure resistance between turn signal switch terminal wire No.L07 wire GR and combination meter connector terminal wire No.L07 wire GR. Standard resistance : 10 Ω or less • If above item (1) or (2) is NG, harness is faulty.
2. Turn Signal Switch
• When turn signal switch lever is moved, check continuity between turn signal switch terminals. Turn signal (L) : Between wire No.L06 wire LY and wire No.L08 wire G Turn signal (R) : Between wire No.L06 wire LY and wire No.L07 wire GR There is continuity in normal condition. • If there is no continuity, turn signal switch is faulty.
3. Combination Meter (Turn signal indicator lamp)
(1) W hen starter switch is ON, measure voltage between Replace combination combination meter terminal wires and ground terminal meter. wire. • Battery 12 V (+) terminal wire No.P05 inlet wire BW and ground terminal wire No.N wire B • Starter switch (ACC) terminal wire No.V13 inlet wire LgR and ground terminal wire No.N wire B Standard voltage : 12 V or more (2) W hen starter switch is ON and turn signal switch is moved, measure voltage between combination meter terminal wires and chassis ground. • Turn signal (L) terminal wire No.L08 inlet wire G and chassis ground • Turn signal (R) terminal wire No.L07 inlet wire GR and chassis ground Standard voltage : 12 V or more with constant intervals • If above items (1) and (2) are OK and turn signal indicator lamp does not light, combination meter is faulty.
Replace turn signal switch.
10-083
TROUBLESHOOTING
Fig.: 2-7-6
N B
G
HORN
L15 GY
4
L14 P
5
3 P15 RY
2
1
P15 RY
HORN SWITCH HORN RELAY
L16 W
R B
BACKUP BUZZER SWITCH
BACKUP BUZZER L09 WR
P22 Y
B
BR
C
P04 5W
P09 5WR P11 LgR ACC
65A
R2
P03 5W
R1
65A
B
ON
FUSE BOX (1)
P08 5WR
ST
P19 LR
P04 5W
P09 5WR
P19 LR
FUSE BOX (2)
15A 12 5A 11 5A 10 15A 9 15A 8 15A 7 15A 6 20A 5 15A 4 15A 3 20A 2 20A 1
N/A 24 N/A 23 N/A 22 N/A 21 5A 20 5A 19 20A 18 5A 17 5A 16 15A 15 5A 14 20A 13
P22 Y
W
NO
COM
BR
E
P11 LgR
OFF HT
BATTERY RELAY
STARTER SWITCH STARTER SWITCH B OFF ON ST
ACC B R
C
P11 LgR N B
AV60 B(HEB 60)
Y
P15 2RY
L09 WR
P09 5WR
TO BACKUP LAMP
AV60 B(HEB 60)
+ 12V 115D31R BATTERY
SW654-10011
10-084
TROUBLESHOOTING
2-7-22. Horn does not sound Reference Fig. : 2-7-6 Check point
Check/Cause
Action
1. Horn
• Disconnect horn and directly connect battery positive terminal to horn terminal wire GY side and negative terminal to horn terminal wire B side. • If horn does not sound, horn is faulty.
Replace horn.
2. Horn Relay
(1) W hen starter switch is ON, measure voltage between horn relay terminal 1 and 3 inlet wire RY and chassis ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and horn switch pressed, measure voltage between horn relay terminal 5 outlet wire GY and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, horn relay is faulty.
Replace horn relay.
3. Horn Switch
• When horn switch is ON, check continuity between horn switch terminals. There is continuity in normal condition. • If there is no continuity, horn switch is faulty.
Replace horn switch.
4. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
2-7-23. Backup buzzer does not sound Reference Fig. : 2-7-6 Check point
Check/Cause
Action
1. Backup Buzzer
• Disconnect backup buzzer and directly connect battery Replace backup buzzer. positive terminal to backup buzzer terminal wire W side and negative terminal to backup buzzer terminal wire B side. • If backup buzzer does not sound, backup buzzer is faulty.
2. Backup Buzzer Switch
Replace backup buzzer (1) W hen starter switch is ON, measure voltage between backup buzzer switch terminal inlet wire Y and chassis switch. ground. Standard voltage : 12 V or more (2) W hen starter switch is ON and F-R lever is “R” , measure voltage between backup buzzer switch terminal outlet wire WR and chassis ground. Standard voltage : 12 V or more • If above item (1) is OK and item (2) is NG, backup buzzer switch is faulty.
3. Harness Connecting Between Terminals
• Measure resistance of harness connecting between terminals. Standard resistance : 10 Ω or less • If resistance is abnormal, harness is faulty.
Repair or replace harness.
10-085
TROUBLESHOOTING
3. HYDRAULIC SYSTEM TROUBLESHOOTING 3-1. When Performing Hydraulic System Troubleshooting • The largest factor in the majority of failures of hydraulic devices operating under conditions of higher pressure and greater precision is the entry of dirt (foreign substances) into the hydraulic circuit. Particular caution is required when supplying hydraulic oil or when disassembling and assembling hydraulic devices. 1) Pay attention to the work environment. As much as possible, avoid performing tasks such as supplying hydraulic oil, replacing filters and repair work on rainy days, when there is strong wind, or in locations where there is much dust. 2) Disassembly and maintenance work in the field There is the danger of dust entry when disassembly and maintenance work for hydraulic components is performed in the field. In addition, because performance verification after repairs are completed is difficult, replacement of the entire assembly is preferred. Perform disassembly and maintenance of hydraulic components in a special room protected from dust, and use special testers to verify the performance. 3) Sealing of openings Use caps, tape, plastic bags or other means to seal the openings of removed pipes and components in order to prevent foreign substances from entering. Never leave the openings exposed or put a shop cloth into them. There is the danger of foreign substances entering or of leaking oil causing environmental contamination. Do not dispose of waste oil on-site. Either deliver it to the customer and request disposal or take it back with you and dispose of it. 4) Prevent entry of foreign substances when supplying oil. Take care that foreign substances do not enter when supplying hydraulic oil. Clean the oil supply port and the area around it, as well as the supply pump, oilcan and other items. A more reliable method is to use oil cleaning equipment, which can filter out the contamination that occurred during storage. 5) Change hydraulic oil while the temperature is still high. All oils, including hydraulic oil, flow more readily when they are warm. Higher temperatures also make it easier to eject the sludge and other substances outside the circuit together with the oil. For these reasons, oil changes should be performed while the oil temperature is high. When changing the oil, it is necessary to drain out as much of the old hydraulic oil as possible. (In addition to the hydraulic oil tank, also drain the oil from the filter and circuit drain plugs.) If old hydraulic oil remains in the system, the contaminants and sludge in the old oil will mix with the new oil and shorten the hydraulic oil lifetime.
10-086
TROUBLESHOOTING
3-2. Propulsion System If a problem occurs in the propulsion systems such as the propulsion pump, propulsion motor and brakes, determine the cause and carry out action as required, according to the following general troubleshooting items. (NOTICE) • When checking whether or not the pressure is correct, refer to the pressure standard value for each hydraulic circuit.
3-2-1. Machine moves neither forward nor backward 1/2 Check point
Cause
Check/Action
1. Oil Level of Hydraulic Oil Tank
Oil level in hydraulic oil tank is low.
Fill tank until correct oil level is obtained.
2. Bypass Valve
Bypass valve is open.
Close bypass valve.
3. F-R Lever Linkage
F-R lever linkage is faulty.
Check and adjust F-R lever linkage or replace it if necessary.
4. Charge Circuit Pressure
Propulsion pump does not discharge oil because charge pressure is low.
• Measure charge pressure. • If low, check and adjust charge relief valve or replace it if necessary.
Charge pressure decreases due to pressure Check and adjust cut off valve or replace it leakage from cut off valve. if necessary. Insufficient steering • charge pump discharge.
Repair steering • charge pump or replace it if necessary.
Charge pressure decreases due to internal leakage of solenoid valve connecting oil 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 valve or replace it if necessary.
5. Servo Bypass Solenoid Valve
If spool of servo bypass solenoid valve is stuck, pressure in both sides of servo cylinder chamber is equalized. This causes propulsion pump unable to discharge oil.
• Measure pressure in servo cylinder chambers. • If pressure is equal in both chambers, repair servo bypass solenoid valve or replace it if necessary.
6. Suction Filter for Steering • Charge Pump
Steering • charge pump flow is reduced due Clean suction filter or replace it if necessary. to clogged filter.
7. Propulsion Circuit Pressure
Pump does not discharge oil because setting pressure of cut off valve is low.
Measure propulsion circuit pressure. If low, check and adjust cut off valve or replace it if necessary.
Circuit does not obtain required pressure because setting pressure of high pressure relief is low.
• Measure propulsion circuit pressure. • If low, check and adjust high pressure relief valve or replace it if necessary.
Propulsion circuit pressure is not held in propulsion motor case.
• Measure propulsion motor case pressure. • If case pressure is not within allowable pressure, repair propulsion motor or replace it if necessary.
Internal leakage of propulsion motor.
• Measure drain quantity from propulsion motor. • If drain quantity is larger than standard value, repair propulsion motor or replace it if necessary.
Sticking of disc brakes causes brakes to remain applied.
• Replace disc brakes.
8. Propulsion Motor
10-087
TROUBLESHOOTING
3-2-1. Machine moves neither forward nor backward 2/2 Check point
Cause
Check/Action
9. Propulsion Pump
Discharge flow rate is insufficient due to efficiency degradation of propulsion pump.
• Measure discharge flow rate of propulsion pump with flow meter. • If discharge flow rate is not within specified range, repair propulsion pump or replace it if necessary.
Discharge flow rate is insufficient due to Replace propulsion pump. wear of propulsion pump drive shaft splines. Propulsion circuit pressure is not held in propulsion pump case.
• Measure propulsion pump case pressure. • If case pressure is not within allowable pressure, repair propulsion pump or replace it if necessary.
10. Parking Brake Solenoid Valve
Brake remains applied because spool of parking brake solenoid valve does not shift.
Repair parking brake solenoid valve or replace it if necessary.
11. B rake Inlet Pressure
Brake cannot be released because brake inlet pressure is low.
• Measure brake release pressure. • If low, repair or replace propulsion motor.
12. Flange
Drive torque is not transmitted to pump due to faulty flange.
Replace flange.
3-2-2. Machine moves in one direction only (forward or backward) Check point
Cause
Check/Action
1. F-R Lever Linkage
F-R lever linkage is faulty.
Check and adjust F-R lever linkage or replace it if necessary.
2. High Pressure Relief Valve
Low circuit pressure due to incorrect high • Interchange two high pressure relief pressure relief setting or internal leakage of valves. high pressure relief valve. • If faulty condition is accordingly reversed, check and adjust high pressure relief valve or replace it if necessary.
3-2-3. Slow machine speed or small drive force 1/2 Check point
Cause
Check/Action
1. Bypass Valve
Bypass valve is slightly open.
Close bypass valve completely.
2. F-R Lever Linkage
F-R lever linkage is faulty.
Check and adjust F-R lever linkage or replace it if necessary.
3. Charge Circuit Pressure
Stroke of propulsion pump swash plate is small because charge pressure is low, decreasing discharge rate of propulsion pump.
• Measure charge pressure. • If low, check and adjust charge relief valve or replace it if necessary.
Insufficient steering • charge pump discharge.
Repair steering • charge pump or replace it if necessary.
Charge pressure decreases due to internal leakage of solenoid valve connecting oil 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 valve or replace it if necessary.
Flow rate of steering • charge pump decreases as well as charge pressure decreases due to clogged filter.
Clean suction filter or replace it if necessary.
4. Suction Filter for Steering • Charge Pump
10-088
TROUBLESHOOTING
3-2-3. Slow machine speed or small drive force 2/2 Check point 5. Propulsion Motor
6. Propulsion Pump
Cause
Check/Action
Propulsion motor inlet pressure is low.
• Measure propulsion motor inlet pressure. • If low, check and adjust high pressure relief valve or replace it if necessary.
Propulsion circuit pressure is not held in propulsion motor case.
• Measure propulsion motor case pressure. • If case pressure is not within allowable pressure, repair propulsion motor or replace it if necessary.
Output of propulsion motor decreases and number of revolutions decreases due to internal leakage of propulsion motor.
• Measure drain quantity from propulsion motor. • If drain quantity is larger than standard value, repair propulsion motor or replace it if necessary.
Discharge flow rate is insufficient due to efficiency degradation of propulsion pump.
• Measure discharge flow rate of propulsion pump with flow meter. • If discharge flow rate is not within specified range, repair propulsion pump or replace it if necessary.
Discharge flow rate is insufficient due to Replace propulsion pump. wear of propulsion pump drive shaft splines. Propulsion circuit pressure is not held in propulsion pump case.
• Measure propulsion pump case pressure. • If case pressure is not within allowable pressure, repair propulsion pump or replace it if necessary.
3-2-4. Machine speed cannot be switched Check point
Cause
Check/Action
1. Speed Change Solenoid Valve
Machine speed does not change because spool of speed change solenoid valve does not change.
Repair speed change solenoid valve or replace it if necessary.
2. Propulsion Motor Swash Plate Stroke Cylinder
Faulty propulsion motor swash plate stroke cylinder.
Repair propulsion motor or replace it if necessary.
3-2-5. Machine does not stop completely with F-R lever in “N” Check point
Cause
Check/Action
1. F-R lever Linkage
F-R lever linkage is faulty.
Check and adjust F-R lever linkage or replace it if necessary.
2. Servo Control Valve
Servo control valve neutral position adjustment failure.
Check and adjust servo control valve or replace it if necessary.
3. Propulsion Pump Servo Cylinder
Faulty propulsion pump servo cylinder or faulty pump swash plate setting.
Repair propulsion pump or replace it if necessary.
10-089
TROUBLESHOOTING
3-2-6. Propulsion system is overheating Check point
Cause
Check/Action
1. Oil Level of Hydraulic Oil Tank
Oil level in hydraulic oil tank is low.
2. Oil Cooler
Cooling efficiency is reduced due to clogged Clean oil cooler fins. oil cooler fins.
3. Flushing Valve
Hydraulic oil in propulsion closed circuit is insufficiently cooled due to flushing valve shuttle spool sticking.
Repair flushing valve or replace it if necessary.
Hydraulic oil in propulsion closed circuit is insufficiently cooled because flushing valve relief setting pressure is excessively high.
Check dust or damage in flushing relief valve and replace it if necessary.
Hydraulic oil in propulsion closed circuit is insufficiently cooled due to flushing valve relief valve poppet sticking.
Clean flushing relief valve or replace it if necessary.
4. Propulsion Circuit Pressure
Fill tank until correct oil level is obtained.
If circuit pressure setting is excessively low, • Measure propulsion circuit pressure. relief valve opens, causing temperature of • If low, increase relief setting pressure. hydraulic oil in circuit to rise. If load is excessively 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
Load of steering • charge pump increases Clean suction filter or replace it if necessary. due to clogged filter, causing temperature of hydraulic oil in circuit to rise.
6. Hydraulic Oil Filter
Charge circuit pressure increases due to clogged filter.
Clean hydraulic oil filter or replace it if necessary.
3-2-7. Abnormal noise from propulsion system Check point
Cause
Check/Action
1. Roller Bearings
Roller bearings supporting front and rear drums are damaged.
Replace roller bearings.
2. Hydraulic Hose Clamp
Vibrator sound of hydraulic hose is generated because clamp securing hydraulic hose is loose.
Tighten bolts of loose hydraulic hose clamp to specified torque.
3. Suction Filter for Steering • Charge Pump
Cavitation is occurring in steering • charge pump due to clogged filter.
Clean suction filter or replace it if necessary.
4. Charge Circuit Pressure
If charge pressure is low, brake cannot be released completely, which causes brake drag.
• Measure charge pressure. • If low, check and adjust charge relief valve or replace it if necessary.
5. Propulsion Motor
Internal bearing of propulsion motor is damaged.
Repair propulsion motor or replace it if necessary.
10-090
TROUBLESHOOTING
3-3. Vibrator System If a problem occurs in the vibrator systems such as the vibrator pump, vibrator motor and vibrator solenoid valve, determine the cause and carry out action as required, according to the following general troubleshooting items. (NOTICE) • When checking whether or not the pressure is correct, refer to the pressure standard value for each hydraulic circuit.
3-3-1. No vibration 1/2 Check point
Cause
Check/Action
1. Oil Level of Hydraulic Oil Tank
Oil level in hydraulic oil tank is low.
Fill tank until correct oil level is obtained.
2. Charge Circuit Pressure
Vibrator pump does not discharge oil due to • Measure charge pressure. low charge pressure. • If low, check and adjust charge relief valve or replace it if necessary. Charge pressure decreases due to pressure Check and adjust cut off valve or replace it leakage from cut off valve. if necessary. Insufficient steering • charge pump discharge.
Repair steering • charge pump or replace it if necessary.
Charge pressure decreases due to internal leakage of solenoid valve connecting oil 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 valve or replace it if necessary.
3. Suction Filter for Steering • Charge Pump
Steering • charge pump flow is reduced due Clean suction filter or replace it if necessary. to clogged filler.
4. Vibrator Circuit Pressure
Pump does not discharge oil because setting pressure of cut off valve is low.
Measure vibration circuit pressure. If low, check and adjust cut off valve or replace it if necessary.
Circuit does not obtain required pressure because setting pressure of high pressure relief is low.
• Measure vibrator circuit pressure. • If low, check and adjust high pressure relief valve or replace them if necessary.
5. Vibrator Solenoid Valve
Vibrator pump cannot discharge oil because Repair vibrator solenoid valve or replace it if spool of vibrator solenoid valve does not necessary. shift.
6. Vibrator Motor
Vibrator circuit pressure is not held in vibrator motor case.
• Measure vibrator motor case pressure. • If case pressure is not within allowable pressure, repair vibrator motor or replace it if necessary.
Internal leakage of vibrator motor.
• Measure drain quantity from vibrator motor. • If drain quantity is larger than standard value, repair vibrator motor or replace it if necessary.
Output torque is not transmitted due to worn Replace vibrator motor. spline of vibrator motor output shaft.
10-091
TROUBLESHOOTING
3-3-1. No vibration 2/2 Check point 7. Vibrator Pump
Cause
Check/Action
Insufficient discharge rate from vibrator pump due to reduced efficiency of vibrator pump.
• Measure discharge flow rate of vibrator pump with flow meter. • If discharge flow rate is not within specified range, repair vibrator pump or replace it if necessary.
Insufficient pump discharge due to wear of vibrator pump drive shaft spline.
Replace vibrator pump.
Vibrator circuit pressure is not held in vibrator pump case.
• Measure vibrator pump case pressure. • If case pressure is not within allowable pressure, repair vibrator pump or replace it if necessary.
3-3-2. Vibrator frequency is too low Check point
Cause
Check/Action
1. Oil Level of Hydraulic Oil Tank
Oil level in hydraulic oil tank is low.
Fill tank until correct oil level is obtained.
2. Charge Circuit Pressure
Stroke of vibrator pump swash plate is small • Measure charge pressure. because charge pressure is low, decreasing • If low, check and adjust charge relief valve discharge rate of vibrator pump. or replace it if necessary. Insufficient steering • charge pump discharge.
Repair steering • charge pump or replace it if necessary.
Charge pressure decreases due to internal leakage of solenoid valve connecting oil 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 valve or replace it if necessary.
3. Suction Filter for Steering • Charge Pump
Flow rate of steering • charge pump decreases as well as charge pressure decreases due to clogged filter.
Clean suction filter or replace it if necessary.
4. Vibrator Motor
Vibrator motor inlet pressure is low.
• Measure vibrator motor inlet pressure. • If low, check and adjust high pressure relief valve or replace it if necessary.
Vibrator circuit pressure is not held in vibrator motor case.
• Measure vibrator motor case pressure. • If case pressure is not within allowable pressure, repair vibrator motor or replace it if necessary.
Decrease in vibrator motor rpm due to internal leakage in vibrator motor.
• Measure drain quantity from vibrator motor. • If drain quantity is larger than standard value, repair vibrator motor or replace it if necessary.
Insufficient discharge rate from vibrator pump due to reduced efficiency of vibrator pump.
• Measure discharge flow rate of vibrator pump with flow meter. • If discharge flow rate is not within specified range, repair vibrator pump or replace it if necessary.
Insufficient pump discharge due to wear of vibrator pump drive shaft spline.
Replace vibrator pump.
Vibrator circuit pressure is not held in vibrator pump case.
• Measure vibrator pump case pressure. • If case pressure is not within allowable pressure, repair vibrator pump or replace it if necessary.
5. Vibrator Pump
10-092
TROUBLESHOOTING
3-3-3. Vibration mode does not switch Check point
Cause
Check/Action
1. Vibrator Solenoid Valve
Vibrator solenoid valve spool shifts only in one direction.
Repair vibrator solenoid valve or replace it if necessary.
3-3-4. Vibratory drum does not changeover vibrating Check point 1. Vibratory Drum Select Solenoid Valve
Cause
Check/Action
Vibratory drum does not changeover vibrating because spool of vibrator solenoid valve does not change.
Repair vibrator solenoid valve or replace it if necessary.
3-3-5. Vibrator does not stop Check point
Cause
Check/Action
1. Vibrator Solenoid Valve
Vibrator solenoid valve spool does not return to neutral position.
Repair vibrator solenoid valve or replace it if necessary.
2. Vibrator Pump
Vibrator pump swash plate does not return to neutral position.
Repair or replace vibrator pump or replace it if necessary.
3-3-6. Vibrator system is overheating Check point
Cause
Check/Action
1. Oil Level of Hydraulic Oil Tank
Oil level in hydraulic oil tank is low.
2. Oil Cooler
Cooling efficiency is reduced due to clogged Clean oil cooler fins. oil cooler fins.
3. Flushing Valve
Hydraulic oil in vibrator closed circuit is insufficiently cooled due to flushing valve shuttle spool sticking.
Repair flushing valve or replace it if necessary.
Hydraulic oil in vibrator closed circuit is insufficiently cooled because flushing valve relief setting pressure is excessively high.
Check dust or damage in flushing relief valve and replace it if necessary.
Hydraulic oil in vibrator closed circuit is insufficiently cooled due to flushing valve relief valve poppet sticking.
Clean flushing relief valve or replace it if necessary.
4. Vibrator Circuit Pressure
Fill tank until correct oil level is obtained.
If circuit pressure setting is excessively low, • Measure vibrator circuit pressure. relief valve opens, causing temperature of • If low, increase relief setting pressure. hydraulic oil in circuit to rise. If load is excessively heavy, relief valve opens, causing temperature of hydraulic oil in circuit to rise.
• Measure vibrator circuit pressure. • If high, decrease vibration load.
5. Suction Filter for Steering • Charge Pump
Load of steering • charge pump increases Clean suction filter or replace it if necessary. due to clogged filter, causing temperature of hydraulic oil in circuit to rise.
6. Hydraulic Oil Filter
Charge circuit pressure increases due to clogged filter.
Clean hydraulic oil filter or replace it if necessary.
10-093
TROUBLESHOOTING
3-3-7. Abnormal noise from vibrator system Check point
Cause
Check/Action
1. Vibrator Bearings
Vibrator bearings supporting eccentric shaft Replace vibrator bearings. are damaged.
2. Hydraulic Hose Clamp
Vibrator sound of hydraulic hose is generated because clamp securing hydraulic hose is loose.
Tighten bolts of loose hydraulic hose clamp to specified torque.
3. Suction Filter for Steering • Charge Pump
Cavitation is occurring in steering • charge pump due to clogged filter.
Clean suction filter or replace it if necessary.
4. Vibrator Motor
Internal bearing of vibrator motor is damaged.
Repair vibrator motor or replace it if necessary.
10-094
TROUBLESHOOTING
3-4. Steering System If a problem occurs in the steering systems such as the steering • charge pump and orbitrol, determine the cause and carry out action as required, according to the following general troubleshooting items. (NOTICE) • When checking whether or not the pressure is correct, refer to the pressure standard value for each hydraulic circuit.
3-4-1. Steering wheel is hard to turn Check point
Cause
Check/Action
1. Oil Level of Hydraulic Oil Tank
Oil level in hydraulic oil tank is low.
Fill tank until correct oil level is obtained.
2. Orbitrol
Relief valve is open or setting pressure is low.
• Measure steering circuit pressure. • If low, check and clean relief valve or replace it if necessary.
Flow to steering cylinder circuit is insufficient Check and clean check valve or replace it if due to leakage from check valve. necessary. Spool and sleeve of orbitrol are contaminated or clearance is incorrect.
Check and clean orbitrol or replace it if necessary.
3. Steering Circuit Pressure
Pressure in return circuit from orbitrol Clean hydraulic filter or replace it if increases due to clogged charging hydraulic necessary. filter.
4. Steering Cylinder
Cylinder thrust decreases due to internal leakage of steering cylinder.
Repair steering cylinder or replace it if necessary.
5. Suction Filter for Steering • Charge Pump
Steering • charge pump discharge rate decreases due to clogged filter.
Clean suction filter or replace it if necessary.
6. Steering • Charge Pump
Discharging pressure is insufficient due to efficiency degradation of steering • charge pump.
• Measure steering circuit pressure. • If low, replace steering • charge pump.
7. Steering Column
Column shaft and orbitrol shaft center are misaligned.
Align column shaft with orbitrol shaft center or replace it if necessary.
Column shaft bearing is worn or damaged.
Repair column shaft or replace it if necessary.
3-4-2. Steering response is slow Check point
Cause
Check/Action
1. Oil Level of Hydraulic Oil Tank
Oil level in hydraulic oil tank is low.
Fill tank until correct oil level is obtained.
2. Orbitrol
Oil is bypassing because relief valve is open.
• Measure steering circuit pressure. • If low, check and clean relief valve or replace it if necessary.
3. Steering Cylinder
Internal leakage of steering cylinder.
Repair steering cylinder or replace it if necessary.
4. Suction Filter for Steering • Charge Pump
Steering • charge pump discharge rate decreases due to clogged filter.
Clean suction filter or replace it if necessary.
5. Steering • Charge Pump
Discharging pressure is insufficient due to efficiency degradation of steering • charge pump.
• Measure steering circuit pressure. • If low, replace steering • charge pump.
10-095
TROUBLESHOOTING
3-4-3. Steering wheel backlash or play is large Check point 1. Steering Column 2. Steering Wheel
Cause
Check/Action
Spline of column shaft or orbitrol is worn.
Replace column shaft or orbitrol.
Column shaft bearings are worn.
Replace column shaft bearings.
Serration (spline) of wheel or column shaft is worn.
Replace wheel or column shaft.
3-4-4. Steering system is overheating Check point
Cause
Check/Action
1. Oil Level of Hydraulic Oil Tank
Oil level in hydraulic oil tank is low.
2. Oil Cooler
Cooling efficiency is reduced due to clogged Clean oil cooler fins. oil cooler fins.
3. Steering Circuit Pressure
If circuit pressure setting is excessively low, • Measure steering circuit pressure. relief valve is open, causing temperature of • If low, replace relief valve. hydraulic oil in circuit to rise. If load is excessively heavy, relief valve is open, causing temperature of hydraulic oil in circuit to rise.
4. Suction Filter for Steering • Charge Pump
Fill tank until correct oil level is obtained.
• Measure steering circuit pressure. • If high, decrease steering load.
Load of steering • charge pump increases Clean suction filter or replace it if necessary. due to clogged filter, causing temperature of hydraulic oil in circuit to rise.
3-4-5. Abnormal noise from steering system Check point
Cause
1. Oil Level of Hydraulic Oil Tank
Pump suction pressure is high because oil level of hydraulic oil tank is low, causing cavitation in steering circuit system.
Fill tank until correct oil level is obtained.
2. Steering Circuit
Cavitation is caused by air in circuit.
Bleed circuit.
3. Hydraulic Hose Clamp
Vibrator sound of hydraulic hose is generated because clamp securing hydraulic hose is loose.
Tighten bolts of loose hydraulic hose clamp to specified torque.
4. Suction Filter for Steering • Charge Pump
Cavitation is occurring in steering • charge pump due to clogged filter.
Clean suction filter or replace it if necessary.
10-096
Check/Action
SAKAI HEAVY INDUSTRIES, LTD. Head office: Telephone:
Seiwa Bldg., 4-8, Shibadaimon 1-chome, Minato-ku, Tokyo, Japan +81-3-3434-3401
Global Service Division: 2500 Takayanagi, Kuki-shi, Saitama, Japan Telephone:
+81-480-52-1111
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